A New Multi-Physics Coupled Method for the Temperature Field of Dry Clutch Assembly

Abstract

The temperature field of the clutch assembly is critical for the clutch design and operation life. Current modeling methods of the temperature of the clutch assembly suffer from insufficient accuracy or a limited time scale for the complicated multi-physics coupling between the contact force, friction-generated heat, heat transfer, and thermal deformation in the clutch assembly in harsh operation conditions. In order to improve the accuracy of temperature field simulation and achieve long-term time scale, a new approach to modeling the temperature is proposed based on CFD simulation and decoupling technology. Firstly, the flow-thermal bi-directional coupling method is employed to determine the convective boundary conditions between the clutch assembly and the ambient air, improving the model’s accuracy. Secondly, the thermal-solid decoupling method is then used to reduce the computational time. The temperature of the clutch assembly during the continuous engagement and disengagement process is performed using this approach and verified by the rig test. The results demonstrate that the temperature of the outer, middle, and inner diameters of the pressure plate by the model agrees well with that by the rig test. For the first engagement and disengagement processes, the proportion of simulated temperature deviations exceeding 5 °C from the measured data is only 3.03%. For the last engagement and disengagement process, while the maximum temperature of the clutch is above 350 °C, the maximum temperature deviation between simulation and measurement is 4.99%. It proves that the approach proposed for modeling the dry clutch assembly temperature field has high accuracy while achieving long-term time-scale simulation.