International Journal of Pure and Applied Mathematics Volume 118 No. 20 2018, 941-944 ISSN: 1311-8080 (printed version); ISSN: 1314-3395 (on-line version) url: http://www.ijpam.eu Special Issue ijpam.eu CLUTCH PLATE FABRICATION BY USING AL-SIC METAL MATRIX COMPOSITES K.Ramesh 1, Karthick 2, S.Arunraj 3, J.Ajitkumar 4 1Assistant professor, Department of Mechanical Engineering, Karpagam College of Engineering, Coimbatore 2Assistant Professor, Department of Mechanical Engineering, Paavai Engineering College, Namakkal 3,4 UG student, Department of Mechanical Engineering, Paavai Engineering College, Namakkal Abstract: In this paper, fabrication of Stircasting setup 2. Definition of Composite which was used for the production of clutch plate using 7075 Al-SiC Metal Matrix Composites was discussed. A composite is a structural material consists of two or The mechanical properties, advantages of MMC’s, more combined constituents that are combined at a experimental procedure of stir casting were explained. macroscopic level and are not soluble in each other. The present investigation shows that MMCs have Generally, a composite material is composed of considerable higher wear resistance than conventional reinforcement (fibers, plastics, flakes and fillers) grey cast iron while sliding against automobile clutch embedded in a matrix (polymers, metals or ceramics). plate under identical conditions. The matrix holds the reinforcement to form a desired shape while the reinforcement improves the overall 1. Introduction mechanical properties of the matrix. The new combined material (composite material) will exhibit better strength The ever increasing demand for light weight, fuel when compared with other structural materials. efficiency and comfort in automobile industries has lead Composite materials are cohesive structures made by to the development of advanced materials along with physically combining two or more compatible materials. optimized design. There is a need for materials with properties such as low density, improved strength, 3. Metal Matrix Composites (MMCs) stiffness and wear resistance has led to the introduction of MMCs. MMCs are widely used in industries, as they Metal Matrix Composites is a combination of a Metal have excellent mechanical properties in wear resistance. Matrix and a reinforcement component. The matrix is The introduction of 7075aluminium- silicon carbide defined as a metal in all cases, but a pure metal is rarely composite materials made it possible to reduce the weight used as the matrix, it is generally an alloy. In productivity of clutch plate. The silicon carbide reinforced aluminum of MMCs the matrix and the reinforcement are mixed composites are increasingly used as substitute materials together. The main characteristics of MMCs include for cylinder liners, pistons, cylinder heads, brake rotors superior strength, stiffness, high wear resistance and high and calibers in automobile industries. The addition of low creep resistance on comparison with their corresponding volume fraction of silicon carbide particle (upto 8%) to wrought alloys. aluminium silicon alloys significantly reduces the wear rate and the wear resistance has been found to increase with percentage of reinforcement. The wear and frictional behavior of clutch disc is very complex and is characterized by non steady state, high pressure and high temperature process. In our paper we are going to discuss about fabrication of clutch disc using 7075Aluminium- Silicon Carbide composite with 25% of silicon carbide by Stir Casting method. Figure 1 941 International Journal of Pure and Applied Mathematics Special Issue 4. Advantages and Disadvantages of MMCS heating coils; Aluminium is placed in the crucible and heated above the melting temperature. SiC particles are MMCs are mainly used to provide advantages over added and stirred for uniform distribution in the monolithic metals such as steel and aluminium. MMCs aluminium. have several advantages over the polymer composites. These includes higher elastic properties, higher service 6. Construction of Stir Casting Machine temperature, insensitive to moisture, higher electrical, thermal conductivities, better wear, fatigue and flaw Stir casting machine consists of following components resistances. o Heating coil The drawbacks of MMCs over PMCs include higher o Graphite crucible processing temperature and higher densities, low o Silicon carbide particulate feeder dielectric, corrosion resistance, aero elastic tailoring and o Stirrer high production cost, difficult to repair, material o Drive assembly for stirrer (pulley drive) susceptible to damage. o Motor o Pulley o Column o Counter weight o Wire rope The crucible made up of hot bricks within which graphite crucible is placed. The heating coil is used to produce the heat required for melting the composite materials and it is also used to maintain the temperature inside the crucible. The heating coil is present below the graphite crucible. A stirrer and feeder is provided at the crucible. The shaft of the stirrer is connected with the pulley driven by the electric motor by means of belt. The motor and pulley assembly for stirrer is capable of moving vertically along the column. The motion of this assembly is subjected by counter weight with the help of wire rope. Figure 2 Specifications Stirring Velocity : 600 rpm Stirring duration : 15 min 5. Fabrication of Clutch Plate 0 SiC particle adding : 800 C Stir Casting Method temperature Pressure : Atmospheric pressure 0 Stir Casting is a liquid state method of composite Pouring temperature : 630 C materials fabrication, in which a dispersed phase (ceramic particles, short fibers) is mixed with a molten 7. Experimental Procedure matrix metal by means of mechanical stirring. The liquid composite material is then cast by conventional casting For performing the stir casting operation for composites methods and may also be processed by conventional the following machines/equipments were used: resistance metal forming technologies. Content of dispersed phase heated muffle furnace, shaper machine, graphite crucible, is limited (usually not more than 30% volume). impact, graphite stirrer, aluminium rod and SiC, green Distribution of dispersed phase throughout the matrix is sand and mould boxes (Cope and Drag). 7075Aluminium not perfectly homogeneous. Distribution of dispersed alloy with composition (wt %) Si-25%, Mn-0.4%, Mg- phase may improved if the matrix is in semi solid 2.5%, Cu-1.6, Fe-0.3, Cr-0.23, Ti-0.20, and Al- reminder condition .The method using stirring metal composite is used as the base matrix. The dispersions used are SiC materials in semi solid state is called Stir casting. particles 25% by weight. Stir casting method is most suitable for Al-SiC Metal Matrix Composites. A crucible is placed in electrical 942 International Journal of Pure and Applied Mathematics Special Issue 8. Conclusion The development of a metal matrix composite Aluminium Silicon Carbide Clutch Plate having constant cross sectional area, where the stress level at any point is considered to be constant, has proved to be effective. The study demonstrated that composite can be used for clutch plate for light weight vehicles and it meets the requirement together with substantial weight savings. The wear test of composite Clutch plate is under process. Reference Figure 3 [1] “Method For Determining Refractory Specimen Heat Resistance” by M.Dimitridzhiviæ,D. Dostaniæ, and About 2 kilograms of 7075aluminium alloy is cleaned T. Volkov-Husovia. and loaded in the SiC crucible and heated to above its liquid temperature. The temperature was recorded using [2] D.P.H Hasselmann., “Thermal Stress Resistance chrome-alumel thermo couple. The specially designed parameters for brittle refractory ceramics” (Bulletin of mechanical graphite stirrer is introduced into the melt and the American Ceramic Society). stirred at 600 rpm. The depth to which the impeller was rd immersed is approx. 1/3 the heights of the molten melt [3] “Thermal shock behaviour of a kaolinte refractory from the bottom of the crucible. The preheated (8000C) prepared using a natural organic binder” by A. A. SiC particulates were added through a preheated pipe by Ogacho Æ B. O. Aduda. manual tapping into the slurry; while it was being stirred the post addition stirring time of 15 min was allowed to [4] N D R Goddard, R M J Kemp and R Lane (“An enhance the wetting of particulates by metal. The overview of Smart Technology) Packaging Technology temperature of the slurry was sufficiently raised above and Science, Volume 10, pp 129 – 143 (1997) the melting range of the matrix alloy before pouring the composite melt into preheated permanent mold of Clutch [5] “Material science and manufacturing” M.Moallem Disc. 1987. Compositions [6] “Materials science and engineering” K.M.Gupta, Umesh publications. Zn Mg Cu Mn Fe Cr Ti Si Al [7] “ Elements of material science and engineering” 5.6% 2.5% 1.6% 0.4% 0.3% Van Vlack / Adison Wesley 0.23% 0.20% 0.15% Remaining [8] Aruljeyakumar.A, Srinivasan.V “Thermal Properties Characteristics of Chitoson Filled PLA/Basalt Fiber The mechanical properties of 7075 aluminium depend Hybrid Composites” International Innovative Research greatly on the temper of the material. Journal of Engineering and Technology ISSN NO: 2456- 1983. Volume 1 Issue No: 1 September 2016. 16 – 22. • It has good tensile strength. • It has good yield strength. • As it is made up of combination of other materials it has combined properties of all the materials. • Normally the aluminium alloy has good impact strength, since it has applied in pistons, brakes etc. • It has the density of 2810 kg/m³. • Since it is a composite material it has weight lesser than the other material used in manufacturing the clutch plate. 943 944.