Fatigue analysis of Diaphragm spring in double dry clutch including manufacturing process

Abstract

In the automotive light-duty passenger vehicles, double dry clutch provides high comfort and fuel efficiency to passengers with automated gear box. Its functional performance and quality depends on its diaphragm spring. Fatigue analysis on this component and correlation is quite complex because of several manufacturing processes involved like stamping, heat stabilization and shot-peening. The procedure to predict the diaphragm fatigue strength is described in the paper; also it integrates the new simulation softwares capabilities to handle the process effects for evaluation of diaphragm.This paper outlines the different simulation stages involved to access the fatigue assessment on diaphragm spring; also it is done at various life situations of vehicle: normal, parking, overloading conditions. A great attention is paid for correlation through measurement fitting in simulation.Between each manufacturing process simulation, the deformed shape and its residual stress-strain data are mapped using customized scripts. After the process simulations, fatigue actuation on diaphragm is done for new, semi-worn and worn positions of clutch. Miner’s damage and its summation are done at each critical point in diaphragm to determine its total life under nominal design.