In the design of an automotive single-plate clutch, two pairs of friction surfaces are utilized: one between the friction lining and the pressure plate and the other between the friction lining and the flywheel. The axial thrust required on the friction surfaces is achieved by 12 identical helical compression springs arranged in parallel. The total spring force exerted by all springs is 2500 N, with each spring experiencing a deflection of approximately 65 mm. To begin the design process, it is crucial to select an appropriate spring material that can withstand the operating conditions and load requirements of the clutch. Consider factors such as strength, durability, and resistance to fatigue. Additionally, evaluate the available spring wire diameters provided: 1.8 mm, 2.0 mm, 2.1 mm, 2.3 mm, 2.4 mm, and 2.6 mm.

In the design evaluation process, start by determining the required spring rate based on the given total spring force and deflection. Calculate the average spring rate by dividing the total force (2500 N) by the deflection of each spring (65 mm). This value will provide a guideline for selecting an appropriate wire diameter. Next, consider the assembly constraints specified. The solid height of the spring cannot exceed 35 mm, and the free length should not exceed 125 mm. These limitations will help determine the maximum allowable number of active coils and the corresponding wire length. Using the calculated average spring rate and the available wire diameters, compute the necessary number of active coils to achieve the desired spring rate. It may be necessary to perform multiple iterations to find the optimal combination of wire diameter and number of coils that meet the design requirements while satisfying the assembly constraints.

Evaluate each potential design configuration to ensure that the selected spring material can withstand the expected forces, deflection, and cyclic loading. Consider factors such as stress levels, fatigue life, and safety factors. Verify that the chosen spring material can provide the necessary performance and durability for the automotive clutch application. Document the design evaluation process, including the calculations, iterations, and reasoning behind each decision made. This documentation will serve as a comprehensive record of the design process and enable future analysis and modifications if necessary.

Mechanical design

(DESIGN OF MECHANICAL SPRING AND ROLLING CONTACT BEARING)

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Design of Automotive SinglePlate Clutch Spring 1 Determination of Required Spring Rate Total spring force 2500 N Deflection of each spring 65 mm Avera... View the full answer