A comprehensive numerical model was established based on the Navier-Stokes equations, KE rough contact mechanics and heat transfer theory with grooves consideration in order to analyze the effect of the operating conditions on the engagement behavior of wet clutches. The orthogonal experiments were conducted to analyze the effect of the operating parameters such as applied pressure, the temperature of automatic transmission fluid (ATF), the relative rotation speed, the permeability and the grooves based on the independently developed experimental setup. Results show that the applied pressure not only affects the engagement time, but also the engagement torque. The first torque judder that appears at the moment of the piston touching the plates depends on the stability of the applied pressure. The second torque judder that appears at the end of the engagement process is caused by the difference of dynamic and static friction coefficient. The increase of the temperature of ATF makes the dynamic viscosity decrease, which delays the rough contact and engagement process. The hydraulic torque decreases accordingly. The higher the relative rotation speed is, the longer the engagement time is. The higher the permeability of the friction material is, the faster the decrease of the film thickness and the engagement response is. The larger the groove width is, the smaller the engagement torque is, the longer the engagement time is. The larger the initial film thickness is, the smaller the shearing torque is.
Chen-long YANG,Peng-hui WU,Xiao-bo SHANG,Zhao-shuai WANG. Simulation and experimental study of engagement process with groove consideration. Journal of ZheJiang University (Engineering Science), 2019, 53(7): 1225-1236.
Fig.3Rough contact analysis model of friction plates
Fig.4Schematic diagram of radial grooves of wet clutches
参数
数值
参数
数值
${R_{\rm{i}}}$
0.378 m
${E_2}$
2.06×109 MPa
${R_{\rm{o}}}$
0.421 m
${\nu _1}$
0.3
$d$
0.5 mm
${\nu _2}$
0.4
${E_1}$
1.059×108 MPa
–
–
Tab.1Parameter list of test plates of large size wet clutch
参数
数值
参数
数值
$\mu $
0.086 Pa·s
B
0.2 mm
${h_{\rm{o}}}$
2.54×10-5
${\sigma _{\rm{s}}}$
1.012×10-6
${h_{\rm{g}}}$
4×10-4
${\sigma _{\rm{f}}}$
8.32×10-6
$\rho $
850 kg/m3
–
–
Tab.2Parameter list of operating conditions of wet clutches in simulation and experiments of dynamic engagement
Fig.5Test method of infrared temperature sensors
Fig.6Experimental results of temperature distribution during engagement process of wet clutches
Fig.7Simulated results of temperature distribution during engagement process of wet clutches
Fig.8Automatic test system of engagement performance of wet clutches
Fig.9Schematic diagram of automatic test system for wet clutches
Fig.10Cooling and lubrication system of wet clutches
Fig.11Experimental results of applied pressure of wet clutches (1.1，1.3和1.5 MPa)
Fig.12Simulated results of engagement performance with different applied pressures (1.1，1.3和1.5 MPa)
Fig.13Experimental results of engagement process with different applied pressures (1.1，1.3和1.5 MPa)
Fig.14Experimental curves of engagement process with different PID parameters
Fig.15Experimental curves of relationship between applied pressure and engagement torque
Fig.16Simulated curves of engagement process with different temperature of lubrication oil (65 °C，50 °C and 35 °C)
Fig.17Experimental curves of engagement process with different of lubrication oil (65，50 and 35 °C)
Fig.18Experimental curves of engagement process with different initial rotation speeds
Fig.19Simulated curves of engagement process with different initial rotation speeds
Fig.20Experimental curves of engagement process with different initial rotation speeds
Fig.21Experimental curves of instantaneous sliding power with different initial rotation speeds
Fig.22Simulated curves of film thickness with different permeability
Fig.23Simulated curves of engagement process with different permeability
Fig.24Experimental curves of engagement process with different permeability
Fig.25Simulated curves of engagement torque with different groove widths
Fig.26Experimental curves of engagement performance with different groove widths
Fig.27Experimental curves of hydraulic viscous torque with fixed clearance
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