Topology optimization of clutch drive plate for commercial vehicles

Abstract

The drive plate is one of the main components of the clutch disc which transmits the torque from engine to transmission. For commercial vehicle applications, the drive plate works under immense torsional forces thanks to high engine torque values. Therefore, high durability is expected during the operational life of the clutch disc drive plate. On the other hand, the lightweight of the vehicle components has an important role in CO2 emission standards. To be able to assure this regulation, companies conduct studies for decreasing the vehicle mass. In this study, the drive plate's 3D CAD data is created based on the current design by using CATIA solid creation software. Finite Element Analysis (FEA) was carried out in a statical analysis tool and to be verified for real-life working conditions. The topology optimization was performed using CAE software (ANSYS) in order to reduce the weight of the drive plate without compromising on mechanical durability. The optimized design was proposed based on topology optimization outputs. The strength of the proposed design was investigated by using FEA analysis and results are compared to the acceptance criteria of the material. The optimized geometry is equally durable and lighter in weight compared to the existing model. Mass was decreased %18 without compromising mechanical durability.