Thermal and mechanical analyses of dry clutch disk made of functionally graded aluminum matrix composite

Abstract

This research work presents an innovative utility of Functionally Graded Aluminum Matrix Composite with Silicon Carbide as a friction material in clutches' plate since it has an acceptable friction coefficient and a high wear resistance which may lead to longer working life. Functionally Graded Aluminum Matrix Composite's properties are calculated using rule-of-mixture and power law, and simulated as layered geometry. Clutches designed based on the standard size and working conditions of clutches in mid-size and heavy automobiles. Functionally Graded Aluminum Matrix Composite's behavior is examined considering statics, dynamics, thermal and wear. Analyses are done using Finite Element method, by ANSYS with boundary conditions that represent the actual working conditions of clutch in automobiles. The developed finite element model is validated by comparing it to literature and has achieved good agreement. Results are discussed by comparing functionally graded aluminum matrix composite's clutch performance to aluminum matrix composite with 20% of silicon carbide clutch and e-glass clutch performances. FGAMC clutch showed excellent behavior considering static analysis where deformations were the least among the three materials. The thermal and free vibrational performance of the FGAMC were not the best but with very small differences compared to aluminum matrix composite and e-glass clutches. Very unwanted performance of FGAMC is recognized in forced vibration analysis, as it has very high stresses, strain and deformation compared to the other two materials. Structural transient behavior of FGAMC is acceptable as it has the lowest deformations and strains from the highest stresses but in small area of the contact surface of the clutch. Volume loss in FGAMC due wear is less compared to traditional aluminum matrix composite by more than 4 times.