CLUTCH DESIGN

In clutch design, calculations were performed with Matlab or using a calculator. The formulas of all of our calculations in clutch design is shown below. Step 1: We selected the clutch type: Disk Clutch Disk Clutch: A friction clutch in which the gripping surfaces are disks or more or less resemble disks. Step 2: We selected the material of the Clutch: Wound asbestos yarn and wire This meterial is used for vehicle clutches. We selected it from Shigley Table 16-3 Specifications: f = 0.38 Pmax = 0.7 MPa Tmax = 350 0C Tmax = 150 0C Vmax = 18 m/s friction coefficient maximum pressure instantaneous maximum temprature continuose maximum temprature maximum velocity

Step 3: We find all required disc clutch actuation forces and dimensions a) Uniform Pressure Assumption Thw clutch is new so we use the equation (from Shigley) below:

Assumpitons: F = 1500 N clamping force of the pads (From nlsoy 1000-2000 for most automobiles) As a rule of thumb, it is recommended to use, T=Tf=(1.3-1.5) Temax Tf=(1.5) Temax = 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

Pa < Pmax = 0.7 MPa T < Tmax To find clutch dimensions: d (mm) 380 410 420 460 500 540 580 620 660 From Shigley; d/D X 0.9775 0.9296 0.7508 0.5855 0.4237 0.2457 0.1381 X D(mm) X 419.437 451.787 612.679 853.970 1274.303 2360.58 4487.518 X D (chosen) X 420 452 613 854 1275 2361 4488 X R X 0.207 0.218 0.270 0.346 0.478 0.825 X X

1. Pa=0.23 MPa for d=410 mm, D=420 mm 2. Pa=0.06 MPa for d=420 mm, D=452 mm We take the first one because its R is closer to 0.1<R<0.2 interval. Pa=0.23 MPa<Pmax=0.7 MPa F=1498.56 N (Necessary actuation force)

b) Uniform Wear Assumption From Shigley;

f=0.38 friction coefficient for uniform wear assumpiton Pa=0.1477 MPa from Equation Pa=0.1477 MPa< Pmax=0.7 MPa

F=950.74 N (necessary actuation force) Result: Funiform Pressure = 1498.56 N Funiform wear= 950.74 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 nlsoy- belongs to a small car ) rotating at engine speed : 0.28 kgm2 ( Je ) rotating at propeller shaft speed : 0.03 kgm2 ( Jp ) rotating at wheel speed : 6.76 kgm2 ( Jw ) First gear ratio : 3.818 ( it ) Differential ratio : 4.412 ( id ) Transmission efficiency : 0.85 ( nt ) Tire rolling radius :

m=0.35574 kg m=0.35574 kg