Work term presentation

LuK-Schaeffler

Introduction

• Hamaish Khan 3rd year Mechanical Engineering with Automotive honors student

• Extended work term (12-months) in Durability department at LuK-Schaeffler, Buehl, Germany

• Company overview:

LuK is a member of the Schaeffler Group along side with INA and FAG, which is internationally renowned automotive manufacturer for clutch, transmission components, torque converters and torsion dampers etc

Job responsibilities

•Making finite element models, performing analysis, reporting and presentation

•Performing static, temperature, heat transfer and modal analysis

•Strength assessment

•Performing highly non-linear simulations

•Supporting in new method development of thermo-shock and thermo- mechanical test for clutches

•Simulating diaphragm spring characteristics

•Parametric study on the influence of material properties on deflections in clutches

•Validations of FEA models

•Working with externals CADFEM GmbH for programming models

Agenda

• Introduction to work term report topic

• Current Project status

• Further requirements for the project

Project - Topic• The problem was to model the outcome from thermo-shock test for clutches

in the ANSYS Workbench (FEA software). Precisely, to get the same results (e.g. deflections, cracks etc.) as seen in thermo-shock test

Automotive clutch FEA model

Overview of test• Thermo-shock test

The goal of the test is to verify the pressure plate/flywheel strength durability mounted in the clutch plate during an energy overload of 15 sec.

• Working of mechanical clutch

Thermo-shock test results

• Results from the actual test rig

Overview of FEA model

Pressure plate

Simplified clutch disk

Simplified clutch disk would be axially fixed

Axial force is applied on the load clamp areas of pressure plate

A pressure dependent heat flux is introduced into the contact using UPFs (User programmable features).

Pressure plate geometry CAD

Results from FEAContact pressure (LC 1)

MPa

Contact pressure (LC 6)

Local High pressure

MPa

Avg. difference : 1537°C

Temperature distribution (LC 6)

Avg. difference : 230 °C

Temperature distribution (LC 1)

Results from FEAHeating up time (LC 6)

Heating up time (LC 1)

Significant increase in axial delfection

Furture concern• Integration of wear model

Without wear With wear

1 sec

10 sec

15 sec

Pressure distribution

Conclusion

• Experienced gained

Finite element modelling

knowledge of User programmable features UPFs (ANSYS)

High performance computing (HPC)

Working of mechanical clutches

Knowledge of thermo-shock and thermo-mechanical test for clutches

Thank you for your attendance