Design optimization of clutch cushion disc with the integration of finite element analysis and design of experiments

Abstract

In recent years, growth of automotive market and the need for competent design of components has developed an over-reliance on advanced CAE tools. Design objectives of these automotive components are evaluated through simulations that are expensive in terms of money, resources and time. In such cases, evaluating all the design variables types and arriving at an optimized design makes it very computationally exhaustive. To overcome this complication and arrive at the optimized design, design of experiment (DOE) with combination of response surface method (RSM) has been adopted. One of the most important components in an automobile power transmission is clutch system, its main function is to permit soft and steady engagement of the torque transmission through its axial stiffness. The progressive axial stiffness is achieved by a cushion disc placed between the two friction facings. The undulating model of the cushion disc acts like a spring, thus providing gradual stiffness during engagement and disengagement of the clutch system. This work presents an approach to the design optimization of the clutch cushion disc with the integration of FEA and design of experiment to achieve the target cushion curve and minimize the stress induced during the action using Ansys Design explorer.