What is a clutch?
A clutch is a mechanical device used in vehicles and machinery to engage and disengage the power transmission from the driving shaft (engine or motor) to the driven shaft (transmission or wheels). It allows for the control of power flow in various operations, particularly in automotive applications, to manage the connection between the engine and the wheels.
Functions of clutch
Engagement and disengagement
The primary function of the clutch is to engage and disengage the engine from the driveline. When the clutch engages, power flows from the engine to the wheels. When the clutch disengages, the flow of power is interrupted, allowing the vehicle to stop without the engine stalling.
Smooth operation
The clutch enables smooth starting and stopping of the vehicle by gradually engaging the engine with the transmission. This helps reduce shock loads and ensures smooth power delivery.
Shifting
The clutch makes it easy to shift gears without causing damage by temporarily disconnecting the engine from the transmission.
The main component of the clutch
Flywheel
The flywheel is attached to the engine crankshaft and provides an engaging friction surface for the clutch disc.
Clutch Disc (Friction Plate)
The clutch disc is sandwiched between the flywheel and pressure plate. It is lined with friction material and engages the flywheel and pressure plate to transmit power.
Pressure Plate
The pressure plate exerts pressure on the clutch disc and presses it against the flywheel to engage the clutch. It is operated by a spring or diaphragm mechanism.
Release Mechanism (Release Bearing and Fork)
This mechanism disengages the clutch by moving the pressure plate away from the clutch disc. It is activated by the clutch pedal in manual transmissions and hydraulically in some systems.
Clutch Cover
Also known as the clutch housing, it surrounds the clutch assembly and provides a mounting point for the pressure plate and other components.
Types of Clutch
Friction Clutch
The most commonly used type in vehicles, which relies on the friction between the clutch disc, flywheel and pressure plate to transmit power.
Centrifugal Clutch
Uses centrifugal force to automatically engage and disengage the clutch according to the engine speed, commonly found on small motorcycles and go-karts.
Hydraulic Clutch
In a hydraulic clutch system, the coupling is hydrodynamic and there is no contact between the shafts. Hydraulic fluid is used to operate the clutch mechanism, providing smoother, more consistent engagement.
Single-disc clutch
A single-disc friction clutch is a common type of clutch that operates by utilizing the friction between two discs to transmit torque and motion.
This type of clutch is characterized by the fact that the two shafts can be disengaged or engaged at any speed with smooth engagement and low shock and vibration. When overloaded, slippage occurs between the two friction surfaces, providing protection. Consists of a single friction disc that engages the flywheel and pressure plate, commonly used in standard passenger cars.
Multi-disc friction clutches
Cone Clutch
Uses conical surfaces for engagement and disengagement, providing smooth, progressive engagement. Commonly used in certain industrial applications and older vehicles.
Overrunning Clutch
The operating principle of an overrunning clutch is based on the connection of the star wheel to the shaft. When the outer ring turns clockwise at a slow speed, friction causes a roller to tightly connect the outer ring to the star wheel, which in turn drives the shaft to turn at the same speed. At this time, the inner ring also rotates.
When the inner ring is driven by a reversible motor to rotate rapidly, regardless of direction, the shaft can be rotated rapidly by the star wheel. When such a rotation occurs, the rollers are withdrawn from the wedge, while the outer ring maintains its original speed and continues to rotate.
Electromagnetic clutch
The Electromagnetic Clutch is a type of clutch that utilizes magnetic force for transmission. It controls the engagement and disengagement of the clutch by energizing and de-energizing a coil. In some designs, such as placing magnetic powder between the driving and driven parts, the engagement force between the two can be strengthened, and such clutches are called magnetic powder electromagnetic clutches. Commonly used in mechanical and automotive air conditioning systems.
Toothed clutch
Uses interlocking teeth to engage and disengage the clutch, providing a slip-free, reliable connection. Used in applications requiring precise timing and torque transmission, such as certain industrial machinery.
CNC machining for clutch
Using CNC machining to manufacture key clutch components
- Flywheel: The flywheel is a critical component in a clutch system. CNC machining ensures that the flywheel is perfectly balanced and has a smooth surface, which is essential for optimum performance and longevity.
- Clutch Discs: Clutch discs require precision machining to ensure proper engagement and disengagement. CNC machining produces clutch discs with precise specifications and consistent quality.
- Pressure Plates: Pressure plates must apply uniform pressure to the clutch disc. CNC machining helps to achieve the precise tolerances required for even pressure distribution.
- Clutch Covers: CNC machines produce clutch covers with complex geometries and tight tolerances to ensure perfect fit and function of the clutch system.
CNC machining processes for clutch manufacturing
1. CNC turning: For machining cylindrical parts such as flywheels and pressure plates. CNC lathes can accurately shape these parts and create features such as grooves and tapers.
2. CNC Milling: For machining more complex geometries on clutch covers and clutch disks. CNC milling machines can perform a variety of operations such as drilling, boring and contouring.
3. Grinding: To ensure smooth contact surfaces, which are critical to clutch performance. CNC grinding machines can produce highly accurate and smooth surfaces.
4. Drilling: Drill holes for bolts and other components using CNC drilling machines to ensure precise location and diameter.
Materials used in the manufacture of clutches
– Steel: Commonly used for its strength and durability.
– Aluminum: Lightweight, often used for parts that contribute to weight reduction.
– Composite materials: Used in high performance clutches to improve heat resistance and reduce weight.
Conclusion
A clutch is an essential component in many mechanical systems, especially in vehicles, enabling controlled power transmission and smooth operation.At EASIAHOME, we specialize in customizing precision auto parts for your project. We have experienced engineers and professional machining equipment.If you want to manufacture precision automotive parts with limited cost, you can contact us here and we will provide you with the optimal solution.
