Experimental Research and Mathematical Model of Drag Torque in Single-plate Wet Clutch

Reduction of drag torque is one of important potentials to improve transmission efficiency.Existing mathematical model of drag torque was not accurate to predict the decrease after oil film shrinking because of the difficulty in modeling the flow pattern between two plates.Flow pattern was considered as laminar flow and full oil film in the gap between two plates in traditional model.Subsequent equivalent circumferential degree model presented an improvement in oil film shrinking due to centrifugal force,but was also based on full oil film in the gap,which resulted difference between model prediction and experimental data.The objective of this paper is to develop an accurate mathematical model for the above problem by using experimental verification.An experimental apparatus was set up to test drag torque of disengaged wet clutch consisting of single friction and separate plate.A high speed camera was used to record the flow pattern through transparent quartz disk plate.The visualization of flow pattern in the clearance was investigated to evaluate the characteristics of oil film shrinking.Visual test results reveal that the oil film begins to shrink from outer radius to inner radius at the stationary plate and only flows along the rotating plate after shrinking.Meanwhile,drag torque decreases sharply due to little contact area between the stationary plate and the oil.A three-dimensional Navier-Stokes （N-S） equation based on laminar flow is presented to model the drag torque.Pressure distributions in radial and circumferential directions as well as speed distributions are deduced.The model analysis reveals that the acceleration of flow in radial direction caused by centrifugal force is the key reason for the shrinking at the constant feeding flow rate.An approach to descript flow pattern was presented on the basis of visual observation.The drag torque predicted by the model agrees well with test data for non-grooved wet clutch.The proposed model enhances the precision for predicting drag torque,and lays down a framework on which some subsequent models are developed.

Drag Torque Prediction Model for the Wet Clutches

Reduction of drag torque in disengaged wet clutch is one of important potentials for vehicle transmission improvement. The flow of the oil film in clutch clearance is investigated. A three-dimension Navier-Stokes(N-S) equation based on laminar flow is presented to model the drag torque. Pressure and speed distribution in radial and circumferential directions are deduced. The theoretical analysis reveals that oil flow acceleration in radial direction caused by centrifugal force is the key reason for the shrinking of oil film as constant feeding flow rate. The peak drag torque occurs at the beginning of oil film shrinking. A variable is introduced to describe effective oil film area and drag torque after oil film shrinking is well evaluated with the variable. Under the working condition, tests were made to obtain drag torque curves at different clutch speed and oil viscosity. The tests confirm that simulation results agree with test data. The model performs well in the prediction of drag torque and lays a theoretical foundation to reduce it.

Research on Drag Torque Prediction Model for the Wet Clutches

Considering the surface tension effect and centrifugal effect, a mathematical model based on Reynolds equation for predicting the drag torque of disengage wet clutches is presented. The model indicates that the equivalent radius is a function of clutch speed and flow rate. The drag torque achieves its peak at a critical speed. Above this speed, drag torque drops due to the shrinking of the oil film. The model also points out that viscosity and flow rate effects on drag torque. Experimental results indicate that the model is reason-able and it performs well for predicting the drag torque peak.

Dynamic engagement characteristics of wet clutch based on hydro-mechanical continuously variable transmission

The effect of the design parameter on the clutch engagement process of the hydro-mechanical continuously variable transmission(CVT)was investigated.First,the model of the power train was developed with the software of SimulationX,and the clutch shift experiment was used to validate the correctness of the model.Then,the friction coefficient function was fitted with the test data to get the friction coefficient model suitable for this paper.Finally,based on the evaluating index of the friction torque and the friction power,two groups of design parameters(oil pressure and friction coefficient)were simulated and explained the changing regulation theoretically.According to the simulation results,the high oil pressure and friction coefficient can reduce the slipping time.The large oil pressure can increase the peak torque but the effect of friction coefficient on the peak torque is not so significant.The friction power reaches the maximum value at 3.2 s,the peak value increases as the oil pressure and friction coefficient increase.The effect of the oil pressure on the clutch engagement and thermal performance is greater than the friction coefficient.

Dynamic Engaging Characteristics of Wet Clutch in Automatic Transmission

Wet clutch is an important shifting component in automatic transmission,and its properties will affect the gear shift performance. By comparing the calculated and test results,the static friction torque model was proved to be capable of describing the real pressure and torque only in the situation of high-energy engagement.Therefore,a dynamic torque model was proposed on basis of hydrodynamic properties between friction surfaces, in which the clutch engagement was divided into three phases for hydrodynamic lubrication, mixed lubrication, and mechanical contact. The proposed dynamic torque model was validated by comparing the calculated and test results. The effects of temperature,pressure,and pressure changing rate of automatic transmission fluid( ATF) on the clutch torque were analyzed. Based on these results,the clutchto-clutch torque control during shifting in automatic transmission was optimized,and as a result,the shifting comfort was significantly improved since the problems such as the fluctuation and sudden drop of the engine rotating speed during shifting were eliminated.

Mathematical Model of Drag Torque with Surface Tension in Single-Plate Wet Clutch

Reduction of drag torque in disengaged wet clutches is essential for transmission research because it is one of the potentials of e ciency improvement. Aeration of oil film between two closely rotating plates promotes the decrease of drag torque at high speed region. The e ects of surface tension and static contact angles during aeration are nonnegligible showed by test results. The traditional lubrication model does not adequately predict the experimental results with di erent surface tension and contact angles during aeration. Hence, in this present paper, contact angles between Aluminum and Teflon materials were firstly measured, and the drag torques under two di erent contact angles were examined experimentally. An improved lubrication model of drag torque based on Navier–Stokes equations at the gas-liquid interface was built. The lubrication boundary condition was modified to introduce the e ects of surface tension and contact angle. The model shows that the e ects at the beginning of aeration of oil film are significant. These e ects almost occur at stationary plate due to low Reynolds number and Weber number. The model shows that an increase in the surface tension promotes aeration, but does not a ect the peak drag torque. Increasing contact angle also promotes the aeration, and accelerates the decrease of drag torque. The larger contact angle is, the smaller the peak drag torque will be. A computational fluid dynamics(CFD) model based on volume of fluid(VOF) method was presented to validate the interface shape when aeration occurs. The model prediction has a good agreement with experimental observations for Aluminum plates and Teflon plates. The modified lubrication model of drag torque gives a convenient description of the e ects of surface tension and contact angel, and lays down a frame to understand the beginning of aeration.

Experimental and Theoretical Analysis of the Drag Torque in Wet Clutches

Traditional mathematical models cannot predict and explain the phenomenon by which the drag torque(DT)in wet clutches rises in the high-speed zone.In order to evaluate the DT in such conditions,a two-phase air-fluid mathematical model for a DT with grooves was elaborated.The mathematical model was based on the theory of viscous fluid flow.A two-phase volume of fluid model was also used to investigate the distribution and volume fraction of air and fluid.Experiments on three friction plates with different grooves were conducted to validate the resulting mathematical model.It was found that the gap between plates decreased in the high-speed zone,thereby producing an increase of the DT in the high-speed zone.These results support the understanding of the physical phenomena relating to disengaged wet clutches,and provide a theoretical basis for the future improvement of drive systems.

Modeling and analysis of wet clutch engagement characteristics

A mathematical model was developed to analyze the characteristics of the wet clutch during engagement. The lubricant squeeze action was simulated with Patir and Cheng average flow model in which the permeability of friction material is taken into account, and the asperity load is calculated according to the Greenwood and Tripp approach. In this model, effects of friction material permeability, applied load and driving velocity on the engagement characteristics of the wet clutch were studied. The results show that friction material with high permeability reduces the film thickness rapidly and increases the torque peak; the applied load increases the asperity contact pressure and the friction torque, and reduces the engagement time; the driving velocity mainly increases the engagement time. The theoretical torque and relative velocity curves agree qualitatively with the experimental ones, which verifies the wet clutch engagement model.

Wear Calculation Model Considering the Effect of Porosity and Wear Properties of Wet Clutch Friction Disc

This paper aims to investigate the effect of porosity percentage on the wear performance of a wet clutch. A wear calculation model for the relationship of porosity and wear mass loss is established. The results of experiments conducted verify the wear coefficient expression used in the model. The influence of porosity on the wear performance of a friction disc was also analyzed for various pressures and speeds. Specifically,the 80 min sliding test was performed with three different friction disc porosity percentages using a wet clutch test rig. Comparison of the model calculation results with the measured values confirmed the accuracy of the calculation model. The test results show that the calculated and detected data fit well,which indicates that the wear calculation model can be used to estimate the wear mass loss of wet clutch friction plates. These research results will help to improve the anti-abrasion properties and employment lifespan of wet clutch friction discs.

Analysis Groove Characteristics of Friction Dishes in Wet Speeding Clutch

The impacts of different groove shapes, numbers, and angle of friction dish on transmitting torque, speed, push pressure in wet speeding clutch are discussed in this paper. Since the wet speed governing clutch works within hydrodynamic lubrication, mixture lubrication, boundary lubrication and contact situation, the oils combining with α hydrocarbon or polyester are getting widely used as lubricant. The power law fluid model with Patir Cheng average flow model, GT asperity contact model and oil film inertia are applied for average Reynolds equation setting. In order to investigate the relationship between average push pressure within hydrodynamic lubrication and mixture lubrication, average transmitting torque and output speed, the numeral calculation and analysis are presented. According to calculation, it is found that the groove shape, groove angle and groove numbers affect the average transfer torque and push pressure with the speed rate.

高速湿式离合器摩擦片表面微织构优化设计

湿式离合器是车辆传动系统核心元件,在高速分离状态下易出现摩擦片和钢片之间的碰撞摩擦,由此引起离合器带排转矩的急剧增大,影响其传动效率和可靠性。因此,本文以降低离合器高速段碰摩带排转矩为目标,对摩擦片表面微织构进行了优化设计。首先提出了摩擦片表面任意微织构形线参数化建模方法;然后选取了微织构的数量、深度、周向占比、径向占比和形线参数,构建了微织构优化的设计变量、约束条件和优化目标函数,通过将试验设计、模拟近似模型和搜索寻优相结合,建立了摩擦片表面微织构优化设计模型;最后进行了微织构优化前后的带排转矩对比试验。结果表明优化后的微织构可显著降低高速段碰摩带排转矩,并大幅推迟摩擦副高速碰摩现象出现的线速度。

考虑实际工况的湿式离合器动密封装配间隙分析方法

湿式离合器动密封装配间隙是车辆传动系统中的重要装配要求,直接影响车辆运行性能与行驶安全。为保障实际工况下其装配间隙符合设计要求,基于有限元分析方法与雅可比旋量理论,提出考虑实际工况的湿式离合器动密封装配间隙分析方法。针对某湿式离合器动密封装配间隙问题,计算转动状态下的最小装配间隙分布区间,并定量分析各载荷变形对装配间隙的贡献度。结果表明:实际运行状态下最小装配间隙分布区间为[-0.022,0.098]mm,与设计要求[0.025,0.207]mm严重不符;采用装配后再对内孔精加工的工艺对贡献度为74.22%的配流套内孔过盈装配变形进行调控后,最小装配间隙分布区间提升至[0.027,0.139]mm,符合设计要求,车辆运行性能得到有效保障。

混合动力汽车湿式离合器摩擦副温度场及其影响因素研究

热失效是混合动力汽车湿式离合器发生故障的主要原因之一。摩擦副滑摩过程中具有高度非线性,同时摩擦副温度场受到多个参数影响。为深入研究混合动力汽车离合器摩擦副温度场分布情况,通过搭建混合动力汽车离合器热结构耦合分析模型,对滑摩过程进行仿真计算。在此基础上,深入研究初始转速、接合油压、对偶钢片厚度和摩擦衬片材料等因素对摩擦副温度场的影响。

空载湿式离合器临界碰摩转速影响机理分析

定义空载湿式离合器摩擦片/钢片的周期无量纲轴向位移范围λ,根据其值确定湿式离合器的临界碰摩转速。通过分析润滑油温度、供油流量、摩擦副间隙与特征量λ变化趋势的关系,得到工况参数对湿式离合器临界碰摩转速的影响规律。从力学角度出发,分析流场刚度和阻尼的变化规律,探寻摩擦片/钢片三自由度运动的影响因素,在此基础上提出流场临界刚度和临界阻尼的概念,揭示湿式离合器工况参数对其临界碰摩转速的影响机理,并进行了试验验证。研究结果表明:润滑油温度升高或摩擦副间隙增大会导致流场中的交叉刚度系数和交叉阻尼系数变大,湿式离合器的临界碰摩转速降低;供油流量增大会导致流场中的交叉刚度系数和交叉阻尼系数减小,湿式离合器的临界碰摩转速升高。

考虑离合器摩擦性能衰减的湿式DCT车辆起步控制研究

建立了考虑离合器摩擦系数变化及离合器性能衰减的湿式双离合变速器(dual clutch transmission,DCT)车辆起步过程动力学模型,以车辆起步过程冲击度、滑摩功和起步滑摩时间为优化目标,采用线性二次型最优控制方法获得了车辆起步过程离合器最优传递转矩。针对离合器摩擦系数变化及离合器性能衰减对车辆起步过程离合器压力控制的影响,提出了一种离合器压力非线性鲁棒控制策略,以实现对离合器最优传递转矩的跟踪。结果表明,所提出的非线性鲁棒控制策略能够在离合器摩擦系数变化的情况下实现对离合器最优传递转矩的有效跟踪,跟踪误差不大于0.02 N·m,且能够适应摩擦性能衰减导致不同寿命阶段摩擦系数的不同变化规律,与比例-积分-微分(proportion-integral-differential,PID)控制策略相比具有更精确的控制效果和更强的鲁棒性。

高速湿式离合器低带排转矩参数优化设计

为了降低湿式离合器高速工况下产生的带排转矩,以某履带车辆湿式离合器为研究对象,在传统低速带排转矩模型中引入并计算了等效半径,推导了含径向槽湿式离合器高速工况下的带排转矩计算模型;建立了以离合器3个工况参数、摩擦片5个结构参数为设计变量,以最小带排转矩为优化目标的优化设计模型,基于鲸鱼优化算法(Whale Optimization Algorithm,WOA)对目标函数进行求解,优化后带排转矩减小了35.6%;并利用Simulink建立了目标函数的动态响应模型,对优化结果进行验证。结果表明,所设计优化方法有效,可为湿式离合器的结构设计和参数优化提供参考。

考虑界面接触状态的湿式离合器扭矩特性

为提升重型车辆传动系统中湿式离合器可靠性及使用寿命,建立了考虑界面接触状态的湿式离合器扭矩模型,通过模型研究了不同参数对离合器扭矩特性的影响规律。首先,对湿式离合器进行仿真模拟,增加界面接触状态参数,搭建湿式离合器充油模型与结合模型。其次,基于SAE#2试验台开展湿式离合器扭矩试验,将仿真获得的结果与离合器试验数据进行对比,验证了仿真模型的有效性。最后,结合模型研究了油压、油温和碟形量对湿式离合器扭矩特性的影响规律。结果表明:考虑了界面接触状态的模型相较于传统模型具有更高的准确性,提高了22.30%;随着控制油压的减小,离合器的总扭矩降低,当压力从1.5 MPa减小到1.0 MPa时,扭矩峰值降低了22.38%,同时制动时间延长了46.05%;润滑油温度对离合器的黏性转矩和摩擦扭矩都具有一定程度的影响,温度越高,黏性转矩越小,摩擦扭矩越大,整体制动时间稍有减小;摩擦片碟形量对离合器扭矩的影响主要体现在扭矩产生时间,碟形量的增加会导致离合器制动时间增加。

机械压力机液压离合/制动器结构、原理与应用

冲压设备是汽车生产过程中常用的关键生产设备,在采用气动摩擦离合器/制动器之后,机械压力机才实现了滑块在任意位置驱动和制动的功能,使操纵更方便安全。但频繁的工作负荷和常年累月的高运转率,造成离合器/制动器的摩擦材料迅速磨损,发热严重,并产生粉尘和噪声,既带来环境污染,又造成电器元件和控制阀故障,机器停机频繁,维修工作繁重。液压湿式离合器/制动器的出现完全避免了气动离合器/制动器的上述缺陷。目前已得到先进的压力机制造商和冲压行业用户的选用与青睐。

大功率拖拉机湿式离合器液压系统特性分析

大功率拖拉机湿式离合器具有复杂、高阶、非线性强等特点,是动力换挡变速箱(Power Shift Transmission,PST)执行换挡动作的关键部件。首先,分析了大功率动力换挡拖拉机湿式离合器液压系统的组成和工作原理,然后,搭建了基于dSPCE的湿式离合器液压系统试验台,开展了湿式离合器液压系统特性试验,分析了比例减压阀和湿式离合器的稳态特性和动态特性。最后,通过改造离合器试验台,采集离合器活塞位移和离合器油压,掌握了PST湿式离合器的活塞位移行程和基本运动特性。研究成果可为离合器压力控制和换挡质量控制研究提供模型依据。

大功率拖拉机湿式离合器液压系统建模与验证

湿式离合器是动力换挡拖拉机执行换挡动作的关键部件,具有复杂、高阶、强非线性等特征。首先,通过分析大功率动力换挡拖拉机湿式离合器液压系统的结构与工作原理,建立了其数学模型;然后,基于MATLAB和AMESim搭建了系统仿真模型;最后,通过对比MATLAB与AMESim模型仿真结果,验证了所建数学模型的准确性。研究成果可为离合器压力控制及换挡品质控制研究提供模型基础。