Wet-running multi-plate clutches and brakes are important components of modern powershift gearboxes and industrial powertrains. In the open stage, drag losses occur due to fluid shear. The identification of drag losses is possible by experiment or CFD-simulation. For the calculation of the complex fluid flow of an open clutch, CFD-approaches such as the volume of fluid (vof) method or the Singhal cavitation model are applicable. Every method has its own specific characteristics. This contribution sets up CFD-calculation models for different clutches with diverse groove designs. We present results of calculations in various operating conditions obtained from the Singhal cavitation model and the vof method. The usage of modern commercial CFD-Tools (Simerics MP+) results in short calculation times. The developed CFD-models consider the geometry of a complete clearance consisting of a friction plate and a separator plate, the gap between the plates and the flow conditions arising from the design of the plate carriers. The full 360-degree modeling makes it possible to take arbitrary groove designs on the friction and separator plate into account in contrast to frequently used circumferential symmetry. We carried out a high number of calculations with various influencing factors such as operating conditions, groove design, speed ratio and feeding oil temperature. We proof the numerical solutions with results from experiments. The basis of a broad validation of the models are characteristic values obtained from experimental investigations on the drag loss test rig LK-4. The usage of serial production parts from automobile and industrial applications ensures a data basis that is reliable and relevant for practical work. The contribution characterizes the examined CFD-approaches with respect to computing effort and the validity of the results. Furthermore, it shows the pros and cons of the specific CFD-approaches (vof and cavitation) to calculate the drag losses of wet multi-plate clutches.

For wet disk clutches, the energy input is strongly influenced by its friction behavior. However, the friction behavior cannot be simulated and therefore is mostly derived from experimental data for specific clutch systems. This paper presents a new approach for the identification and validation of linear friction models using analysis of variance (ANOVA) and stepwise regression. Therefore, we use experimental data of three different friction systems with paper- and carbon-based friction lining. The designed experiments support an efficient parameter-based analysis of the friction behavior. The obtained models can be used as an input for thermal simulations, for example, but can also support a better understanding of the main influencing factors and are applicable to various friction systems. For validation, the obtained models are applied to measured data. A good correspondence between the simulated and measured friction behavior can be shown for speeds in the investigated operating range. The presented procedure can be easily adapted, for different factors and operation modes, as well as other applications.

Safety and comfort, while ensuring torque transfer capability, are essential for wet multi-plate clutches. The safety of the torque transmission process largely depends on the endurance of the tribological system against spontaneous and long-term damages. Modern Carbon friction linings in wet multi-plate clutch applications offer superior wear resistance compared to other friction materials, but there is hardly any published data on their spontaneous damage behavior. This article therefore presents results from experimental studies on the spontaneous damage of innovative Carbon friction linings carried out on a component test rig. Furthermore, the influence of different steel plate thicknesses (3.5 mm vs. 6 mm) was investigated. 16 step tests, including visual assessments of the clutches, were performed with Carbon-fiber reinforced plastic (CFRP) and Carbon-fiber reinforced Carbon (C/C) linings in brake operations.The results of the step tests are documented in friction work over friction power diagrams. Results show excellent endurance of modern Carbon friction linings against spontaneous damage and thus makes them suitable for safety relevant high-performance applications. There was no clear influence of the steel plate thickness on spontaneous damage. However, the C/C friction lining ran at a specific energy of up to 5.26 J/mm² in combination with sliding velocities of up to 67 m/s (high speed application) without failure. This is the highest published spontaneous damage resistance identified for wet clutches.

Many applications of wet multi-plate clutches are within safety-critical areas since malfunction or failure of the clutch is often equivalent to “loss of drive”.The main criterion for the estimation of damage and endurance of wet multi-plate clutches is the temperature on the friction interface. Owing to the thin, rotating geometry of the plates, determination of relevant temperatures in operation mode is almost impossible. State of the art is that there is no general applicable model for real-time estimation of clutch temperatures during operation.This contribution presents a validated parametric real-time temperature model that is applicable to various use cases and operating conditions. The model enables the calculation of the actual clutch temperature during operation and the prediction of temperature for future shifting operations.The model is validated by comparing temperature measurements from a component test rig and from the KUPSIM thermal clutch design tool with the developed real-time temperature calculation. The validity of the model for serial parts from industry and automotive applications under various load cases (clutch mode, continuous slip, non-steady slip) is demonstrated. The deviation between measurement and calculation are typically very small (< 5 K). The temperature prediction allows a highly accurate (deviations typically < 5 K) conservative prediction of the thermal load for future shifting operations.The model can thus contribute to the increase of operational safety of wet multi-plate clutches while at the same time facilitating optimal component design by reducing thermal over-dimensioning of clutches.

The torque transfer capability as well as long-term endurance are essential for wet multi-plate clutches. The quality of the torque transmission process largely depends on the tribological system consisting of friction pairing, lubricant and applied loads. The requirements on friction linings in wet multi-plate clutches increase continuously due to stricter CO₂ reduction regulations and the demand of higher power densities.There is a lack of published data and information about the friction behavior of modern Carbon friction linings in wet multi-plate clutch applications, although these friction materials have successfully proven their performance capabilities over the last two decades in synchronizers. Therefore, this article presents results from experimental studies on the friction behavior of innovative Carbon friction linings carried out on a component test rig. Friction screening tests were performed with Carbon-fiber reinforced plastic (CFRP) and Carbon-fiber reinforced Carbon (C/C) linings in brake and constant slip operation. Furthermore, our research included long-term tests with different lubricants (engine/marine/tractor oil).Results show that modern Carbon friction linings can offer advantages over other materials. In the friction screening (brake and constant slip operations) and long-term tests, the torque transfer capability of both friction linings is very stable, even at high specific loads—sliding velocities near 30 m/s and axial pressures of 2.5 MPa. Influences of sliding velocity, pressure and lubricant on the friction performance are presented. Furthermore, the gradient of the Coefficient of Friction (CoF) curve usually decreases at the end of the engagement to enable good control and shift comfort.