Friction plate clutch disc

Types of Friction Plate Clutch Discs

There are several types of friction plate clutch disc, including:

• Organic clutch discs:

  These types of discs are made using composite materials that are similar to organic materials. Organic materials are made from different materials like plastics, resins, and natural fibers. An organic clutch disc is known for its smooth engagement and low noise levels. Unfortunately, these organic plates wear out quickly and may not be ideal for heavy-duty applications.

• Sintered clutch discs:

  A friction plate clutch disc is made using metal particles that are bonded together. They are designed to withstand high temperatures and high wear rates. This makes them ideal for heavy-duty vehicles like trucks and for use in motorsports. Sintered discs can also be used in applications where high torque and frequent clutch engagement are expected. Their major downside is that they can be noisy and cause damage to the flywheel.

• Metallic clutch discs:

  These are clutch discs made from steel or aluminum. They are suitable for high-performance applications, such as racing. Metallic clutch discs can handle a lot of heat and are very durable. The downside is that they can be heavy and noisy.

• Ceramic clutch discs:

  These types of clutch discs are made of ceramic materials. Ceramic clutch discs are designed to withstand high temperatures and are very hard. This makes them suitable for high-performance applications, such as racing. The downside of ceramic clutch discs is that they can be very abrupt during engagement, which can lead to driveline shock.

• Kevlar clutch discs:

  A friction plate clutch disc is made of Kevlar, which is a very tough material. Kevlar clutch discs are designed for high-performance applications. They are very durable and can handle high torque and tension. The only problem with Kevlar clutch discs is that they can be very noisy during operation.

Specifications and Maintenance of Friction Plate Clutch Discs

• Size and Dimension

  In friction clutch plates, the size is important for fitting and working. They are measured in mm or inches and have a diameter range of 180 to 400 mm. The disc area, which is the surface that touches the flywheel or pressure plate, is also measured and affects how much friction is created.

• Material

  The friction clutch plate is made of what is called clutch friction material. This is often a mix of metals, like steel or copper, combined with organic materials, like rubber or resins. The clutch disc assembly material is chosen based on how much friction it can provide without wearing out too quickly.

• Friction Coefficient

  The friction coefficient shows how sticky the surface is. It needs to be just right, not too high or too low. A high coefficient means too much friction, leading to clutch wear. A low coefficient causes slippage. It should be between 0.3 and 0.6. This ensures smooth gear changes and long clutch plate life.

• Load Capacity

  The load capacity of a clutch friction plate is how much force it can handle before slipping, measured in Newtons (N). The load capacity must match the engine's power and torque. For small cars, a load capacity of 1500 to 2000 N is enough. Sports cars need 2500 N or more. If the load capacity is too low, the clutch will slip. A too high rating makes the clutch hard to press.

• Thickness

  Clutch friction plates come in different sizes. The thickness affects how long the plate will last. A thick plate has a better lifespan. However, it may cause the clutch pedal to feel heavy. Plates are usually up to 10 mm thick.

• Balance

  The friction plate must be balanced well. An unbalanced plate causes vibration, making it wear out fast. It is important to check that the friction plate is evenly balanced before fitting it in the vehicle.

• Surface Finish

  The surface finish of the friction plate is important for how well it grips. The finish should be rough enough to hold on but not so rough that it damages the other parts. A balanced roughness ensures a good grip without excessive wear.

• Quality Control

  Quality control stops problems with the friction plate. Tests check things like if it slips too much or not enough, how loud it is, and how strong it is. These checks make sure the friction plate works well and lasts.

To take care of a friction plate clutch disc, first, ensure proper installation. This is very important for the clutch plate to work well. Follow the manufacturer's instructions for putting it together. Check the clutch pedal freeplay and adjustment. A loose pedal makes the clutch slip, ruining the plate. Keep the plate clean, too. Don't let oil, grease, or dirt get on it, as these make it slip. Use a dry cloth to wipe it clean. It is also important to use the right gear while driving. Don't force gears that don't want to go in. This puts extra stress on the clutch disc and makes it wear out faster. Avoid riding the clutch. Press the pedal all the way down when stopping and changing gears. Half-clutching makes the disc rub and wear down.

Check the hydraulic system or clutch linkage to ensure proper pedal action. Problems here can cause the clutch not to disengage fully, leading to slipping. If the vehicle has a pull-type clutch, watch the release bearing. A faulty bearing can cause the clutch to drag. Replace it if needed.

Overheating is bad for the friction plate. Take breaks when driving in heavy traffic or up steep hills. This prevents the clutch from getting too hot. Finally, stick to the manufacturer's advice on how to use and care for the clutch plate. This helps it to last a long time.

How to Choose Friction Plate Clutch Discs

Choosing the right friction plate clutch disc for a given vehicle requires careful consideration of several factors. Here are some of them:

• Vehicle type and specification

  This is the first and foremost factor to consider. One must consider the make, model, and year of the vehicle. This is because every vehicle has its own clutch disc size and specification requirement. For example, a heavy-duty truck requires a larger and more robust clutch disc than a small passenger car. The vehicle specification will help determine the diameter, thickness, and material of the friction plates.

• Driving habits

  Driving habits such as the type of terrain and driving style should be considered. For example, a driver who frequently drives in stop-and-go traffic or on hilly terrain requires a more durable clutch disc. This is because such driving conditions put more stress on the clutch and can lead to premature wear.

• Load and towing capacity

  Clutch discs are also chosen based on the load and towing capacity of the vehicle. A vehicle that tows heavy trailers or carries heavy loads requires a more robust clutch disc. This is because a more heavy-duty friction plate is required to handle the extra stress during towing or hauling.

• Performance requirements

  Performance requirements, such as the need for quick engagement and disengagement of the clutch, should also be considered. For example, a racing vehicle requires a high-performance clutch disc. This is because racing vehicles need quick engagement and disengagement of the clutch to maximize engine power and performance.

How to Replace Friction Plate Clutch Discs

Replacing a clutch disc requires a good understanding of the car's transmission system. Here is a step-by-step guide on how to replace a friction plate clutch disc:

• Step 1: Safety First and Prepare the Vehicle

Ensure the working area is well ventilated. The vehicle should be parked in a level area with the parking brake engaged. Disconnect the battery's negative terminal (12V) and ensure the vehicle is shut off. Gather all tools needed for the project and ensure they are within reach. Also, lift the vehicle using a jack and place jack stands under it to provide support.

• Step 2: Remove the Wheels and Access the Clutch

Loosen the lug nuts and remove the wheels. Then, remove the protective cover on the vehicle's clutch to enable access.

• Step 3: Remove the Clutch Pedal Assembly

Remove the clutch pedal assembly from the vehicle. Disconnect all electrical components connected to the clutch pedal.

• Step 4: Drain Transmission Fluid and Remove Drive Shafts

Drain the transmission fluid from the vehicle by removing the drain plug. Removing the drive shafts is also necessary to ensure the clutch is adequately accessible.

• Step 5: Remove the Old Clutch Disc

Loosen the pressure plate's bolts and use a wrench to loosen them slowly. Then, pry out the old clutch disc from the flywheel using a clutch alignment tool. It may be necessary to pull out the pressure plate.

• Step 6: Install the New Clutch Disc

Align the new clutch disc with the flywheel using the alignment tool. Ensure it is well seated.

• Step 7: Reassemble the Clutch Assembly

Reinstall the pressure plate and tighten its bolts. Reinstall the clutch pedal assembly and connect all the electrical components. Refill the transmission fluid by replacing the drain plug and pouring in the fluid.

• Step 8: Reassemble and Test the Vehicle

Reassemble all other components removed during the process. Reinstall the wheels and lower the vehicle. Reconnect the battery's negative terminal. Start the vehicle and test the new clutch disc to ensure it functions properly.

Q&A

Q1: What is a clutch friction plate made of?

A1: Traditionally, friction plates were made using natural fibers. Nowadays, manufacturers use synthetic materials. These materials offer better performance compared to the traditional ones.

Q2: How long does a friction plate last?

A2: There is no specific time a friction plate will last. Different factors affect the lifespan of a friction plate. For instance, the driving conditions and the quality of the friction plate can determine how long it will last. Generally, a friction plate can last between 50,000 to 100,000 miles.

Q3: What are the signs of a worn-out clutch friction plate?

A3: The first sign that the car has a worn-out friction plate is slippage. The driver might have a hard time shifting gears. There will be a grinding noise when changing gears. The clutch pedal will feel different and take more effort to push.