BorgWarner_DCTWet_ClutchesFrictionMtrls_Gold

ModuleXSlide0DualClutchesandFrictionMaterialsWetDCTModuleXSlide1Content•FunctionofaDualClutch•DCArchitecture•ClutchSizing•ThermalSimulation•WetversusDry•DCWetFrictionMaterial•DCTrendsandNewDevelopmentsSlide2DualClutchFunctionModuleXSlide3PrincipleofDualClutch•2clutches,eachofthemconnectedtoatransmissionshaft•Independentopeningandclosingofclutches•Verysmoothshifting–nopowerflowinterruption•Clutches=launchclutches;noTCrequiredModuleXSlide4DualClutch–maincomponentsPistonsActuationofclutchesMainhubDistributionofoilflowsReturnSpringsOpentheclutchesClutchpacksFrictionandSeparatorplatesfortorquetransferClutchHubsConnectiontotransmissionshaftsInputhubConnectiontoengineModuleXSlide5ActuationofOuterClutchPressureOilPistonRingOCmovementModuleXSlide6ActuationofInnerClutchPistonringICmovementPressureOilModuleXSlide7CoolingofClutchesLubeOilSlide8ArchitectureofWetDualClutchesModuleXSlide9TraditionalarchitecturesNestedvsParallelClutchpacksModuleXSlide10ClutchpackarchitecturenestedparallelmoreefficientuseofcoolingflowbothclutchessamethermalcapacityshorteraxiallengthsmallerouterdiametersmallerinertiastobesynchronizedlowercostModuleXSlide11DualTronicPowerSplitTransmission•2singleclutches•Drivenbyachain•Smallandmicrocars•Compacttransmissiondesign•Lowertorqueapplications(~200Nm)ModuleXSlide12Clutchconceptsw/osupportwithsupportnestedparallelTechnicallypossiblebutlongaxialdimensionSlide13ClutchSizingModuleXSlide14ClutchcapacitycalculationG=Md/p=*zf*AAp*rmeanpmax,st=pmax-psprAAp=applypistonareaMd=*zf*p*AAp*rmeanrmean=2/3*(r3f,out–r3f,in)/(r2f,out–r2f,in)=frictioncoefficientZf=numberoffrictionsurfacesModuleXSlide15OddClutch0.0000.2000.4000.6000.8001.0001.2001.4001.6001.8000100020003000400050006000700080009000100001100012000Drehzahl[U/min]Druck[bar]resultierenderZentrifugaldruckFederdruckFederdruck-res.DifferenzdruckEvenClutch-4.000-3.000-2.000-1.0000.0001.0002.0003.0004.0005.0006.0000100020003000400050006000700080009000100001100012000Drehzahl[U/min]Druck[bar]resultierenderZentrifugaldruckFederdruckFederdruck-res.DifferenzdruckClutchhydraulicbalancingFc=m*v2/rPressurechamberBalancechamberSlide16ThermalSimulationModuleXSlide17Simulation(hillholdandlaunch)2400U/min141°C4000U/min@5sModuleXSlide18Simulation(racestart)4500U/min142°CSlide19WetvsDryModuleXSlide20MaincharacteristicsWetClutch*DryClutch**compactsizeactuationsystemspacedemandingcoolinglubricantnolubricanthighenergyinputspossiblelimiteduseallvehicleclasseslimitedusepumptocirculatecoolingoilrequiredambientaircooledminimalwearhighwear*withhydraulicpistonactuationsystem**withreleasesystemModuleXSlide21ProjectsinseriesproductionNmrpm60007000800090001003005007009001100BWWetDCTWetDCTDryDCTSlide22FrictionMaterialModuleXSlide23CurrentTrendsinTransmissionsandRequirementsofWetFrictionMaterialsTRANSMISSIONTRENDSWETFRICTIONMATERIALREQUIREMENTSHigherpressuresLowdeformation,lowlininglossImprovedefficiencySmallerpump,lowerATFflowHigherenergyfacings,higherheatresistanceatlowlubricationflowReducedraglossImprovedgroovepatterndesignReducedsize/weightHigherµ,increasedheatresistanceHigherspeeds,higherenergiesStablecoefficientsoffriction,nohotspotsContinuousslipclutchesGoodµV;noshudder;nonoiseATFcompatibilityInerttochemicalandphysicalinteractionswithfluidsBetterconsistencyofshiftqualityBetterµPVTstability,positiveµ-Vslope;reducedvariationundervariousconditionsModuleXSlide24DevelopmentofToday’sHighHeatResistanceandHighPerformanceFrictionMaterialsFRICTIONPROPERTYWETFRICTIONMATERIALCONTROLLINGFACTORSµo,lowspeeddynamiccoefficientFrictionmaterialingredientsandATFadditivesadsorptionµi,initialdynamiccoefficientathighspeedHydrodynamiceffects/porosity/compression/roughnessMechanicalstrengthFibertype,fiberfibrillation,fiber/resinbondstrengthsHeatresistanceMoresyntheticfibers(aramid,carbon),higherporosityPositiveµ-VslopeBalanceofpaperingredientswithATFadditivesadsorptionandporesizeHotspotresistanceResiliency,oilfilmGlazingIngredientcompatibilitywithATFadditives,poresizeCompressionsetOptimizationoffibers/,fillersandresinstype/amountsModuleXSlide25ATFadditivesFrictionMaterialchemicaleffectsSmoothness/uniformityATFfilmLiningpermeabilityCompressibilityGrooveeffectsSurfaceSmoothness00.20.40.60.810100200300Time(seconds)Torque(Nm)AsperityTorqueHydrodynamicTorqueTotalTorqueControllingFactorsforEngagementTorqueCurveSlopeTime(seconds)Torque(Nm)LiningpermeabilityCompressibilityGrooveeffectsSurfaceSmoothnessATFadditivesFrictionMaterialChemicaleffectsSmoothness/uniformityATFfilmModuleXSlide26BW’sUnifiedFrictionSystemModelRegionIOilFilmRegionIIOilFilmRegionIIIOilFilmRegionIVOilFilmRPMDragTorqueRegionIFullOilSheetRegIIIRivuletSheetRegionIVNoOilSheetRegIITran-sitionInterfaceTemperaturevsTime020406080100050100150200250300Time-SecondsInterfaceTemperature-CSingleEventRPMApplyPressureThermoelasticInstabilityThermoplasticInstabilityTEI:NoFunctionalProblem,NotProgressiveTPI:Distortion,ProgressiveThermalDamageTemperaturePredictionENGAGE_WModelHeatTransferCoefficientsTorqueModelBreakawayCoefficientThermalDegradati