This study aims to investigate and mitigate clutch wear, a major factor affecting performance degradation, maintenance frequency and efficiency in automotive transmission systems. A modified single-plate clutch design incorporating an annular friction ring between the flywheel and friction plate is proposed to redistribute contact loads and reduce wear. The research focuses on evaluating the effectiveness of this modification in minimizing wear depth, volumetric loss and contact pressure, thereby enhancing clutch lifespan, reliability and overall system performance under realistic operating conditions.
A three-dimensional finite element model (FEM) was developed to simulate clutch engagement behavior incorporating an annular friction ring. Archard’s adhesive wear law was applied to predict wear evolution under realistic thermal and mechanical loading conditions. The model included contact interactions among the flywheel, pressure plate, annular ring and friction plate, using material properties of steel and friction composites. Comparative analyses were conducted between conventional and modified clutch configurations to evaluate wear depth, volumetric wear loss and pressure distribution over multiple engagement cycles.
The introduction of an annular friction ring significantly reduced clutch wear and improved load distribution. The modified configuration decreased volumetric wear loss by 38.14% and maximum contact pressure by 30.66% compared to the conventional clutch. The ring acted as a sacrificial layer, absorbing initial contact stresses and ensuring a more uniform pressure distribution across the friction surface. This progressive engagement mechanism enhanced the clutch’s operational smoothness, minimized localized wear and extended the component’s service life, demonstrating the effectiveness of the proposed design modification.
This research presents a novel approach to reducing clutch wear through the integration of an annular friction ring, a concept not widely explored in existing clutch system designs. By combining experimental insights with advanced FEM-based wear modeling, the study provides a deeper understanding of the mechanisms driving wear reduction and pressure redistribution. The findings offer valuable guidance for the design of more durable, efficient and cost-effective clutch systems, potentially influencing future automotive transmission technologies and maintenance strategies focused on performance longevity and reduced wear-related failures.
The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-10-2025-0496/
