BHILAI INSTITUTE OF TECHNOLOGY , DURG

MINI Project Report

on
TOPIC

“ Machine Design – I- LAB ”

Guided By :- Submitted By :-
DR. SHUBHRATA NAGPAL NAME OF STUDENTS

PROFESSOR (I/C) (Univ. ROLL NO.)

B.E. 5th Sem “A”, SESSION – ODD 2018

Mechanical Engineering Department

Bhilai Institute of Technology, Durg (C.G.)

 CERTIFICATE

This is to certificate that report of the mini project submitted is an outcome of the project work entitled
“title” carried out by

NAMES Univ Roll No.

Univ Roll No.

Univ Roll No.

Univ Roll No.

Carried out under my guidance and supervision in Bachelor of Engineering , Fifth Semester in
Mechanical Engineering at Chhattisgarh Swami Vivekanand Techanical University, Bhilai (C.G),
India

To best of my knowledge the report is

 Embodied the work candidates themselves

 Has duty been completed

 Is up to the desired standard for the purpose of which is submitted

Dr. Shubhrata Nagpal

Professor In charge Project

 ABSTRACT

The clutch is one of the main components in automobiles. The engine power transmitted to the system
through the clutch. The failure of such a critical component during service can stall the whole
application. The driven mainplate failed normally during its operation due to cyclic loading. This project
explains the structural analysis of the clutch plate by changing fillet radius. This project finds the
maximum stress in failure region during operation. It also suggests design modifications to improve the
life time of the clutch plate.
1. INTRODUCTION
A clutch is a mechanical device that engages and disengages the power, transmission, especially from
driving shaft to drivenshaft. Clutches are used whenever the transmission of power or motion must be
controlled either in amount or over time (e.g., electric screwdrivers limit how much torque is transmitted
through use of a clutch; clutches control whether automobiles transmit engine power to the wheels).
In the simplest application, clutches connect and disconnect two rotating shafts (drive shafts or line
shafts). In these devices, one shaft is typically attached to an engine or other power unit (the driving
member) while the other shaft (the driven member) provides output power for work. While typically the
motions involved are rotary, linear clutches are also possible.
In a torque-controlled drill, for instance, one shaft is driven by a motor and the other drives a drill chuck.
The clutch connects the two shafts so they may be locked together and spin at the same speed (engaged),
locked together but spinning at different speeds (slipping), or unlocked and spinning at different speeds
(disengaged).

Figure 1: clutch plate with mountings.

1.1 Requirements of clutch

Transmit maximum torque of the engine
Engage gradually to avoid sudden jerks
Dissipate maximum amount of heat
Damp the vibrations and noise
Dynamically balanced
As small as possible
Easy to operate
1.2 Clutch material
Table 1.1

1.3 Clutch plate material properties

Table: 1.2
2. THEORETICAL ANALYSIS ON DRIVEN PLATE
2.1 Design of a Disc or Plate Clutch
When the pressure is uniformly distributed over the entire area of the friction face then the intensity of
pressure,
P = (W)/ Π *r1²- r2²]
P=intensity of pressure,
(From the table or data book given for various materialsi.e. 0.25 -0.4 Mpa for cast iron or steel)
P = Taking average 0.32 Mpa
W=Axial thrust
R1= Outer Radius (55mm)
R2= Inner Radius (16mm)
Therefore W = 2.7 kN
2.2 Max Pressure
Since the intensity of pressure is max at the inner radius (r2) therefore
P max, (r2)= C (Constant)
C= 16 P max
We also know that total force on the constant surface (W)
2.7 KN= 2 ΠC *r1²- r2²]
Note: {[P=C/r] Let P be the Normal Intensity Of pressure at a distance “r”from the AXIS OF THE
CLUTCH. Since the intensity of pressure varies inversely with the distance, thereforethat is the reason
why intensity of pressure is Maximum at inner radius (r2) which causes propagation of crack.}
2.7 KN= 2 Π(16 P max ) *55²- 16²]
P max = 0.68N/mm²
2.3 Min Pressure
Since the intensity of pressure is min at the outer radius (r1), therefore
Pmin (r1)= C (Constant)
C= 55 P min
2.7 KN= 2 Π(55 P min ) *55²- 16²]
P min = 0.2 N/mm²
2.4 Average Pressure
Pavg = Total Normal Force/ Area
Pavg = W/ Π *r1²- r2²]
Pavg = 0.31 N/mm²
3. DESIGN OF CLUTCH PLATE IN CATIA V5 SOFTWARE

3.1 Model of Clutch Plate

Open CATIA V5 software, select X-Y plane and draw the 2D diagram of the clutch plate

Figure 3.1 Dimensions of Clutch plate

Dimensions of the clutch plate

Outer diameter: 110mm
Inter Diameter: 32
Hole Diameter: 5mm
No of Holes: 6
Clutch plate thickness: 3mm
Rectangle dimensions: 23mm×17.66mm×3mm
Fillet radius:0mm, 1.5mm, 2mm, 2.5mm, 3mm
Clutch plate material: Structural steel

3.2 DESIGN OF CLUTCH PLATE

Figure 3.2 Solid Model of Clutch Plate

4. CLUTCH PLATE ANALYSIS USING ANSYS WORKBENCH
To analyzing this product the ansys work bench is required. So after design completed, the model is
imported into the ansys work bench
The Material For Clutch (Structural Steel)

Figure 4.1: After importing

After importing the model into ansys work bent, meshing is required

Figure 4.2 After meshing

 Figure 4.3Fixed Support

Figure 4.4: Pressure force

4.1 Without Fillet:

Figure4.5:Total Deformation
 Figure 4.6: Equivalent Stress

Figure4.7: Maximum Principal Stress

Figure4.8: Middle Principal Stress

Figure 4.9: Minimum Principal Stress

Figure4.10: Normal Stress

 4.2 With 1.5mm Fillet

Figure 4.11: Total Deformation

Figure 4.12: Equivalent Stress

Figure4.13: Maximum Principal Stress

 Figure4.14: Middle Principal Stress

Figure 4.15: Minimum Principal Stress

4.3 with 2mm fillet

Figure 4.17: Total Deformation

Figure 4.18: Equivalent Stress

Figure4.19: Maximum Principal Stress

 Figure 4.20: Middle Principal Stress

Figure4.21: Minimum Principal Stress

Figure4.22: Normal Stress

 4.4 With 2.5mm fillet

Figure4.23: Total Deformation

Figure4.24: Equivalent Stress

Figure4.25: Maximum Principal Stress

 Figure4.26: Middle Principal Stress

Figure4.27: Minimum Principal Stress

Figure4.28: Normal Stress

 4.5 with 3mm fillet

Figure 4.29: Total Deformation

Figure 4.30: Equivalent Stress

Figure 4.31: Maximum Principal Stresses

 Figure4.32: Middle Principal Stress

Figure 4.33: Minimum Principal Stress

Figure 4.34: Normal Stress

5. Results

We done the Static structural analysis on driven plate of clutch of structural steel
material with different fillet radius on Ansys work bench
After done the analysis on clutch plate the following results are occurred
6. Conclusion
By reference of above table the stress and the deformation are slow down at the fillet radius of
2.5mm.
The stress and deformation are without fillet respectively is 258.58mpa, 0.2457mm.
The stress and deformation are 2.5mm fillet respectively is 251.3mpa, 0.24289mm.
By compare with all the data the 2.5mm fillet clutch plate is better than all the clutch plates’
models because the stress development and total deformation is low.
Finally the 2.5mm fillet radius of driven plate is suitable for design of clutch and life of the clutch
is increases.
References
[1]. Mr.N.V.Narasimharao.L, Ch.Chandrarao ―Static and Dynamic Analysis of Clutch Plate With
Crack‖, IJRMET, Volume 4, Issue Spl - 1, Nov 2013
[2]. Dr. J. P. Modak, ShrikantV.Bhoyar, Dr. G. D. Mehta, ―Dynamic Analysis Of Single Plate
Friction Clutch‖, IJERT, Vol. 2, Issue 7, July – 2013
[3]. Mr.Prashil M. Mhaiskar, Nitin D. Bhusale, Mayur D. Pastapure ―Vibration Analysis of Dry
Friction Clutch Disc by Using Finite Element Method‖, IJERT, Volume 3, Issue 1, January – 2014
[4]. Mr.RajeshPurohit, PoojaKhitoliya and Dinesh Kumar Koli, ―Design and Finite Element
Analysis of an Automotive Clutch Assembly‖, ScienceDirect, Procedia Materials Science 6, 2014
[5]. Mr.Monarch K. Warambhe, Gautam R. Jodh, Mamta G. Pawar, ―Design and Analysis of
Clutch Using Sintered Iron as a Friction Material‖ ,IJITEE, Volume-3, Issue-7, December 2013
[6]. Mr. P.NagaKarna, TippaBhimasankaraRao, ―Analysis of Friction Clutch plate using
FEA‖,IJERD, Volume 6, Issue 2, March 2013
[7]. B. Nivas, M. Nithiyanandam, S. Tharaknath, A. AvinashKumar, ―Design and Analysis of
Clutch Plate Using Steel Material [En –Gjs-400 -15steel+‖, IOSR-JDMS, Volume 13, Issue 5, May.
2014
[8]. Automobile engineering by Dr. Kirpal Singh
[9]. Strength of materials by Dr. R.K. Bansal
[10]. Machine design by R.S. Khurmi& S. Chand publications
[11]. Finite element analysis by S.S. Bhavikatti