PROBLEM5.

145
KNOWN: Reaction and composite clutch plates, initially at a uniform temperature, T
i
= 40C, are
subjected to the frictional-heat flux shown in the engagement energy curve,
f
q vs. t '' .
FIND: (a) On T-t coordinates, sketch the temperature histories at the mid-plane of the reaction plate,
at the interface between the clutch pair, and at the mid-plane of the composite plate; identify key
features; (b) Perform an energy balance on the clutch pair over a time interval basis and calculate the
steady-state temperature resulting from a clutch engagement; (c) Obtain the temperature histories
using the finite-element approach with FEHT and the finite-difference method of solution with IHT
(Ax = 0.1 mm and At = 1 ms). Calculate and plot the frictional heat fluxes to the reaction and
composite plates,
rp cp
q and q , '' '' respectively, as a function of time. Comment on the features of the
temperature and frictional-heat flux histories.
SCHEMATIC:
Reaction plate (rp)
Steel (s) Steel (s)
Friction
material (fm)
Composite plate (cp) Engagement energy curve
2L = 2 mm
rp
T(x,0) = T
i
2L =
cp
1 mm L =
fm
0.5 mm
q
cp
q
rp

Time, t(s)
t
lu
0
t
lu
= 100 ms
q

(
t
)
=
+
q
q
r
p
c
p

q
o
q = 1.6x10 W/m
o
7 2

ASSUMPTIONS: (1) One-dimensional conduction, (2) Negligible heat transfer to the surroundings.
PROPERTIES: Steel,
s
= 7800 kg/m
3
, c
s
= 500 J/kgK, k
s
= 40 W/mK; Friction material,
fm
=
1150 kg/m
3
, c
fm
= 1650 J/kgK, and k
fm
= 4 W/mK.
ANALYSIS: (a) The temperature histories for specified locations in the system are sketched on T-t
coordinates below.
T(x,t)
T
i
t
lu
Time, t(s)
Steady-state condition
Mid-plane (cp)
Interface
Mid-plane (rp)
Initial condition
T( ) oo
Initially, the temperature at all locations is uniform at T
i
. Since there is negligible heat transfer to the
surroundings, eventually the system will reach a uniform, steady-state temperature T(). During the
engagement period, the interface temperature increases much more rapidly than at the mid-planes of
the reaction (rp) and composite (cp) plates. The interface temperature should be the maximum within
the system and could occur before lock-up, t = t
lu
.
Continued
PROBLEM5.145 (Cont.)
(b) To determine the steady-state temperature following the engagement period, apply the
conservation of energy requirement on the clutch pair on a time-interval basis, Eq. 1.12b.
T = 40 C
i
o
T(t ) =
Clutch pair - energy balance
q(t) = 1.6x10 W/m 0 t
2 7
lu
t
T( ) oo oo
cp rp
(s)
(fm)
(s)
The final and initial states correspond to uniform temperatures of T() and T
i
, respectively. The
energy input is determined from the engagement energy curve,
f
q vs. t '' .
in out
in out gen st E E 0
E E E E
'' '' = =
'' '' '' '' + = A
( )
( )
( )
lu
t
0
f f i s s rp cp fm fm fm f i
q t dt E E c L / 2 L / 2 c L T T
(
'' '' '' = = + +

}
Substituting numerical values, with T
i
= 40C and T
f
= T().
( )
( ) ( )
o lu s s rp cp fm fm fm i
0.5 q t c L / 2 L / 2 c L T T
(
'' = + +

( )
7 2 3
0.5 1.6 10 W/ m 0.100 s 7800 kg / m 500 J / kg K 0.001 0.0005 m

= +

( ) ( )
3
1150 kg / m 1650 J / kg K 0.0005 m T 40 C
(
+
(

( ) T 158 C = <
(c) Finite-element method of solution, FEHT. The clutch pair is comprised of the reaction plate (1
mm), an interface region (0.1 mm), and the composite plate (cp) as shown below.
Continued ...
PROBLEM5.145 (Cont.)
The external boundaries of the system are made adiabatic. The interface region provides the means to
represent the frictional heat flux, specified with negligible thermal resistance and capacitance. The
generation rate is prescribed as
( )
11 3
lu
q 1.6 10 1 Time / 0.1 W/ m 0 Time t = s s
where the first coefficient is evaluated as
3
o
q 0.1 10 m /

'' and the 0.1 mm parameter is the thickness
of the region. Using the Run command, the integration is performed from 0 to 0.1 s with a time step of
110
-6
s. Then, using the Specify|Generation command, the generation rate is set to zero and the
Run|Continue command is executed. The temperature history is shown below.
(c) Finite-difference method of solution, IHT. The nodal arrangement for the clutch pair is shown
below with Ax = 0.1 mm and At = 1 ms. Nodes 02-10, 13-16 and 18-21 are interior nodes, and their
finite-difference equations (FDE) can be called into the Workspace using Tools|Finite Difference
Equations|One-Dimenisonal|Transient. Nodes 01 and 22 represent the mid-planes for the reaction and
composite plates, respectively, with adiabatic boundaries. The FDE for node 17 is derived from an
energy balance on its control volume (CV) considering different properties in each half of the CV.
The FDE for node 11 and 12 are likewise derived using energy balances on their CVs. At the
interface, the following conditions must be satisfied
11 12 f rp cp
T T q q q '' '' '' = = +
The frictional heat flux is represented by a Lookup Table, which along with the FDEs, are shown in
the IHT code listed in Comment 2.
Nodal arrangement, FDE solution
Reaction plate (rp) Composite plate (cp)
Ax = 0.1 mm
02 03 10 01 11 17 12
(fm) (s) (s)
13 18 22 16 21
q
cp
q
rp

q(t)
Continued ...
PROBLEM5.145 (Cont.)
The temperature and heat flux histories are plotted below. The steady-state temperature was found as
156.5 C, which is in reasonable agreement with the energy balance result from part (a).
COMMENTS: (1) The temperature histories resulting from the FEHT and IHT based solutions are in
agreement. The interface temperature peaks near 225C after 75 ms, and begins dropping toward the
steady-state condition. The mid-plane of the reaction plate peaks around 100 ms, nearly reaching
200C. The temperature of the mid-plane of the composite plate increases slowly toward the steady-
state condition.
(2) The calculated temperature-time histories for the clutch pair display similar features as expected
from our initial sketches on T vs. t coordinates, part a. The maximum temperature for the composite is
very high, subjecting the bonded frictional material to high thermal stresses as well as accelerating
deterioration. For the reaction steel plate, the temperatures are moderate, but there is a significant
gradient that could give rise to thermal stresses and hence, warping. Note that for the composite plate,
the steel section is nearly isothermal and is less likely to experience warping.
(2) The IHT code representing the FDE for the 22 nodes and the frictional heat flux relation is shown
below. Note use of the Lookup Table for representing the frictional heat flux vs. time boundary
condition for nodes 11 and 12.
// Nodal equations, reaction plate (steel)
/* Node 01: surface node (w-orientation); transient conditions; e labeled 02. */
rhos * cps * der(T01,t) = fd_1d_sur_w(T01,T02,ks,qdot,deltax,Tinf01,h01,q''a01)
q''a01 = 0 // Applied heat flux, W/m^2; zero flux shown
Tinf01 = 40 // Arbitrary value
h01 = 1e-5 // Causes boundary to behave as adiabatic
qdot = 0
/* Node 02: interior node; e and w labeled 03 and 01. */
rhos*cps*der(T02,t) = fd_1d_int(T02,T03,T01,ks,qdot,deltax)
.
/* Node 10: interior node; e and w labeled 11 and 09. */
rhos*cps*der(T10,t) = fd_1d_int(T10,T11,T09,ks,qdot,deltax)
/* Node 11: From an energy on the CV about node 11 */
ks * (T10 - T11) / deltax + q''rp = rhos * cps * deltax / 2 * der(T11,t)
Continued ...
Temperature historyfor clutch pair, 100 ms lock-up time
0 200 400 600 800 1000
Engagement time, t (ms)
0
50
100
150
200
250
T
e
m
p
e
r
a
t
u
r
e
,
T
(
C
)
Midplane, reaction plate, T01
Interface, T11 or T12
Midplane, composite plate, T22
Heat flux histories for clutch pair during engagement
0 20 40 60 80 100
Engagement time, t (ms)
-0.5
0
0.5
1
1.5
2
H
e
a
t
f
l
u
x
,
q
''
(
W
/
m
^
2
*
1
0
^
7
)
Frictional heat flux, q''f
Reaction plate, q''rp
composite plate, q''cp
PROBLEM5.145 (Cont.)
// Friction-surface interface conditions
T11 = T12
q''f = LOOKUPVAL(HFVST16,1,t,2) // Applied heat flux, W/m^2; specified by Lookup Table
/* See HELP (Solver, Lookup Tables). The look-up table, file name "HFVST16' contains
0 16e6
0.1 0
100 0 */
q''rp + q''cp = q''f // Frictional heat flux
// Nodal equations - composite plate
// Frictional material, nodes 12-16
/* Node 12: From an energy on the CV about node 12 */
kfm * (T13 - T12) / deltax + q''cp = rhofm * cpfm * deltax / 2 * der(T12,t)
/* Node 13: interior node; e and w labeled 08 and 06. */
rhofm*cpfm*der(T13,t) = fd_1d_int(T13,T14,T12,kfm,qdot,deltax)

/* Node 16: interior node; e and w labeled 11 and 09. */

rhofm*cpfm*der(T16,t) = fd_1d_int(T16,T17,T15,kfm,qdot,deltax)
// Interface between friction material and steel, node 17
/* Node 17: From an energy on the CV about node 17 */
kfm * (T16 - T17) / deltax + ks * (T18 - T17) / deltax = RHS
RHS = ( (rhofm * cpfm * deltax /2) + (rhos * cps * deltax /2) ) * der(T17,t)
// Steel, nodes 18-22
/* Node 18: interior node; e and w labeled 03 and 01. */
rhos*cps*der(T18,t) = fd_1d_int(T18,T19,T17,ks,qdot,deltax)
.
/* Node 22: interior node; e and w labeled 21 and 21. Symmetry condition. */
rhos*cps*der(T22,t) = fd_1d_int(T22,T21,T21,ks,qdot,deltax)
// qdot = 0
// Input variables
// Ti = 40 // Initial temperature; entered during Solve
deltax = 0.0001
rhos = 7800 // Steel properties
cps = 500
ks = 40
rhofm = 1150 //Friction material properties
cpfm = 1650
kfm = 4
// Conversions, to facilitate graphing
t_ms = t * 1000
qf_7 = q''f / 1e7
qrp_7 = q''rp / 1e7
qcp_7 = q''cp / 1e7