design, development and evaluation of dual belleville...
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International Journal of Mechanical & Mechatronics Engineering IJMME-IJENS Vol:15 No:01 79
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152301-8484-IJMME-IJENS © February 2015 IJENS I J E N S
Design, Development and Evaluation of Dual
Belleville Clutch in Front End Loader Tractor for
Clutch Life Enhancement
1Dr.P.S.Senthil Kumar., Professor, Department of Mechanical Engineering.,VEL TECH UNIVERSITY, Avadi, Chennai-
600062,Tamil nadu,India
Email: [email protected] 2P.Srinivasan,Member R&D.,Tractor & Farm Equipments Limited,TAFE.,Sembium, Chennai,Tamil Nadu,India.
Email:[email protected] 3Kishore Kumar Palati., Assistant Professor.,. Department of Mechanical Engineering.,VEL TECH UNIVERSITY,
Avadi,Chennai-600 062,Tamil nadu,India
Email: [email protected] 4Gandhi Mallela., Assistant Professor., Department of Mechanical Engineering. VEL TECH UNIVERSITY, Avadi,Chennai-
600 062,Tamil nadu,India
Email: [email protected]
Abstract-- In tractors, during front end loader, dozer, dry and
wet puddling applications there will be higher frequency of
operation of clutch because of increased need of quick forward
and reverse transmissions. This leads to the slippage of dry clutch
because of the usage of coil type clutch where there is reduction
in clamp load within minimum hours of time because of inability
of the coil springs to withstand high temperature. This would
result in excessive scoring marks in pressure plate and flywheel,
and glazing of friction material, effecting in slip of the clutch
leading to replacement of dry clutch assembly as a whole. In this
experimental work, it is proposed to modify the design and
replace the coil springs used in the dry clutch with belleville
spring which has the ability to withstand high temperature
leading to enhanced clutch life in high torque applications of the
tractor. This project comprises of calculations and analysis made
in support to the usage of belleville spring in dry clutch for front
end loader and other high torque applications. The result is a
theoretical comparison of existing coil springs with the belleville
spring in the clutch to prove the enhanced heat carrying capacity
of the belleville spring and thus resulting in improved reliability
of dry clutch in tractors.
Index Term-- Belleville clutch, operating temperature,
slippage, excessive scoring, slip
1. INTRODUCTION
Agricultural tractor attached with the front end loader
is commonly used in construction site because of its cheaper
price as compared to earth moving machine. The tractor used
for this application need to move forward and backward
repeatedly because of this clutch need to operate very
frequently which lead to increase the temperature of clutch. If
during single clutch engagements or in many repeated
applications the fiction surface temperature generated
becomes coefficient of fiction between the mating surfaces
fluctuates appreciably (generally µ decreases with increase in
temperature); steel contacting bodies distort and develop
surface cracks, metallic plates weld together and non-metallic
clutch plates wear at a greater rate than at lower temperatures.
The most failures and damages in the friction clutch occur due
to excessive frictional heat and heat fluctuations. These
situations lead to generate high thermal stresses, which causes
cracks and deformation for the friction material of clutch.
Finally, these disadvantages lead to reduce the lifecycle of the
friction material. After repeated clutch engagement the
temperature on the clutch facing could attain very high values,
around 300-350°C and, above 350-400°C the friction system
starts to suffer permanent damage.
In Heavy Duty front end loader application the
frequency of operation even reach to 7 to 8 application of
clutch per minute. As a result the temperature of the clutch
assembly rises beyond their temperature limit thereby
decreasing torque transmitting capacity of the clutch due to
fading or glazing of clutch friction material. In normal
application of tractor, the expected life of clutch is 500 h of
operation but when the tractor is used for this application the
life of clutch is reduced to 300 h of operation. The coil starts
to lose its load carrying capacity because of increased heat at
the clutch. In other words, the clamping load reduces for the
clutch, resulting in clutch slippage at frequent intervals. In
order to compensate the above loss, it is proposed to replace
the coils in the dry clutch with modification in belleville
spring to avoid failure.
2. LITERATURE REVIEW
2.1 H.K.Dubey and Dr. D.V. Bhope (2012), Many
researchers have carried out stress and deflection analysis of a
Belleville spring. the stress and deflection analysis to prepare
a CAD method for the checkout and design of the Belleville
springs. The method eliminates the need to resort to
conventional trial-and-error techniques. In a matter of seconds,
it rapidly and accurately checks out and designs Belleville
springs, outputting the load deflection characteristics in
graphic and table formats and can generate a dimensioned
drawing. the stress and deflection analysis of a slotted
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Belleville spring to develop a analytical relationship for
deflection and stress of a slotted conical spring.
2.2 Abdullah and Schlattmann (2012) developed a
two dimensional model to obtain the numerical simulation for
band contact of disc clutch during slipping. In this study, three
type of pressure application was used viz. constant pressure,
linearly increasing pressure and parabolically increasing
pressure. Finite element method was used to calculate the heat
generated on the surfaces of friction clutch and temperature
distribution for case of bands contact between flywheel and
clutch disc, and between the clutch disc and pressure plate.
They found that both slipping time and contact area ratio are
intensely effect disc clutch temperature fields in the domain of
time. Temperature distribution for constant pressure type is
higher than the other types of pressure, because of the total
quantity of thermal load is applied in short time with
compared to other types of thermal loads. In case of repeated
engagement, the linearly increasing pressure developed
maximum temperature. The damaged or incorrectly machined
flywheel causes many of problems one of them is focusing the
pressure on small regions of nominal frictional interface (e.g.
bands and spots).
2.3 Cappetti, et. al. (2012) observed the influence of
temperature on the cushion spring behavior in terms of the its
load-deflection curve and in terms of the axial thermal
expansion. They developed FE model for cushion disk and it
was validated by measuring actual load deflection of the
cushion spring at temperature of 20°C. Afterward, FE model
was set to different temperature and observed the change in
load-deflection curve as an effect of temperature. In their
study, they had found that at higher temperatures the curves
start deflecting before of the reference curve at 20°C start
deflecting. This effect is due to thermal expansion which
produces axial size increase and consequently a change of the
kiss point position.
2.4 Yevtushenko e al (1999) applied one-
dimensional transient heat conductivity to study the contact
problem of a sliding of two semi-spaces, which induces effects
of friction, heat generation and water during braking. In the
present temperature analysis the capacity of the frictional
source on the contact plane dependent on the time of braking.
The problem solved exactly using the Laplace transform
technique. Numerical results for the temperature are obtained
for the different values of the input parameter, which
characterize the duration of the increase of the contact
pressure during braking from zero to the maximum value. An
analytical formula for the abrasive wear of the contact plane is
obtained in the assumption, that the wear coefficient is the
linear function of the contact temperature
3. PROBLEM DESCRIPTION
The major cause of clutch failure can be
summarized with two words, “EXCESSIVE HEAT”
extreme operating temperatures (excessive heat) can cause the
clutch to fail because the heat generated between the
flywheels. Driven discs, coil spring and pressure plate are high
enough to cause the metal to flow and the friction material to
be destroyed. During high torque applications like front end
loader, dozer, dry and wet puddling, there will be higher
frequency of operation of the clutch as forward and reverse
gears will be used regularly and the application would
continue for around eight hours together. Since the clutch
engagement frequency is around seven to eight times per
minute and it is persistent for very long duration, during the
above mentioned applications, there will be increased heat
generation in the clutch.The coil starts to lose its load carrying
capacity because of increased heat at the clutch. In other
words, the clamping load reduces for the clutch, resulting in
clutch slippage at frequent intervals. In order to compensate
the above loss, it is proposed to replace the coils in the dry
clutch with belleville spring to avoid failure due to facing
wear.
Fig. 1. Front end loader
Fig. 2. Dry puddling
Fig. 3. Dozer
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Fig. 4. Wet puddling
Figure 1 details about the use of front end loader and
figure 2 describes the dry puddling application.In figure 3 the
dozer is used for special purpose in fields.Tractor is used for
wet puddling in figure 4.
4. PROPOSED WORK
In this project, the study and analysis is made on a 55kw
tractor subjected to front end loading and back hoe
applications. This duty cycles were chosen since the rate of
failure is higher with the existing dry clutch tractors (Coil
type).
The design approach adapted to this work is as
follows
Evaluation of different concepts to derive the optimal
design
Detailed design and analysis of finalized concept
Mathematical model to derive
Disc belleville load calculation.
Clutch clamp load Vs Travel
Clutch release load Vs Travel`
Torque capacity of clutch
Development and assembly of proto samples in the
base tractor, testing and experimental evaluation
Comparison of results from mathematical analysis
with the experimental measurement.
4.1 OBJECTIVE
Based on the above brief discussion, the following objectives
have been decided.
1. Study and Analysis of exiting clutch system
and parameter affecting clutch system.
2. Design and fabrication of belleville system
of clutch.
3. Performance evaluation of the Designed
clutch system
5. METHODOLOGY
5.1 DISC BELLEVILLE LOAD CALCULATIONS
The Nomenclature section describes the spring
parameters used in calculations. Load in lbs at a given
deflection and flat are the formulas. When calculating loads
take care to pay special attention to the four factors mentioned
below.
Nomenclature of belleville
5.2 LOAD FOR A GIVEN DEFLECTION.
In flattened condition, the deflection f is equal to the
conical height h and the equation becomes. If Pf
5.3 DYNAMIC LOADING AND FATIGUE LIFE
5.3.1 DYNAMIC LOADING
Dynamic loading of disc springs occurs when the
load continuously changes from preload to final load. The
"stress-time" curve of such disc springs which pulsate
uniformly is sinusoidal. This is not true in cases of impact
loading and therefore it is difficult to predict their life and
behavior.
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Disc spring "life" may be differentiated into 2
categories:
1. Limited life: where cycles vary without failure
between 40,000 and 2,000,00 cycles.
2. "Unlimited life": cycles in excess of 2·106 without
failure. For virtually indefinite life, the table below indicates
the appropriate values required given in percent of travel,
relating preload to final load and considering the disc spring
thickness Table I
Maximum deflection
Max Deflection
in % of h
Preload
in % of
h
Disc
Thickness <=.039
Disc
Thickness
b>=.157
15 50 44
25 56 49
50 67 64
5.3.2 FATIGUE LIFE
Fatigue life for a disc spring is defined by the
effective number of stress cycles that can be sustained prior to
failure under certain conditions. This depends on the minimum
stress, maximum stress and stress range.
The diagrams presented here are for evaluating
fatigue life of single disc springs or series stacks not more than
6 springs. There are three basic groups, depending on
thickness (see legend under each diagram).The horizontal
border line enclosing the top portion of the graph (zone)
represents the yield strength of the spring steel material.
Intersection points of min/max stress limits which fall outside
the graph/zone boundaries are to be avoided as they indicate
spring failure is likely at an early stage.
The graphs were developed based on empirical test
data. The test loads were sinusoidally executed.
Graph 1: Final stress Vs Preload stress
Graph 2: Final stress Vs Preload stress
Graph 3: Final stress Vs Preload stress
5.4 LOAD AND STRESS CALCULATIONS.
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5.2 CLUTCH CLAMP LOAD / RELEASE LOAD VS
TRAVEL
As well as enabling a compact design, transmission
disc springs offer an additional functional advantage. As
opposed to coil spring packs, which always have a linear load
curve, slotted disc springs can achieve a mainly horizontal
load curve if desired. The spring load can be kept constant
during the stroke ( working range ) , i.e. between E.H (
engaged height ) and spring height at closed clutch including
wear F.L.H. ( fully loaded height ). In spite of the somewhat
higher manufacturing tolerances required for disc springs (
standard wise +/- 10% compared to +/- 6% for coil springs ),
this results in a significantly lower load difference between the
two working points E.H and F.L.H . In addition, tighter load
tolerances can be kept for specific working points if desired.
Graph 4: Clamp load Vs Travel (Comparison of coil
Vs Diaphragm)
This leads to a big advantage with respect to gear
change, particularly with the control of the hydraulic system.
The spring load is constant, regardless of the actual position of
the piston in the engaging range, and the oil pressure can be
controlled within a much smaller range, as less hydraulic
pressure is required due to the lower load difference between
E.H and F.L.H. In this study, the hydraulic pressure required
for torque transmission could be reduced by 60Kpa, leading to
an improvement of more than 0.2% in total efficiency at the
F.L.H. point.
5.2.1 Radial Rigidity at High Revolutions
A further benefit offered by disc springs as opposed
to coil springs is the high shape retention and stiffness against
external forces. This is particularly noticeable at high clutch
revolutions, which lead to high radial centrifugal forces. The
single coil springs have a tendency here to “bulge out “radially
which has a negative impact on performance. belleville disc
springs are not affected due to high revolutions
Fig. 6. Stiffness at high revolutions
5.3.1 Torque capacity of the clutch A simplified clutch diagram is shown in
figure given below
Fig. 7. Line Diagram of Clutch
In this figure
F = Clamping force of the clutch, N.
P = Pressure on the contact surface, N/ m2.
μ = co-efficient of friction.
Ri = Inner radius of the friction disk, m.
Ro = Outer radius of the friction disk, m.
Consider an elemental ring of radius ‘r’ having thickness of
‘dr’ as shown in above figure.
Force acting on the elemental ring, dF = 2πrpdr
Total force , -----------------
-------------- (1)
Torque transmitted by the elemental ring, dT =
2πrpdr ×μ×r
Total torque transmitted, -----
----------- (2)
There are two case
Case 1: Uniform pressure condition, (p =
constant)
From equn (1), we have,
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--(3)
From equn (2) , we have,
By using equ
n. (3), we have,
---------(4)
Case 2: Wear rate is constant
The rate at which surfaces wear depends not only on
the pressure but also on the velocity of sliding between the
surfaces.
rate of wear = f(p, v)
rate of wear = a1pv [ where a1 = constant]
rate of wear = a2pr [v = 2πrω and a2 =
2πωa1]
If the rate of wear is constant,
pr = constant = a3
The equn. (1) becomes
-----------(5)
And equation (2) becomes
By using equation (4),
-------------- (6)
In our calculation we are going to use equn. (6)
because the torque capacity given by the equn. (6) is less as
compared to the torque given by equn. (4) on top of this when
the clutch is used for longer period the concept of uniform
pressure is no longer valid rather it is a constant wear.
5.3.2 Variation of coefficient of friction with
sliding velocity
Generally, during the clutch engagement the
transienttemperature causes a variation in μwhich may be
consideredto be included in the change in friction with
slidingvelocity( T. P Newcomb. 1961).
Graph 5: variation of coefficient of friction with the
sliding velocity
The graphs show that the coefficient of friction
decreases withrelative sliding velocity. For many materials,
this variation may be approximated to by the following
relationship.
------------ (7)
where,
= Co-efficient of friction at high velocity
= Static coefficient of friction
μ = Co-efficient of friction value at sliding speed v
a = Constant
The tangential relative velocity at radius r is
v = ωrr
Using above relation in equn.(7), we get
--(8)
Using equn.(8) in equ
n.(2) and adopting constant rate
of wear condition
Solving the above equation by using ILATE, we get
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--
------------------------------------------------------- (9)
5.3.4 Rate of energy dissipation
Consider the basic power transmission
system shown in following diagram.
Fig. 8. Basic power transmission
Let two bodies having inertias II and I2initially
rotating at unequal angular velocities Ωland Ω2, and at any
instant ‘t’ rotating at different angular velocities ω1 and ω2
respectivelythroughout the clutch engagement. Il belongs to
the input shaft being driven by a torque T1 and I2belongs tothe
output shaft having a resistive load torque T2. Duringslipping
the torque capacity of the clutch varies as a functionof time (t).
It is assumed that the torques Tl and T2are constant since any
variation in these values is likely tobe small compared to the
uncertainty of their measuredvalues.
When the clutch is start engaging (ω1>ω2 )
---------(10)
------------- (11)
Where initially at t = 0, ω1= Ωland ω2 = Ω2
Integrating equn. (10) and (11) w.r.t time ‘t’ within interval
(0,t) , we get,
---
-----(12)
-----(13)
The relative angular velocity is given by
Using equ
n. (12) and (13) in above equation, we get
Where,
When the system consists purely of two inertias Iland
I2rotatingat different speeds with no external torques, then M
= 0. The above equation becomes
--------------(14)
The slipping period ts, is determined by putting ωr, = 0.
---------
----- (15)
For the peddle operated clutch, torque transmitted by the
clutch during engagement is increasing linearly (T.P
Newcomb, 1961)
--------- (16)
Where,
To = Engine torque.
Using equn.(16) in equ
n.(15) and solving for ts we get,
----------------------------- (17)
Total thermal energy dissipation is given by
------------- (18)
Solving above equation by using equn. (14) and equ
n. (16), we
get
-------------------
--------------- (19)
5.3.5 Distribution of heat between rubbing
surfaces
Fig. 9. Sketch showing distribution of heat between the rubbing
surfaces The above figure shows a single plate clutch under
the action of and axial clamping force, F. Outer two plates are
Flywheel and pressure plate while the middle plates are
friction plated riveted on the clutch disk. Heat is generated at
the rubbing interfaces i.e. between flywheel-friction material
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and friction material-pressure plate. Generated heat is
dissipated between the rubbing bodies depending upon the
properties of the materials. A heat distribution model given by
T.P. Newcomb in 1960 is given below.
`
------ (20)
Where,
q1(t) = heat flux moving toward body I.
q2(t) = heat flux moving toward body
q(t) = heat flux generated at the interface.
k1 = thermal conductivity of body I.
𝜌1= density of the body I.
c1 = specific heat of body I.
k2 = thermal conductivity of body II.
𝜌2= density of the body II.
c2 = specific heat of body II.
Inthe normal operation of a friction clutch repeated
engagements are made and the average temperature of the
assemblyduring operation under these conditions must
bedetermined. In a single engagement the friction
surfacetemperature is highly transient in nature since the
slippingperiod is usually less than a second. The heat
developedthen flows into the components of the assembly
until allare at a uniform temperature. This occurs within
afewseconds and afterwards the heat transfer is mainly by
convectionand radiation. The average temperature rise in a
single engagement is given by
------------------------------ (21)
Where,
Q = total heat entering to the body.
Δθ = average temperature raise in the body.
m = mass of the body.
c = Specific heat of the body.
In a well-ventilated clutch, the principle method of
heat transfer is by force convection to the atmosphere. If the
thermal conductivity of the material are high and operating
time are fair long, Newton law of cooling may be used.
According to the Newton law of Cooling,
when a solid body of massm, specific heat c, and exposed
surface area A cools slowly from an initial temperature θ", the
temperature θat any subsequent time t is given by
---------- (22)
Where,
h = coefficient of heat transfer
θo= ambient temperature
5.3.6 Stability state temperature determination
Fig. 10. Simplified heat transfer diagram
The figure which is shown in above consists of clutch
assembly, casing and outer atmosphere. Heat is generated in
the clutch assembly and it is transfer to the casing by
convection and radiation. Then finally from casing it was
transfer to the atmosphere. When the system reaches the
stability state, heat transfer rate from clutch assembly to
casing is same as the heat transfer rate from casing to the
outside atmosphere.The average rate of flow of heat,
--------------------------- (23)
Where,
Q = total amount of heat generated in time‘t’.
Heat flux from clutch assembly to casing, -------
-------------- (24)
Heat flux from casing to atmosphere, ------
--------------- (25)
Where,
AI= heat dissipating area of clutch assembly.
AII = heat dissipating area of casing.
By combing radiation heat transfer and convection heat
transfer, we get
If temperature difference ( ) is not large, then an
approximation of the above equation can be given as
----------------------- (26)
The heat flux from casing to atmosphere can be given as
----------------- (27)
Where,
ϵI= Emissivity of clutch assembly.
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ϵII = Emissivity of casing.
θI = Clutch assembly temperature.
θII = Casing temperature.
θIII = Outside atmosphere temperature.
ho= heat transfer coefficient outside the casing.
hi= heat transfer coefficient inside the casing.
σ = Stefan-Boltzmann constant
In above equations, the temperature of the
components can be determined if heat transfer coefficient is
known. For determining heat transfer coefficient, Reynolds
number needs to determine.
Reynolds number,
Where,
= velocity of air with respect to surface
X = Critical length of the surface
υ = Kinematic viscosity of air.
Critical value of Reynolds number = 5 ×105
If the value of Reynolds number is less than critical
value then the mode of flow is laminar and corresponding heat
transfer coefficient is given by
-----------------
---------------------- (28)
If Reynolds number is more than critical value then
the mode of flow is turbulent and corresponding heat transfer
coefficient is given by
-------
----------------------- (29)
Where,
ka= thermal conductivity of air
Pr= Prandtl number =
cp = Specific heat of the air
μ = dynamic viscosity of air
5.3.7 Reduced Moment of inertia
Reduced Moment of inertia of all driven
component at the input shaft of gear box is the inertia that is
required at input shaft to accelerate all the driven components.
Its name is reduced because when calculating equivalent
moment of inertia at the input shaft, moment of inertia of all
the driven components except input shaft are reduced by a
factor of square of train value of the component with respect
to input shaft.
Fig. 11. A Simple gear box
Let,
I1 = Moment of inertia of shaft 1 including all components on
shaft 1, kg m2.
I2 = Moment of inertia of shaft 2 including all components on
shaft 2, kg m2.
I3 = Moment of inertia of shaft 3 including all components on
shaft 3, kg m2.
T1 = Number of teeth on gear 1.
T2 = Number of teeth on gear 2.
T3 = Number of teeth on gear 3.
Then,Grain train value between gear 1 and 2,
Grain train value between gear 3 and 4,
Total Reflected moment of inertia at input shaft
(31)
Assuming the whole tractor is accelerated by the two
rear wheel of tractor i.e. two wheel drive condition.
Let
m = Mass of tractor, kg.
v = linear velocity of tractor, m/s.
I = Equivalent Moment of Inertia, kg m2.
ω = Angular velocity of rear wheel, rad/s.
then,
[since v = ωr]
or, -------------------- (30)
where,
r = rolling radius of rear wheel, m.
6.1 TESTING / EXPERIMENTAL SET UP AND PLAN.
The tractor assembled with dual belleville clutch
system is connected with necessary sensor connections to
continuously monitor and log the speed response, clutch
release load and housing temperature during actuation then
after 500 hours field validation completed .To dismantling the
clutch cover assembly & friction plate to measure clutch
release load and wear measurement details. The experimental
setup is shown
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Field testing of Front-End Loader
Clutch release load Vs Travel Fig. 12. Experimental / Testing Setup
CONCLUSION AND RESULT
7.1 CONCLUSION
The formulated design has eliminated the need for
clutch pedal engagement during forward and reverse motion
and thereby results in reduced operator fatigue. During
operation dual belleville clutch was analyzed for its various
parameters like drag torque, engagement time response,
interfacial surface temperature, wear rate of friction disc
through set of mathematical models.
7.2 RESULT OUT COME These results on the performance parameters of developed
dual belleville clutch show smooth clutch actuation, and
improved reliability suits to perform in heavy duty front end
loading tractor applications.
7.1 FUTURE RESEARCH WORK
The future research work will be extended to
enhancement of the front end loader tractor to provide clutch
breather in clutch housing. This would enable to radiate heat
from one medium to the other and efficiency of the plate will
be more.
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First Author Detail Dr.P.S.Senthil Kumar has 14 years of experience in academics and presently is a Professor working at VEL TECH University.He has done his BE in
Mechanical Engineering from CIT,Coimbatore and ME in Product Design and Development from Sona College of Technology,Salem.His research area is
new product Development and had done his PhD from Anna
University,Chennai.