OBSERVATION AND OPTIMIZATION OF THE CHARACTERISTIC OF THE DIAPHRAGM SPRINGS USED IN CLUTCH SYSTEMS

by Murat ZBAKI

July, 2008 ZMR

OBSERVATION AND OPTIMIZATION OF THE CHARACTERISTIC OF THE DIAPHRAGM SPRINGS USED IN CLUTCH SYSTEMS

ABSTRACT

The purpose of the project is to observe the characterstics of the diaphragm springs used in clutch systems and their optimatizations according to their environment. During the project worked with Dnmez Debriyaj and the behaviour during working of the code A diaphragm spring that are produced by Dnmez Debriyaj is simulated and the simulation results are compared with the test result. Additionaly the behaviour of code A diaphragm spring during working are optimized for different spring measure and montage locations. Key Words: Diaphragm spring, the characteristic of the diaphragm spring, diaphragm springs in clutch systems, optimization.

DEBRYAJ SSTEMLERNDE KULLANILAN DYAFRAM YAYLARIN KARAKTERSTNN NCELENMES VE OPTMZASYONU

Bu projenin amac debriyaj sistemlerinde kullanlan diyafram yaylarn karakteristiinin incelenmesi ve alma artlarna bal olarak optimizasyonudur. Proje kapsamnda Dnmez Debriyaj firmas ile birlikte allarak firma bnyesinde retilen A kodlu diyafram yayn karakteristii, alma artlarndaki davran bilgisayar ortamnda simule edilmi, elde edilen sonular ile gerek test sonular karlatrlmtr. Buna ek olarak A kodlu diyafram yayn, alma artlarndaki davran farkl diyafram yay lleri ve montaj lokasyonlar iin optimize edilmeye allmtr. Anahtar szckler: Diyafram yay, Diyafram yay karakteristii, Debriyaj sisteminde diyafram yaylar, Optimizasyon

1. Introduction Diaphragm springs that are in conical disk shape are used in crushed worked systems, pressing machine, in valves and capscrews connections as washer. The factors which define the behaviour of the diaphragm springs are the inner and the outer diameter ratio, the height and the width ratio and the outer and the width ratio. Usually the characteristic of the nonlinear diaphragm springs are depends on its height and width ratio. (Akkurt, 1990, Makine Elemanlar Cilt 1) The clutch systems are settled between motor and the gear box. They supply the transition from stopping to moving or step changes in gear box during moving they stop the force between motor and gear box. Clutch systems are transmitting the turn moment to the gear box. (Demirsoy, 2005, Motorlu Aralar Cilt 1) The clutch systems are consisting two main groups: 1- clutch disc 2-clut press. Clutch compless are called clutch springs, spiral springs and pod according to elements used in press and pull and press types according to seperation and clutch shapes. The most preferable system is diaphragm spring with press type. Press plates with diaphragm springs are preferred in automobiles because of their low sensibility to high motor cycle numbers, low heights at high press forces, constant press force in all worn spot way and easy montage. The main advantage of the diaphragm clutch is giving smooth clutching. (Demirsoy, 2005, Motorlu Aralar Cilt 1) The effect of the residual stres to diaphragm spring characteristic are observed numerically and experimentally in the study of Yasunori Doman, Toru Fujii, Kazuya Okubo and Hanjun He. In the study, cast iron marbles with 0.5 mm diameter are applied to diaphragm springs from lower part, upper part or both of parts with roughing method, additionally, the spring without roughing is given as an example in order to compare. At the end of the study,it is recognized that the residual stress consists at the roughing surfaces and that stress affect the diaphragm spring characteristic. It is seen that the free height of the spring changes at the roughing surfaces and because of that change the characteristic curve of the spring changed. Furthermore, it is not enough to explain the total effect of the roughing to diaphragm spring characteristic with free change in height of the spring. (Doman, Fujii, Okubo ve He, 2002)

Necmettin Kaya optimized the diaphragm spring slots by using genetic algorithm in order to increase the fatigue resistance of the diaphragm spring. The slot forms at the diaphragm spring are important because of the height stress fatigue resistance at this region. N. Kaya optimized minimum weight and stress of the diaphragm spring using Matlab and Ansys. (Kaya, 2006) In this study, the characteristic of the A code diaphragm spring produced by Dnmez Debriyaj is simulated and the obtained results are compared with test results. Additionally, A code diaphragm spring optimized for the different diaphragm spring measures and montage locations. 2. Determination And Optimization of A Code Diaphragm Spring Characteristic Material of diaphragm spring which defined characteristic is 50 CrV4 spring steel. The modulus of elasticity 50 CrV4 spring steel is 206000 MPa, and its poision ratio is 0.3. Diaphragm spring is modelled as three dimensional and parametric in Pro-Engineer program which is referended by manufacturing drawing and FEM analysis is made by using ANSYSWorkbench (V11) program. 2.1 Definition of the Diaphragm Spring Characteristic First of all, assembly file prepared which consist of diaphragm spring and diaphragm spring ground place in Pro-engineer program. Diaphragm springs have axis symmetry. After the cad file is prepared, the file is transferred into ANSYS-Workbench program in order to define pre-processing and solution. Environment and boundary conditions defined two main groups. First, displacement apply as a step function 3-6-9-12-15-18-21-24-27 mm from diaphragm spring upper diameter edge to ground. Second, ground part upper side fixed and axis symetry conditions added by diaphragm spring side surfaces. Environment and boundary conditions are seen in Figure 1.

Figure 1. Environment and boundry conditions

Test and analysis results are given in Figure 2.As seen as in Figure 2 test and analysis results are in good agreement. Suppose that, given displacement in test and analysis condition is not sencronized so that phase difference can be occuring between two splines.
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Figure 2. Diaphragm spring characteristic according to test and analysis results

2.2 Diaphragm Spring Test Simulation Assembly file created by using Pro-engineer program. Assembly file consist of three main parts; one, diaphragm spring, two, clutch plate which contact bottom side of diaphragm spring and three fulcrum-ring which contact upper side of diaphragm spring. Diaphragm springs have axis symmetry because of this reason only 15 degrees of diaphragm spring is modeled. Figure 3 shows that, material and contact type selection and environment condition. In the analysis study,upper support point (fulcrum-ring) is fixed, displacement is given from bottom support ponit (clutch plate) to down side of diaphragm spring step by step up to 5 mm, and diaphragm spring can be turn around upper support point.

Figure 3. Pre-processign in ANSYS-Workbench

Diaphragm spring element type is chosen as SOLID187 by ANSYS-Workbench automatically. SOLID187 has 10 node quadratic tetrehedral element. Bottom and upper element type is chosen as SOLID186 by ANSYS-Workbench automatically. SOLID186 has 20 node quadratic hexahedron element and also in contact areas quadratic triangular and quadratic quadrilateral elements are chosen. The aim of the analysis is to define the reaction force in contact areas, so that mesh density is not increased at all parts. Test and analysis results are given in Figure 4.

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Figure 4. Spring characteristic according to diaphragm spring test and analysis results

2.3 Diaphragm Spring Optimization The aim of this study is to define the change of the maximum reaction force related to diaphragm spring thickness and upper side support point location. While FEM solution is preparing, Ansys and Pro-engineer program work and communicate each other. In Optimization; Diaphragm spring nominal thickness is 3,85 mm and thickness value of optimization gap is taken from 3 mm than 4 mm. Bottom support point montage location value is 307,5 mm and montage location value of optimization gap is taken from 290 mm than 320 mm. The results of FEM analysis, can be defined maximum reaction force changes between bottom support point (clutch plate) and diaphragm spring which is related to two parameters. Optimization results are shown in Figure 5. It is possible to view relation between three parameters by the Response Surfaces Techniques as the seen at Figure 5. In figure 6, it is shown that the change of reaction force related to the change of support point location by graphically.

Figure 5. Observation of optimization results relative to each others

Figure 6. Relation between the support point location change and reaction force

3. Conclusion It is seen that the characteristic of the diaphragm spring can be calculated during designing accurately while the solutions are observed. Numerical simulations for the clutch plate and fulcrum-ring montage of different diaphragm springs are supplying time and money conservation for Dnmez Debriyaj without doing environment tests, by the time the Project reached to the main goal. In addition to this, the characteristic of the diaphragm springs which are get by numerical simulations for Dnmez Debriyaj is giving a general information in the clutch system but it is not enough alone. Specially, clutch system and the other parts in this system must be observed as vehicle dynamic and diaphragm spring must be analyzed with this system. Both the studies until today and solutions of the projects are observed and it is seen that the factors that affect the diaphragm spring characteristic are its geometry, material and microstructer properties of the material, thermal and surface process. Nowadays, these all parameters cant be defined in numerical simulations. In the future increasing the performance of the computers and the numerical programs provides more accurate numerical results. References Akkurt, M. (1990). Makina Elemenlar, Cilt I. stanbul: Birsen Yaynevi.

Demirsoy, M. (2005). Motorlu Aralar, Cilt I (3. Bask). stanbul: Birsen Yaynevi

Doman, Y., Fujii, T., Okubo, K., He. H. (2003). Influence of residual stress on the load deflection curve of diaphragm springs for automobile clutches. JSAE Review, 24, 197-203, 10 Eyll 2008, www.elsevier.com/locate/jsaerev

Kaya,. N. (2006). Optimal design of an automotive diaphragm spring with high fatigue resistance. Int. J. Vehicle Design, 40, 126-143

Handbook of disc springs, (b.t). Ocak.2008, http://www.schnorr.com/handbook.html