9/11/2016

automotive (2) Lab

EXP1: Clutches

Name: Mohammad yahya Bani issa

Dr. Wael Adaileh

The clutch is located between the transmission and engine where it provides a mechanical coupling
between the engines flywheel and the transmissions input shaft. The driver operates the clutch through
a linkage that extends from the passenger compartment to the bell housing (also called the clutch
housing) between the engine and the transmission.

All manual transmissions require a clutch to engage or disengage the transmission. If the vehicle had no
clutch and the engine was always connected to the transmission, the engine would stop every time the
vehicle was brought to a stop. The clutch allows the engine to idle while the vehicle is stopped. It also
allows for easy shifting between gears. (Of course, all of this applies to manual transaxles as well.)

The clutch engages the transmission gradually by allowing a certain amount of slippage between the
transmissions input shaft and the flywheel. shows the components needed to do this: the flywheel,
clutch disc, pressure plate assembly, clutch release bearing (or throw-out bearing), and the clutch fork.

OPERATION
The basic principle of clutch operation, the pressure plate and flywheel are
the drive or input members of the assembly.

The clutch disc, also called the friction disc, is the driven or output member and is connected to the
transmissions input shaft. As long as the clutch is disengaged (clutch pedal depressed), the drive
members turn independently of the driven member, and the engine is disconnected from the
transmission. However, when the clutch is engaged (clutch pedal released), the pressure plate moves
toward the flywheel and the clutch disc is squeezed between the two revolving drive members and
forced to turn at the same speed.
 Flywheel

The flywheel, an important part of the engine, is also the main driving member of the clutch. It is
normally which has a high graphite content to lubricate the engagement of the clutch. Welded to or
pressed onto the outside diameter of the flywheel is the starter ring gear. The large diameter
of the flywheel allows for an excellent gear ratio of the starter drive to ring gear, which provides for
ample engine rotation during starting. The rear surface of the flywheel is a friction surface machined very
flat to ensure smooth clutch engagement. The flywheel also provides some absorption of torsional
vibration of the crankshaft. It further provides the inertia to rotate the crankshaft through the four strokes.

Clutch Disc
The clutch disc is splined to the transmissions input shaft and receives the driving motion
from the flywheel and pressure plate assembly and transmits that motion to the transmission input shaft.
The parts of a clutch disc

There are two types of friction facings. Molded friction facings are preferred because they withstand
greater pressure plate loading force without damage. Woven friction facings are used when additional
cushioning action is needed for clutch engagement,

Until recently, the material that was molded or woven into facings was predominantly asbestos. Now,
because of the hazards associated with asbestos, other materials such as paper-base and ceramics are
being used instead. Particles of cotton, brass, rope, and wire are
added to prolong the life of the clutch disc and provide
torsional strength.

The clutch disc is designed to absorb such things

as crankshaft vibration, abrupt clutch engagement,
and driveline shock. Torsional coil springs allow the
disc to rotate slightly in relation to the pressure plate
while they absorb the torque forces. The number and
tension of these springs is determined by engine
torque and vehicle weight. Stop pins limit this torsional
movement to approximately 38
Grooves are cut across the face of the friction facings. This promotes clean disengagement of the driven
disc from the flywheel and pressure plate; it also promotes better cooling. The facings are riveted to wave
springs, also called cushioning springs, which cause the contact pressure on the facings to rise gradually
as the springs flatten out when the clutch is engaged. These springs reduce chatter when the clutch is
engaged and also reduce the chance of the clutch disc
sticking to the flywheel and pressure plate surfaces when the clutch is disengaged. The wave springs and
friction facings are fastened to the steel disc
Pilot Bushing/Bearing
is sometimes used to support the outer end of the transmissions input shaft. This shaft is splined to the
clutch disc and transmits power from the engine (when the clutch is engaged) to the transmission

Pressure Plate Assembly

The purpose of the pressure plate assembly First, it must squeeze the clutch disc onto the flywheel with
sufficient force to transmit engine torque efficiently. Second, it must move away from the clutch disc so
the clutch disc can stop rotating, even though the flywheel and pressure plate continue to rotate.

Basically, there are two types of pressure plate assemblies: those with coil springs and those with a
diaphragm spring. Both types have a stamped steel cover that bolts to the flywheel and acts as a housing
to hold the parts together. In both, there is also the pressure plate, which is a heavy, flat ring made of
nodular or gray cast iron. The assemblies differ in
the manner in which they move the pressure plate
toward and away from the clutch disc.
Coil Spring Pressure Plate Assembly A coil
spring pressure plate assembly, uses coil springs and
release levers to move the pressure plate back and
forth. The springs exert pressure to
hold the pressure plate tightly against the clutch disc
and flywheel. This forces the clutch disc against the
flywheel. The release levers release the holding force
of the springs. There are usually three of them. Each
one has two pivot points.
Clutch Release Bearing

Its function is to smoothly and quietly move the pressure plate release levers or diaphragm
spring through the engagement and disengagement process. The release bearing is mounted on a hub,
which slides on a hollow shaft at the front of the transmission housing.

Clutch Fork
The clutch fork is a forked lever that pivots on a support shaft or ball stud located in an opening in the
bell housing. The forked end slides over the hub of the release bearing and the small end protrudes from
the bell housing and connects to the clutch linkage and clutch pedal. The clutch fork moves the release
bearing and hub back and forth during engagement and disengagement.

Clutch Linkage
The clutch linkage is a series of parts that connects the clutch pedal to the clutch fork. It is through the
clutch linkage that the operator controls the engagement and disengagement of the clutch assembly
smoothly and with little effort.

Shaft and Lever Linkage

Found on older vehicles,

the shaft and lever clutch linkage has many parts and
pivot points and transfers the movement of the clutch
pedal to the release bearing via shafts, levers, and bell
cranks. On some vehicles, the pivot points were
equipped with grease fittings; others had low-friction
plastic grommets and bushings at their pivot points.

Cable Linkage A cable linkage can perform the same

controlling action as the shaft and lever linkage but
with fewer parts. The clutch cable system does not
take up much room. It also has the advantage of flexible
installation so it can be routed around the power
brake and steering units. These advantages help to
make it the most commonly used clutch linkage.
Self-Adjusting Clutch

Self-adjusting clutch mechanisms

monitor clutch pedal play and automatically
adjust it when necessary.
Usually the self-adjusting clutch mechanism is a
ratcheting mechanism located at the top of the clutch
pedal behind the dash panel, The
ratchet is designed with a pawl and toothed segment,
and a pawl tension spring is used to keep the pawl in
contact with the toothed segment. The pawl allows
the toothed segment to move in only one direction in
relation to the pawl.

Hydraulic-Operated Clutch Linkage

Frequently, the clutch assembly is controlled by a
hydraulic system
In the hydraulic clutch linkage
system, hydraulic (liquid) pressure transmits
motion
from one sealed cylinder to another through a
hydraulic
line. Like the cable linkage assembly, the
hydraulic
linkage is compact and flexible. Cable linkages
also
allow engineers to place the release fork anywhere
that gives them more flexibility in body design. In
addition, the hydraulic pressure developed by the
master cylinder decreases required pedal effort
and
provides a precise method of controlling clutch
operation.
Brake fluid is commonly used as the hydraulic
fluid in hydraulic clutch systems.
Slippage

Clutch slippage is a condition in which the engine over speeds without generating any increase in torque
to the driving wheels. It occurs when the clutch disc is not gripped firmly between the flywheel and the
pressure plate. Instead, the clutch disc slips between these driving members. Slippage can occur during
initial acceleration or subsequent shifts

Reference.

Automotive technology 4th edition, jack erjavec .

Some text from total automotive technology 4th edition Anthonnye E.Schwaller .