Computer aided design and validation of wear compansation mechanism for self-adjusting friction clutches on commercial vehicles

In this study, force characteristics of friction clutch used on automotive defined by mathematic model and performed design. Since the main variables as engine torque, flywheel dimensions, clutch slave cylinder travel can not be changed clutch diaphragm springs position remains same. Clutch dimensions, clutch disc dimensions, release bearing travel and pressure plate's lift off value is defined for the vehicle. Each part has been modelled and assembled on CAD platform, then the assembly simulated as vehicle conditions and prodution methods. Then force characteristics are corrolated with physical mesurements. By the next step original Self-Adjusting Clutch (SAC) mechanism (which is different from available SACs in market) has been designed in CAD platform and rest of other parts' (springs etc.) force characteristics are defined by freebody diagrams. Then the characteristics are corrolated by simulation. Unigraphics NX11 CAD software is used to create solid models and the analysis (simulations) has been done by Ansys 18.2 simulation software. During design process high attention has been paid to ensure the self adjusting mechanism completely unique on market, the construction of clutch assembly reliable and the easy to install. Keywords: SAC, self-adjusting clutch, wear compensate, diaphragm spring, pressure plate cover assembly, friction clutch, design, analysis