Design of Single Plate Clutch

Shrinivas Chippa, Sanika Pawar,Piyush Ambade, Bhoomi Powar, Kshitij Raikar,

Rohit Ramteke
Department of Mechanical Engineering
Vishwakarma Institute of Technology, Pune, 411037, Maharashtra, India

Dr. Shrinivas Chippa Sanika Pawar Piyush Ambade

Mechanical Engineering Mechanical Engineering Mechanical Engineering
VIT, Pune VIT, Pune VIT, Pune
[email protected] [email protected] [email protected]

Bhoomi Powar Kshitij Raikar Rohit Ramteke

Mechanical Engineering Mechanical Engineering Mechanical Engineering
VIT,Pune VIT,Pune VIT, Pune
[email protected] [email protected] [email protected]

Abstract— This research paper presents a comprehensive and disengagement cycles throughout its service life. This
design and analysis of a single plate clutch system suitable calls for an optimized design incorporating high-
for a compact passenger car such as the Maruti Suzuki Swift performance materials, precise geometric calculations, and
ZXi. The study encompasses the design of the clutch plate, validation through modern CAD tools. This paper focuses
clutch spring system, rivets, friction lining, and spline on the mechanical design of a single plate clutch intended
connections for effective torque transmission. Parameters for the Maruti Suzuki Swift ZXi, a widely used passenger
such as transmitted torque, permissible pressures, material vehicle in India. The study encompasses the clutch plate,
selection, and stress limits are considered to ensure a safe, springs, friction lining, rivets, and spline interface. The
durable, and manufacturable design. The clutch spring, design aims to balance performance, durability, and
plate, and spline geometry are modeled with appropriate manufacturability while ensuring safe operation under
CAD data for Fusion 360, and all design decisions are specified torque and stress conditions.
supported by analytical calculations

Keywords - Single plate clutch, spline design, helical

spring, torque transmission, Maruti Suzuki Swift, CAD II. Literature Survey
modeling, Fusion 360
The development and improvement of single plate clutches
I. Introduction have been the focus of various research efforts over the
years. The findings from significant works are presented
The single plate clutch is a critical component in automotive here. Kuldeep B. et al. conducted a comparative study using
transmissions, providing engagement and disengagement of finite element analysis on various clutch materials and found
engine power to the gearbox. As the connection between the that carbon-carbon composites offered superior thermal
engine and the drivetrain, it must be designed to operate stability and wear resistance [1].Purohit and Kumar
smoothly, transmit required torque without slip, and performed thermal and structural analysis using ANSYS and
withstand high thermal and mechanical stresses. Its proposed heat dissipation and spring stiffness optimization
performance directly affects vehicle drivability, fuel for enhanced performance [2] Gawande et al. analyzed the
efficiency, and mechanical reliability. effect of uniform pressure distribution and rivet positioning
on the performance of single plate clutches [3]Kamble and
Patil introduced multi-coil spring configurations to improve
In modern passenger cars such as the Maruti fatigue life and reduce stress concentration under frequent
Suzuki Swift ZXi, which is equipped with a 4- load cycles [4].The SAE Technical Report highlighted the
cylinder engine and manual transmission system, industry's shift toward NAO materials for environmental
the clutch system must be compact yet robust, cost- safety and better fade resistance in friction linings [5]. The
effective, and capable of enduring numerous engagement paper examines the engagement characteristics and failure

1
analysis of sintered friction pads used in commercial vehicle 4.Pressure Plate: A cast iron component that ensures even
clutch systems. It investigates wear behavior, energy contact and applies clamping force on the clutch plate
dissipation, torque transmission, and friction stability over through coil springs. It is machined to high precision and
5000 engagement cycles, establishing a correlation for fixed to the clutch cover.
predicting clutch lifespan. Microscopic analysis highlights
wear mechanisms, including silica-induced resistance and 5.Clutch Cover: Bolted to the flywheel, this assembly
oxide transfer layers on the pressure plate [6]. The paper houses the pressure plate, pressure springs, and release
investigates how material parameters influence the contact mechanism. It supports uniform pressure distribution and
pressure distribution in a multi-disc clutch system. It clutch engagement-disengagement cycle.
introduces a numerical model validated by experiments and
proposes a new Pressure Distribution Index (PDI) to assess 6.Release Levers: Pivoted to the clutch cover, these levers
pressure differences among friction pairs. The findings control clutch engagement by shifting the pressure plate in
suggest that modifying the elastic modulus and Poisson's or out when actuated. Their alignment and adjustment are
ratio of the backplate improves uniformity in contact crucial for efficient clutch operation.
pressure, reducing maximum pressure and temperature
differences by approximately 27.2% and 10.3%,
7.Clutch Shaft: A splined transmission shaft that connects
respectively [7] The research paper presents both analytical the clutch disc to the gearbox, enabling torque transfer. It
and numerical solutions to the thermal problem in a dry slides to accommodate axial movement during
friction clutch system, focusing on temperature distribution engagement/disengagement.
during the slipping phase. A three-dimensional finite
element model was developed and validated against a newly
Uniform Wear Theory: According to the uniform wear
derived analytical solution, achieving a maximum error of
theory, wear is assumed to be evenly distributed over the
less than 1%. Results emphasize the significance of
entire surface of the friction disc. This theory is especially
understanding thermal behaviors to enhance clutch system
applicable to worn clutches. Axial wear is proportional to
design and reliability [8] The attached research paper the frictional work done, which in turn depends on the
investigates the contact pressure distribution and stress product of the normal pressure (p), coefficient of friction
analysis of a dry friction clutch system during the full (μ), and rubbing velocity (2πrn), where 'r' is the radius and
engagement period using finite element methods (FEM). 'n' is the rotational speed in RPM.
The study explores the effects of axial forces from a
Mathematically: Wear ∝ μ × p × 2πrn
diaphragm spring and centrifugal force on clutch
components (pressure plate, clutch disc, flywheel). Results
from ANSYS simulations highlight that contact stiffness and
algorithms (penalty, augmented Lagrange methods) This principle is used in determining dimensions and contact
significantly impact the behavior of contact pressure, pressure limits for frictional components like the clutch disc
penetration, and friction stresses, providing insights for and pressure plate, ensuring safe and durable clutch
optimizing clutch design [9]. performance.

III. Methodology

The design methodology follows a component-wise analysis

of the single plate clutch assembly based on theoretical
design equations, CAD modeling, and empirical
assumptions for operating parameters:

1.Flywheel: The flywheel acts as the main driving member

and is connected to the pressure plate. It is mounted on the
engine crankshaft and rotates with it. It also houses bearings
and helps maintain consistent torque transmission.

2.Pilot Bearing: Inserted at the end of the crankshaft, this

bearing supports the input shaft of the transmission and
keeps the clutch disc centered, preventing misalignment and
vibration.

3.Clutch Plate or Disc Plate: This is the driven member

with friction lining on both sides. It engages with the
flywheel and the pressure plate. The lining is typically
asbestos-based for high thermal and wear resistance. It Fig 1. Construction and Working of Single Plate Clutch
includes a splined hub to slide on the gearbox input shaft,
allowing torsional damping.
Table 1: Technical specifications of Swift

2
 Maximum Torque 111.7 Nm @4300 RPM I) Calculations of Clutch Disc
4596.7
Maximum Power 80.46bhp @5700 RPM Operating Force P 0 N
Power transmitting
A. Data capacity P 50.27 KW

Table 2 : Input Data

II) Calculations for design of rivets:
Sr Quantity Notatio Value S.I. Mean Radius R 18 mm
no. n unit
Shear Force on rivet P 1379 N
1. Max. Torque M 11170 N.mm
t
Permissible shear stress τmax 80 N/mm^2
2. Power P 80.46 bhp Shear force on one rivet F total 114.9 N
3. Diameter of rivet d 6 mm Shear resistance per pitch
Ps
𝛔
length 2.71 N/mm
4. Yield point stress of yt 250 N/mm 2

Aluminium Length of shank l 18.5 mm

Rivet head dh 9.6 mm
B. Assumptions
Table 3: Assumptions Head height h 3.6 mm

Sr Quantity Symbo Value No. of rivets N 12

no. l

1. Factor of Safety fs 3 III) Calculations for design of springs:

Total operating
2. Friction of Force P 4596.70 N
Coefficient μ 0.3 Number of springs N 8
3. Permissible Helical
Pressure pa Compression
Intensity 0.39 Spring Type Used Spring
Force per spring F 574.6 N
4. d/D 0.70 Maximum
deflection δ max 20 mm
C. Formulae Force transmitted
The Formulae used for the calculation of the by each spring fs 574.59 N
dimension of the friction lining according to uniform shear stress in
wear theory are as follows: spring τ 672.9 MPa
Wire diameter d 5 mm
1.Wearα ( μp )( 2 πrn ) (1) Mean diameter Dm 50 mm
Outer diameter Do 55 mm
π Pa d
2. P= ( D−d ) Inner diameter Di 45 mm
2 Active Coils n 6
(2)
Total coils 8(2inactive)
πμ Pa d 2 2 Pitch p 12 mm
3. M t = ( D −d ) Free Length L 96 mm
8
(3) Solid Length 40 mm
Spring Index C 10 mm
μP Spring stiffness k 28.73 N/mm
4. M t = ( D+ d )
4
(4) IV) Calculations for design of spline:
No. of splines z 10
D. Calculations

3
Module m 2
Pressure Angle ϕ 30 degree
Torque required T 111.7 Nm

Spine Length 100 mm

Tooth height h 3.5 mm
Face width b 20 mm
Mean radius Dm 75 mm
Outer diameter Do 22 mm
Total contact area A 0.0035 m^2
Fig5. Assembly of clutch plate
Permissible
Pressure p 70 MPa
Actual Pressure pactual 0.425 MPa
V.Conclusion
IV. Results and Discussions The design and analysis of the single plate clutch system for
the Maruti Suzuki Swift ZXi have been carried out
successfully, focusing on key components such as the clutch
plate, friction lining, helical compression springs, and spline
interface. Based on the torque requirement of 111.7 Nm, all
design parameters were evaluated using standard mechanical
design theory, including the uniform wear theory for the
clutch disc and shear stress and deflection theory for spring
design.

By choosing Kevlar as the friction material (μ = 0.4) and

SAE 9254 spring steel for springs, the system is ensured to
be both thermally and mechanically resilient. The spring
Fig. 2. Design of Rivets system, consisting of 8 helical compression springs, was
optimized to transmit a total force of 4596.70 N, with each
spring carrying 574.59 N, while maintaining a maximum
shear stress of 524.75 MPa, well below the safe design limit
of 800 MPa.

The geometrical and material selections were validated

within the safe operating limits for stress and deflection,
ensuring high performance, safety, and durability under real
vehicle conditions. The final dimensions and specifications
were modeled in CAD (Fusion 360) to verify
manufacturability and practical integration.

Fig 3. Design of Springs This research establishes a robust design methodology for
automotive clutch systems and demonstrates how theoretical
design, empirical validation, and modern CAD tools can
collectively contribute to an efficient and manufacturable
solution for modern passenger vehicles.

VI.References
[1] Kuldeep B., Rajendra P., Arun L., “Analysis of Single
Plate Clutch Using Finite Element Method,” International
Journal of Research in Engineering and Technology (IJRET),
2014.
[2] Purohit S., Kumar V., “Thermal and Structural Analysis
Fig 4. Design of Clutch plate of Single Plate Clutch,” International Journal for Research in
Applied Science and Engineering Technology (IJRASET),
2017.

4
[3] Gawande P., More N., Pawar R., “Design and Analysis of [8] Sabri, K. Topczewska, M. J. Jweeg, O. I. Abdullah, and
Single Plate Clutch,” International Journal of Engineering A. M. Abed, "Analytical and Numerical Solutions for the
Sciences & Research Technology (IJESRT), 2019. Thermal Problem in a Friction Clutch System," Computation,
vol. 9, no. 122, pp. 1-13, Nov. 2021, doi:
[4] Kamble S., Patil D., “Performance Improvement of
10.3390/computation9110122.
Clutch Spring Design,” International Journal of Engineering
[9] I .Abdullah and J. Schlattmann, "Contact Analysis of a
Research and Technology (IJERT), 2021.
Dry Friction Clutch System," ISRN Mechanical Engineering,
[5] SAE International, “Material Trends in Clutch Friction vol. 2013, no. 495918, pp. 1-9, 2013, doi:
Linings,” SAE Technical Report, 2022. 10.1155/2013/495918.
[6] A. Vadiraj, "Engagement characteristics of a friction pad [10] Design of Machine Elements – V.B. Bhandari
for commercial vehicle clutch system," Sādhanā, vol. 35, no.
5, pp. 585-595, Oct. 2010.
[7] A Y. Liu et al., "Influence of Material Parameters on the
Contact Pressure Characteristics of a Multi-Disc Clutch,"
Materials, vol. 14, no. 6391, pp. 1-14, Oct. 2021, doi:
10.3390/ma14216391.