Thermal Performance Evaluation Methodology for Wet Clutch: Simulation and Testing Correlation

This paper describes a simulation methodology developed to predict the temperature distribution in separator plate and friction disc of the wet clutch corresponding to given slip power, oil flow rate and clutch geometry for off-highway applications. This study adopts a model-based design approach to understand thermal behavior of the wet clutch. This simulation methodology has been developed in a 1D environment with the right fidelity modeling approach to predict thermal performance of the clutch. This model includes heat flow through conduction and convection corresponding to heat generated due to friction between separator plate and friction material. Lab test includes multiple thermocouples installed on separator plate to capture temperature distribution in radial direction. This methodology has been correlated >90% with test data acquired in the lab. This dynamic simulation model aids to identify the potential root cause of clutch failures and risk mitigation. DOE has been performed to assess the impact of various parameters like separator plate thickness, friction disc groove geometry and oil flow rate on the surface temperature and oil exit temperature. This methodology can be used to develop new predictive simulation workflows to address design issues in virtual environments with significant reduction in product development time, cost and risks associated with lab and field tests.