International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 09 Issue: 05 | May 2022 www.irjet.net p-ISSN: 2395-0072

Design and Analysis of a Single Plate Clutch Assembly

Pranjal Sarode1, Anirudh Sharma2

1,2VIT Pune Department of Mechanical Engineering 666, Upper Market Rd, Upper Indira Nagar, Bibwewadi, Pune,
Maharashtra 411037
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Abstract – The goal of this article is to design a single plate This design allows drivers to detach the wheels from the
clutch for a specific pick-up vehicle that is ready to be engine in order to change gear, giving them greater control
manufactured. Auto Cad is used to create sketches using the over their vehicle's speed.
calculations done in this paper. Complete material selection
based on the various components of the assembly is done The main objective of this is project is to design a single plate
according to the requirements of the vehicle and the cost of frictional clutch assembly with theoretical analysis. This
components. Manufacturing procedures for each and every paper serves as a conduit of our work that we have done on
component in the assembly along with the type of fit are our project.[4]
described, and finally pricing for all individual parts is covered
1.1) Specifications of engine
in this paper.
The single plate frictional clutch will be designed for a Pick-
Key Words: Clutch, Design, Auto Cad, Fly Wheel , up -Truck named TATA YODHA 1700ar:[5]
Manufacturing

1. INTRODUCTION

A clutch is essentially a mechanical device whose basic

purpose is to connect and disconnect the power source from
the remaining parts of the transmission system as per the
will of the operator.
It is a vehicle component that joins two or more spinning
shafts. The clutch in a manual transmission car manages the
connection between the engine shaft and the shafts that turn
the wheels. It is an important aspect of the car's functioning
machinery because the engine creates power all of the time
and has sections that rotate constantly, but the wheels do
not. [2] Fig -1: TATA YODHA.

The connection between the wheels and the engine must be

briefly interrupted to allow the car to alter the speed and Engine and Clutch
come to a complete stop without turning off the engine. The Engine Type Tata 2.2L BS6 DI Engine
clutch plate and the flywheel are the two major components
of your clutch.[3] There are springs that keep a pressure Max Engine Output 73.6 kW(100HP)@3750r/min
plate pushed up against the clutch plate if your foot is not Max Engine Torque 250Nm @1000-2500 r/min
pressing down on the clutch pedal.
Fuel Tank Capacity 45L
The clutch plate is pushed up against the flywheel by the Clutch Single Plate Dry Friction Type
spring pressure. This connects the engine to the shaft that 260 mm D
transmits motion to the wheels, causing both to rotate at the
same time. When you press down on the clutch pedal, your
foot presses down on a release fork, which draws the Table 1: Specifications
pressure plate away from the clutch plate via a series of
springs and pins.[2] This cuts the link between the rotating 1.2) Specifications of engine[5]
engine and the wheels, causing the wheels to spin on their
own momentum rather than through the engine's power. • Clutch diameter (D): 260 mm.
• Torque (Engine) : 250 N-m (250,000N-mm).
• Power (Engine) : 100 HP (73.6 kW).
• Number of pairs of contacting surface (n) : 2.

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• Number of springs = 8 . UNS No. S030200 AISI No.302 will be suitable for the
• Service Factor ks = 1.5. application.
• Coefficient of friction (μ) = 0.32 (Sintered metal
(dry) (0.33).) 3. Calculations
• Intensity of pressure at radius r (p) = 0.689
N/mm2. 3.1) Nomenclature for mathematical calculations

2. Material Selection • Outer diameter (friction lining) : R0.

• Inner diameter (friction lining) : Ri.
2.1) Fly Wheel
• Torque : T.
A fly wheel is subjected to heavy torque conditions with high
• Coefficient of friction : μ
temperatures. Hence, selecting Carbon steel AISI 1040 .
• Intensity of pressure at radius r : p .
2.2) Clutch Friction Lining/Clutch Plate
• Number of pairs of contacting surface : n
While selecting the friction lining material higher coefficient • Angular velocity rad/sec : ω.
of friction under lower pressure was considered. Also, the
• Speed of Engine in r.p.m : N.
friction lining should withstand Higher temperatures .Below
are some of the materials with their friction coefficient and • Clutch Outer diameter : R.
maximum pressure required for their operations. As asbestos
• Total operating force (N) = P.
material being harmful for uses, we have decided to choose
the material : Cermet (0.32). To Calculate –
• Design Inner and outer diameter for the friction lining.
• Spring force (axial Force) required to keep the clutch
engaged in its position.
• Torque transmitting capacity of the clutch (Tmax).
• Power transmitting capacity of the clutch (Pmax).
• Design of Spring for the pressure plate.
• Design of damper springs.
• Design of rivets in clutch.
• Design of pedal.
Here we need to manufacture a single plate frictional clutch
Table 2: Material Properties[1] with a service factor (Ks) of 1.5.
2.3) Pressure Plate We know that
(Mt)des = Ks(Mt)
The pressure plate provides axial force for the clutch to
remain in engaged position as well a complex design is Where,
required. Hence, Gray Cast Iron 20 (FS). Ks = Service factor
2.4) Springs in clutch (Mt)des = Torque capacity of clutch for design = 1.5x250
(Mt)des = 375Nm.
The springs in clutch provide axial force which essential for
the engagement and the working of the clutch. They are also Mt = Rated Torque
used for dampening the torque. Stainless Steel with UNS No. Hence torque capacity for design purpose will be 375N-m.
S030300 AISI No. 303b will be suitable for the application.
Service factor is necessary so as to avoid slippage of clutch
2.5) Rivets during the start of engine.
3.2) Inner diameter of friction lining
Rivets are used to hold together the rotating component and
the friction lining of the clutch. Hot Rolled Stainless Steel with

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Volume: 09 Issue: 05 | May 2022 www.irjet.net p-ISSN: 2395-0072

The friction lining is provided on both sides of the friction Taking,

disk. Hence, it has two pairs of contacting surfaces one
Spring index(C) = 5
between flywheel and one between the pressure plate.
Youngs modulus (G) = 81370 N/mm2
Torque transmitting by one pair of contact surface – 375/2
The permissible shear stress for the spring wire is 30% of the
187.5N-m (using uniform wear theory)
ultimate tensile strength.
Mt = π μ pad(o2-d2)/8 [1]
𝜏d = 0.2 σut
d = 235mm ( choosing the higher positive value)
P = 591.85N
Hence , the inner diameter for the friction lining is 235mm.
Wahl’s Factor
K = (4C-1/4C-4) + (0.615/C)[1]
K = 1.3105
𝜏 = K(8PC/ π d2)[1]
Now , solving by trial and error
𝜏 = 8523.21/25 = 340.92N/mm2
𝜏d = 0.3(1390) = 417N/mm2
Now , as 𝜏d> 𝜏 , the design is considered safe.
Fig -1: Friction Lining diameter.
d=5mm.
3.3) Spring pressure plate design
Mean Coil Diameter
Springs play the role of keeping the clutch in the engaged
position by providing the axial force and it will slip when the D = Cxd = 5x5 = 25
spring force is no longer there.
No of turns (n)
Using uniform wear theory – n = Gxd/8c2Ks
n = 3.42
Mt = μ p(D+d)/4[1]
Total no of turns with squared and ground ends –
187500 = Px0.32x(260+235)/4
nt = n+2 = 5.42 ≈ 6
P = 4734.84 N
Free length = 6x5 + 4 + 591.5/118.75 ≈ 39mm.
Since there are 8 springs , the force per spring is -
P/8 = 591.85N
Finally , to check if these 8 springs can be accommodated in
Hence if the force per spring is less than 591.85N , the clutch
the design-
will begin slipping.
Mean diameter of friction disk = (260+235)/2 = 247.5
Space available per spring = 247.5/8 = 31mm
Now, taking a spring which gives 950N (P) of axial force when
compressed 8mm(𝛿). Mean coil diameter = 25mm
Compression of spring = -x (initial compression) Hence spring can be safely fitted.
Stiffness of spring = 591.85/8-x (N/mm) ----(a) 3.4) Torque transmission after the wear
Initially each spring is compressed by 8mm to provide the
• We selected a spring which gives us 960N of axial force
950N force, hence stiffness = 950/8 ----(b)
on compression of 8mm , and on calculation for the spring
From (a) & (b) , we get – x = 3.016mm ----(c) we obtained total free length to be 39mm.
Hence when the wear of friction lining is more than 3.016mm
• The spring has a sold length ≈ 28mm and to transmit the
the spring force will be less than 591.85N and the clutch will
required torque the spring is compressed 8mm. Also the
slip.
compressed length is 31mm for the required torque
Stiffness of the spring = 950/8 = 118.75 ----(d) transmission.

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Volume: 09 Issue: 05 | May 2022 www.irjet.net p-ISSN: 2395-0072

• The force in compressed spring gets reduced due to wear. Therefore – d =4mm
• In our case the clutch begins to slip when a wear of Mean coil diameter D =Cd = 5x4 = 20mm
3.016mm on the friction lining occurs.
To find the deflection of the damper spring –
• Hence , the final compressed length of the spring will be
𝛿 = 8nsFc3/Gd = 5.760mm
34.016mm (after the wear)
Stiffness of the damper spring – K = Fs/𝛿 81.37N/mm
• The force in the compression spring is found by Hooke’s
law 3.6) Design for rivets in friction plate
F = k(Lfree-Ldef) where k is the stiffness constant.
F = 475N
• Hence the total axial force by 8 springs = 475x8=3800N
• Hence now the torque transmitting capacity by using the
uniform wear theory
Mt = 0.32x3800x(260+235)/4
Mt = 150480N
• So the torque transmitted after the wear is 300.96Nm.
• Finally, Initial torque = 375Nm & Torque transmitted
after wear = 300.96Nm.
3.5) Design for damper springs
Fig -2: Rivets on a friction plate.
In the design calculations of damper spring which is used to
lock , the torsional force of the clutch plate is obtained by the • Rivets do the job of holding the friction material lining in
equation – place with the respective rotating components in this case
Tdamper = FsNsRs [1] the clutch plate.
Tdamper = lock torque of damper spring =375Nm • As clutch plate being friction lined , its both sides forces
Fs = Force acting on the spring acting on both sides are to be considered.

Ns = no of springs =4 • Below is the cross sectional view of forces acting on the

rivet.
Rs = distance from axis of clutch to axis of damper = 600mm
Fs = (375x1000)/(4x200) = 468.75N ----(a)
Now to find the diameter of the damper spring, taking –
Spring Index C=5
G = 81370 N/mm
The permissible shear stress for the spring wire is 30% of the
ultimate tensile strength. (𝜏d = 0.3 σut)
Wahl’s factor
K = (4x5-1/4x5-4)+0.615/5 = 1.13015
𝜏 = K(8PC/ π d2) = 6745.08/d2 Fig -3: Cross sectional view of forces on rivet

On comparing with graphs for spring diameter with trial and • Here the force(Fs) is majorly due to the static friction.
error
• P is the axial force required for engagement of the clutch.
d = 4mm , so 𝜏 = 421.56N/mm2
• On analyzing the above we can say that the rivet joint is
(Grade 2 patented cold drawn steel wire) subjected to double shear.
𝜏d = 0.3x(1480) = 444N/mm2 • For diameter of rivet(single riveted lap joint)
Hence 𝜏> 𝜏d , so it is a safe design. Taking rivets made of steel and sheat is 60N/mm2

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Volume: 09 Issue: 05 | May 2022 www.irjet.net p-ISSN: 2395-0072

Fs = μsxN (μs is coefficient of friction , N – normal force) 5. Manufacturing & Costing

Fs = 1514.88N
5.1) Fly Wheel
Ps = 2(π x d2 x 𝜏 x n)/4
As being subjected to heavy torque and friction .Fly wheel
d = 5.67mm ≈ 6mm. will be produced by casting method and holes in wheel must
Hence the diameter for the rivet is 6mm. be made for riveting the friction lining by Drilling. Finishing
Pitch of the rivet = width of the plate/n = 25/3.86 = 6.534 must be done grinding and Heat treatment on required flat
mm surface.

Efficiency of the joint – 5.2) Clutch Plate

𝜂 = Pt/p(lowest) = 19900/26250 = 0.76 = 76%
Precision is required in manufacturing of clutch plate . Hence
3.7) Maximum Power Transmitting Capacity Milling and holes in plate must be made for riveting the
friction lining by Drilling.
By using uniform wear theory
Mt= μ p(235+260)/4 5.3) Pressure Plate

Mt = 193359.02N A major responsibility being providing axial force for

Kw = 2πn Mt/60x106 engagement of the clutch and having complex shapes . The
pressure plate can be manufactured with help of Sand
Max Power Transmitting Capacity = 75.93KW casting with the required mold and holes in plate must be
made for riveting the friction lining by Drilling.
4. Final Features of the clutch assembly
5.4) Springs
Torque Capacity 375 N-m. Spring provides axial force for engagement of the Clutch and
Power Capacity 75.93 Kw. also provide damping of torque for the clutch plate. Spring
Diameter of the clutch. 270 mm. must be manufactured from cold-drawn steel wire of Grade 2.

Inner Diameter of the 235 mm. 5.5) Costing

friction lining.
Outer Diameter of the 260 mm. Component Manufacturing cost
friction lining. Fly Wheel Rs. 500/-
Friction provided by lining. 0.33
Clutch Plate Rs. 650/-
Number of springs. 8.
Pressure Plate Rs. 500/-
Axial force provided by each 591.85 N
spring. Springs Rs. 400/-
Shaft diameter. 50 mm. Total Rs. 2050/-
Service factor. 1.5
Table 4 : Rivets on a friction plate.
Table 3 : Rivets on a friction plate.

4.1) Fits included in design

Interference fit – As interference fit is ideal for heavy torque

transmission, We have taken interference fit at two places.
For both of them a heavy drive fit is selected(50H7-s6)

 Input shaft at engine and fly wheel.

 Clutch plate and output shaft

Clearance fit – At output shaft and pressure plate of the

clutch. For easy running (50H6-e7) is used.

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Volume: 09 Issue: 05 | May 2022 www.irjet.net p-ISSN: 2395-0072

6. Results and discussion 6.4) Pressure Plate

6.1) Clutch Plate

Fig -6: Pressure Plate CAD

7. Conclusion
6.2) Clutch Assembly
In this paper complete design for manufacture of all the
components of a single plate clutch was done along with the
pricing for each individual component.

The sketches were made using AutoCad software with the

help of the calculations shown in the paper.

REFERENCES

[1] Dr. V.B. Bhandari, ”Design Of Machine Elements Third

Edition”, Tata McGraw Hill Publications, 01 Apr 2010.

[2] MAY THIN GYAN, “Design and Structural Analysis of

Single Plate Clutch”, IJSETR, Vol.03, Issue.10 May-2014,

Fig -4: Cross section of clutch [3] Jibin, H., Zengxiong,"Experimental Research on Drag
Torque for Single-plate Wet Clutch." (February 9, 2012).
6.3) Fly Wheel ASME. J. Tribol. January 2012; 134(1): 014502.

[4] Tipirineni, V. Mani Kiran, and P. Punna Rao. "Optimal

Design of a Clutch Plate using Ansys." Editorial
Committees (2013): 58.K. Elissa, “Title of paper if
known,” unpublished.

[5] Tata Motors, “Tata Yodha”. Tata Yodha Pickup.

https://pickup.tatamotors.com/pickup-trucks/tata-
yodha-overview.aspx(09/05/2022)

Fig -5: Flywheel CAD

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