Lightweight innovative composite dry clutch pressure plate

Abstract

Abstract This study presents an innovative lightweight composite dry clutch pressure plate including aluminum foam structure in its core. Mechanical burst performance via finite element method of five different composite designs, in which the core foam structure is planned to be obtained via powder metallurgy, is considered. Moreover, a literature review of the powder mixture effect on aluminum foaming experimentation is presented. Compared to conventional serial clutch pressure plate, proposed composite concept reduces the overall weight by up to 47%, however increases stress by up to 65%. Concept design does not only reduces the weight but also enhances the heat dissipation thanks to the increase of convective surface. Mechanisms in the present study are helpful to motivate further innovative lightweight solutions in order to overcome the challenges related to the recent CO2 regulation for Heavy Duty Vehicles.