Beruflich Dokumente
Kultur Dokumente
By Mr. K.E.Kumaraguru. M.E. (Senior Lecturer) Done By J. Dilip Kumar - 11508102008 V. Kishore - 11508102020 R. Praveen Kumar - 11508102032 D. Vignesh Kumar 11508102045
Abstract
Our Project deals with the failure analysis of clutch arising from the daily operation of the vehicle and to provide an economical solution for the problem. Most common failures occurring in the clutch system are Damper Spring Failure, Drive plate fracture. We aim to rectify this type of failure by re-designing and analysing the Damper Spring for a specific type of clutch and also by re-designing (updating) & analysing Drive plate for the proposed design of the spring.
Introduction
Roles Of Clutch
To transmit the torque fully in engaged position role of the facings (coefficient of friction and mean radius)
To restore the engine torque with progressivity role of the cushion disc (Axial stiffness)
To filter the Torsional vibrations on the driveline in all configurations role of the damper spring. (circumferential stiffness and hysteresis)
Purpose Of Clutch
Torque Transmission: Allow energy dissipation Avoid Slipping Avoid high wearing Withstand maximum Torque in Drive and Coast. Torque Interruption: Shift ability, Ergonomic, Noise Avoid noise during gear-shifting Avoid judder during re-engagement Allow gear shifting without excessive pedal load Filter Vibrations: NVH Comfort Filtering idle rattle-noise Filtering "clack" rattle-noise
Torque Flow
Flywheel
Clutch facing
Cushion plate
Retainer plate
Damper spring
Drive plate
Hub
Role of Damper
It reduces vibrations while transmission of power from engine to gear box. It absorbs the cyclic vibrations from the rotation of crankshaftflywheel-clutch. These cyclic vibrations depend upon the inertia while rotation of crankshaft-flywheel-clutch. These cyclic vibrations give rise to a rough clutch operation to the driver. Hence the presence of damper will eliminate these unnecessary rough operating conditions.
Damper Springs:
These springs are placed radially in the clutch disc assembly. Absorbs the Vibrations produced during the engine operation. These Springs will be compressed while transmitting torque and absorbing torsional vibrations.
Cushion Disc:
It is placed between the two friction facings. These cushion discs are slightly bent to an angle so that it takes up crushing load or impact loading.
Hysteresis curve
PROBLEM DESCRIPTION
We were assigned with the task of identifying, rectifying the problem of particular type of clutch. Based on Customer Complaints & failure reports, we listed out all causes of failures that occurred in the clutches: Damper Spring Failure. Drive Plate Fracture. Uneven Finger height. Clutch Judder. Scoring of pressure plate. Face Wear. Clutch Drag. Clutch Slip. Spline Wear.
Thrust Bearing Damage. Hub Rivet Failure. Mounting Bolt Failure. Flywheel Scoring. Hard Clutch Operation
By Cross referencing the problems and symptoms of failure in clutches, a graph depicting all the problems was plotted and also listing the number of times the each particular type of failure has occurred.
1028 1000
800
No of Pieces
600
400 261 225 200 185 145 100 20 0 Clutch not working Clutch hard Gear Shift hard Juddering Spring Failure Slip / Poor pickup Clutch Jerking Burnt / Damage Visually ok Other Complaints 52 18 0
Models
Result of graph
From the above we can see that the main type of failure and the cause for the clutch to fail or stop working is Damper Spring Failure. This Graph reveals that the failure of Damper Spring has occurred at least 1028 times since the start of production in 2007.
In our root cause analysis study we used 5W+2H and Fish Bone Diagrams to single out our problem.
Our view
What symptom do we see on i. Spring came out from Disc the part? assembly. ii. Spring shear failure. Was part reworked by No company? When was it manufactured at 2007 (Start Of Production ) company? Who manufactured? Company Disc assembly line operator Is the product used in any other No application? Does defect occur when part is No delivered to Customer? Did a similar problem happen No before?
Man:
Based on the Service Report the Following was determined: Clutch riding : It is not the cause of this failure Frequent Clutch change : It is not the cause of this failure Improper Pedal Adjustment : Vehicles were checked for this and this is not the cause of failure Clutch Design : To be reviewed.
Visual
OK
OK
OK
OK
OK
Chemistry
C : 0.5 0.6% Mn : 0.5 0.8% Si : 1.2 1.6% S : 0.025%Max P : 0.025%Max Cr : 0.5 - 0.8%
Not Given
Not Given
OK
3 4
Hardness Microstructure
53 Confirms
54 Confirms
OK OK
5
6
Decarb layer
Shot peening coverage
< 10 microns
Min 90%
Not Given
Confirms
Not Given
Confirms
OK
OK
= (4 x 4.5) 1 (4 x4.5) 4
0.615 4.5
K = 1.352
= 860 N/mm2
FOS = 1.3
Here both deflection and active no. of coils are unknown. So, by assuming Active Coils the Deflection is obtained.
LB = 21mm
LF = 30 mm.
The Specifications of this resultant design is acceptable according to the Torque Application, Stress condition and Space considered. It can be seen that all the parameters have been calculated and are found to satisfy the design criteria. So, spring design is found to be SAFE.
Stage I (prototyping)
If review needed
The modeling of spring was done in CATIA V5 R20 it is obtained by using various techniques such as:
Surface Sweep. (with pulling direction) Extract Boundary. Rib Definition. Pocket Definition. (for squared and ground ends) Close surface.
Entity
Nodes Elements
Size
44026 25165
Materials:
Material Young's modulus Poisson's ratio Density Yield strength Steel 3e+007N/m2 0.3 7860kg/m3 2.5e+008N_m2
Boundary Conditions:
One end of the spring and its washer (spring seat) has been fixed. On the other face a Linear Distributed load of 1541 N has been applied. This load of 1541 N corresponds to Over torque condition (2.3 x Max torque) of Engine.
Meshed Spring:
Finite Elemental Analysis method is used to analyze the drive plate (Pre-processing in hypermesh, solution and postprocessing in Abaqus).
Checked for over-torque and self load arising due to rotation. Drive plate is made from DD11 steel with yield point at 300 N/mm^2
Continued
The load constraints are: The teeth of the drive plate that mates with hub is provided zero Degree of Freedom [no motion]. The Calculated spring load is applied on the face of the drive plate window [1541 N]. Rotational load(centrifugal) constraint is provided for the drive plate @[3500rpm]. Only static analysis is carried out. The real time validation is done with the assembled unit within the customer premises and only the result date is flourished.
Tetramesh with 2D set to tria and 3D to tetra element and feature angle is set to 45
The image shows the max. Von-Mises (in N/m2) stress plot on the drive plate where the before mentioned load constraints are provided and post-processed. The Max stress region is observed in a region between the red and the orange domain on the plot.
Red and Orange domains are observed at the contact region of the spring and the drive plate window.
Max stress region found at the teeth contact point of the drive plate and the drive hub. These have been reduced in order to save teeth damage.
It is evident from the above contour that the critically strained region are those which have the direct contact with the transmitting elements (spring, stop pin, drive hub).
The critically strained region at the teeth contact point. This can be minimized by increasing the thickness of the plate.
Critically strained region at the stop pin contact point. This can be diminished by increasing the thickness of plate.
In order to reduce the max stress and the strain level in the critical points the thickness is increased. The increased value is chosen to be 3.5mm from various iteration on the design.
Tetramesh with 2D set to tria and 3D to tetra element and feature angle is set to 45.
The relieved stress contour plot upon increasing the thickness and under similar load condition.
Relieved stress plot at the spring contact points on the drive plate window. The image highlights the corner points where the stresses are diminished in magnitude.
Relieved max. strain region on the hub teeth contact regions. Proves a safer design.
Relieved max. Strain region at the Spring contact face and the stop pin regions.
The design is proposed for proto-typing at the Stage I of the design loop and the results are purely based on the assembled testing. The components arent tested on individual bases.
We planned to simulate Durability Test For Disc Assembly: the existing failure in test lab. We made the new disc assembly with existing design. After the disc assembly, we started the Over Torque durability test until failure.
Test Condition: Torque No. of Cycle Temperature
Test Result: Disc assembly has failed during the 1,56,875 cycles. Spring failure is similar to field failure. So, confirmed that Drive Plate center & Drive Plate profile design.
Conclusion:
In this project, we have considered all the relevant factors of the types of failures, the different modes of failures of the clutch and then identified the most common type of failure (damper spring failure). The damper spring was modeled and analyzed in Catia V5 R20. The Driveplate has been modeled in Catia V5 R20 and the analysis were done with softwares such as Hypermesh v9.0 and Abaqus 6.10. The Company has validated our design by creating prototypes and then putting them through a series of bench tests, it is found that the parts have substantially passed all the tests.