CLUTCH DESIGN

In clutch design, calculations were performed with Matlab or using a calculator. Now, we
show the formulas of all of our calculations in clutch design.

Step 1 : Firstly, we selected the clutch type that will be used in this project :

Cone Clutch : It was used extensively in automobiles, but nowadays it has been
replaced by the disk clutch. However, we selected it, because the clutch does not have to be
pushed in all the way and the gears will be changed quicker.

Step 2 : Secondly, we selected the material :

Rigid molded asbestos (dry) ( from Shigley Table 16-3 ) : It’s mostly used for clutches
and drum brakes.

Material Specifications :

 f = 0.35-0.41 friction coefficient

 Pmax = 0.7 Mpa maximum pressure
 Tmax = 350-400 ˚C for instantaneous maximum temperature
180 ˚C for continuous maximum temperature
 Vmax = 18 m/s maximum velocity

Step 3 : We calculated all required cone clutch dimensions and necessary actuation forces.

a) Uniform Pressure Assumption

When the clutch is new, uniform pressure assumption is used.

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Assumptions :

 f = 0.37 friction coefficient

 F = 1000 N clamping force of the pads ( From Ünlüsoy, F = 1000 - 2000 N for most
automobiles )
 = 12˚ ( From Shigley , = 10 – 15˚, depending upon the characteristics of the
friction materials )
 As a rule of thumb , it is recommended to use ,

T = Tf = (1.3 - 1.5) Te max ,

Tf = 1.5 Te max = 1.5 x 50 Nm = 75 Nm

Design Specifications :

 0 < d / D < 1 d : inside diameter, D : outside diameter

 0.1 < R < 0.2 for most automobiles , R : mean radius of the clutch friction surface

R=

 Pa < Pmax= 0.7 Mpa

 T < Tmax

In order to find clutch dimensions,

d (mm) d/D D(mm) D (chosen) R

80 x x x x
84 x x x x
85 0.9826 86,5 87 0,207
90 0.8703 103,4 104 0,230
95 0.7627 124,56 125 0,265
100 0.6625 150,94 151 0,306
120 0.26 461,54 462 0,77
140 x x x x

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  Pa = 3.703 Mpa for d = 85 mm, D = 87 mm
 Pa = 0.435 Mpa for d = 90 mm , D = 105 mm

Since Pmax = 0.7 Mpa according to design specification,

Pa= 0.435 Mpa < Pmax= 0.7 Mpa ;

We selected d = 90 mm

D = 105 mm

F = 998.8 N ( necessary actuation force )

b) Uniform Wear Assumption

f = 0.3 friction coefficient for uniform wear assumption

Pa = 0.503 Mpa from this equation

Pa = 0.503 Mpa < Pmax = 0.7 Mpa

F = 1066 N ( necessary actuation force )

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Result : = 998.8 N

= 1066 N

Step 4 : We calculated the synchronization time, synchronization speed of the clutch after
engagement and vehicle speed starting from standstill.

In order to calculate synchronization time (ts) , we need some vehicle specifications :

Vehicle Specifications

 Vehicle Mass : 532 kg ( mv )

 Max. engine torque : 50 Nm @ 3250 rpm
 Assume moment of inertia of parts ; ( from Ünlüsoy- belongs to a small car )
 rotating at engine speed : 0.28 kg ( Je )
 rotating at propeller shaft speed : 0.03 kg ( Jp )
 rotating at wheel speed : 6.76 kg ( Jw )
 First gear ratio : 3.818 ( it )
 Differential ratio : 4.412 ( id )
 Transmission efficiency : 0.85 ( nt )
 Tire rolling radius :

= 0.2715 m

 : Rolling radius






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 i ) Synchronization Time

ts = synchronization time

 Je = 0.28 total inertia of engine, flywheel and input side of the clutch

 Jo = + + = 0.164 total inertia of rotating parts of the output

side of the clutch
 wei = 3250 rpm initial engine speed ( engine speed at maximum torque )
 woi = 0 initial clutch output speed ( zero in case of startup )
 Tf = 75 Nm clutch friction torque ( 1.5 x Te max )
 Te = Te max = 50 Nm engine torque corresponding to wei

 To = Rr + Rg ( ) = 1326 Nm

Assumptions :

1. The speed is not likely to rise significantly and thus it would be reasonable to neglect the
air resistance and velocity dependent part of the rolling resistance.

Rolling Resistance

) = 0.0134 raw coefficient

For radial tires coefficient b is:

Since value of ‘ ’ is very small this term can be neglected. So:

2. On level road , Rg = 0 Gradient Resistance

After calculations for synchronization time , it was found as

ts = 0.632 s
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 ii) Synchronization Speed

ws = wei – ( ) ts synchronization speed

ws = 283.7 rad/s = 2710.87 rpm

iii) Vehicle Speed

Vs = vehicle speed starting from standstill,

Vs = 4.21 m/s < Vmax = 18 m/s

Step 5 : For the heat transfer analysis , we found energy dissipated during engagement and
temperature rise corresponding to this. That we corresponds it with specification of T max.

E = Tf ( wei – weo ) x ts / 2 energy dissipated during engagement

E = 8062 J

= temperature rise , ˚C

Cp = specific heat capacity , use 500 J / kg˚C for steel and cast iron

m = mass of the clutch , kg

m=ρxV=ρx xt

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After some calculations ,

∆T = 131.6 ˚C < T max