Abstract
Repetitive use of the clutch, over a period of time, causes the friction material at the contact surfaces (clutch facing and flywheel/pressure plate) to wear, thus deteriorating its performance and usable life. The working life of a rigid clutch is the limiting factor when it comes to extracting maximum performance from a dual mass flywheel system, which is used in a lot of modern vehicles nowadays to lower fuel consumption and improve ride quality. In this study, we investigate the influence of different groove patterns on wear in rigid clutch facings and estimate their life using a comprehensive finite element model. The wear is calculated and analysed for five different groove patterns across two different inorganic materials, namely FTL180 and TF1600-MC2, using Archard’s Adhesive Wear Model. Coupled multi-physics elements are employed in the analysis to capture the effect of frictional heat generation on wear. We found that the Waffle pattern offered a decrease of 10.4% in volumetric wear loss, a 5.78% decrease in maximum wear thickness and an increase of 11.51% in the average working life is used in city like conditions with frequent engagements. This work sheds light on the impact of groove patterns on clutch facing wear and opens a new path for the design and development of more resilient rigid clutches.
Highlights
Modern engines generate relatively higher torques when they are operated at low engine speeds
dual-mass flywheel (DMF) helps attain the operational smoothness much needed for the modern economic engines
Most manufacturers recommended that DMF must be replaced along with the clutch
Summary
Modern engines generate relatively higher torques when they are operated at low engine speeds. DMF helps attain the operational smoothness much needed for the modern economic engines. The technological advantages such as fuel savings and emission benefits of this system will not let the automobile manufacturers discard their presence in future automobiles. Higher cost and more complicated assembly of DMF system are main drawbacks. It cannot be rebuilt or even resurfaced to eliminate hotspots and worn areas, necessitating a complete replacement. This, in turn, results in a considerable increase in replacement cost compared to traditional flywheel and clutch replacement
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