Modeling and Performance Analysis of an Automotive Friction Clutch Plate Using Thermal Load Resisting Friction Material

Abstract

The clutch is a critical component of the transmission system, responsible for engaging and disengaging power transmission between the engine crankshaft and the gearbox input shaft. However, current clutch materials often face challenges related to thermal load resistance, durability, and efficiency, which can lead to premature wear and reduced performance. This thesis investigates the modeling and analysis of automotive friction clutch plates, with a focus on identifying thermal load-resisting friction materials to address these limitations. The study evaluates the thermal properties of various friction materials and their impact on clutch performance, aiming to determine the optimal material for enhancing durability and efficiency. The research includes an extensive literature review, detailed simulations using ANSYS Ls Dyna software, and a comparative analysis of materials such as E-Glass Epoxy, Aluminum Alloy (6061), Gray Cast Iron, and Kevlar 49. Key parameters such as dynamic pressure, temperature, and equivalent stress are examined. The results reveal that E-Glass Epoxy and Aluminum Alloy (6061) are promising candidates for clutch applications. E Glass Epoxy, in particular, demonstrates superior performance with a maximum dynamic pressure of 0.783 MPa, a maximum temperature of 135.04°C, and a maximum equivalent stress of 6.2538 MPa. Additionally, it boasts a safety factor of 15, indicating high reliability in clutch applications.Despite these promising findings, current clutch materials, such as Gray Cast Iron, often struggle with excessive thermal stress and wear under high-load conditions, leading to reduced lifespan and performance. Kevlar 49, while offering high strength, may not provide sufficient thermal resistance for demanding applications. These limitations highlight the need for advanced materials like E-Glass Epoxy, which offers a balanced performance across critical parameters. In conclusion, this study provides a comprehensive analysis of four materials for clutch friction disks, identifying E-Glass Epoxy as the most suitable due to its well-rounded performance and high safety factor. Future research could explore hybrid materials or optimization techniques to further enhance thermal resistance and durability, addressing the limitations of current clutch materials and improving overall system performance.