Modelling and simulation of thermal strength of clutch pressure plate and flywheel with numerical analysis techniques

Clutch components are inside the main systems at the vehicle. Clutch is a mechanical device located between vehicle engine and transmission that ensure the mechanical coupling among them. Clutch system comprises of flywheel, pressure plate cover assembly and disc assembly. The clutch engages the transmission with allowing a certain amount of slippage gradually between the flywheel and disc assembly. Engagement under rpm is reason to generate frictional heat, which is leading sudden temperature increase on friction surfaces. Sudden temperature increase at friction surface could cause the thermo-mechanical problems such as thermal deformations and thermo-elastic instability, which can lead to thermal cracking, wear and other mode of failure of the clutch components. Cracks on flywheel and p.plate have tendency to extend under rotation and could be reason the burst of components. Cracks at casting parts such as p.plate and flywheel have high safety risk by bursting under rpm. In this study, the present approach is used through the experimental test results to enhance the validity of FEA performances for understanding of the automotive clutch thermal characteristics. The thermal characteristics of the clutch is investigated by finite element analysis (FEA). The reasons for the differences were investigated. In order to improve the analysis made with FEA, the relationship among the theoretical calculations and experimental data was established and the improvement points were determined for the FEA inputs. Furthermore, in order to reduce the thermal effect on the surface of the plate, material changes were made in the critical components (pressure plate, lining) and special prototype parts were produced to test under the same condition. Purpose of material change is examining p.plate thermal strength on different materials. With the help of finite element analysis, which is provided with experimental test results, more accurate simulation results will be achieved and the efficiency of clutch system design will be increased. Before the product validation with experimental test conditions, Part's thermal resistance will be observed by FEA and it will allow engineering improvements on the product before giving the part experimental test. This will provide an advantage in terms of time and cost by reducing prototypes numbers, which are produced during the product development process. By using FEA outputs, designer is able to make modification on product to improve its thermal strength and make optimum designed part, which is validated FEA study. Starting experimental validation tests with this level prototype is accelerated the validation time. Because these optimum parts are more able to pass experimental study than other prototypes which was not analysed with FEA Keywords: Clutch, pressure plate thermal tests, thermal strength analysis of pressure