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Simulations of drag torque affecting synchronisers in a dual clutch transmission

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Abstract

Drag torque contributes significantly to the engagement of synchronisers in vehicle transmissions. Little is understood of how drag torque varies during transient engagement. Considerable analysis, however, has shown it affects engagement and can cause the mechanism to fail. To demonstrate the significance of the role that drag torque plays during synchroniser engagement in a wet clutch dual clutch transmission numerical models of the mechanism and drag torque are developed. This includes torsional resistances from bearings, gear windage and friction, viscous shear in the concentrically aligned shafts and the wet clutch pack. Simulations are performed in Matlab® to evaluate the drag torques acting on the mechanism. The results of simulations using this model demonstrate that the drag torque is dominated by the viscous drag in the wet clutch. Furthermore simulations demonstrate the nonlinear nature of this torque, and the peak drag torque is identified as being significantly larger that typical estimations.

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Abbreviations

b:

Face width

C:

Drag torque

d:

Diameter

F:

Normal force

f:

Friction

Gr:

Turbulent flow coefficient

h:

Fluid spacing

H:

Sliding ratio at the start of the approach

H:

Sliding ratio at the end of the recess

I:

Reflected inertia

K:

load intensity

L:

half cone generatrix

M:

Mesh mechanical advantage

N:

Rotational speed (rpm)

P:

Mesh power loss (kW)

Re:

Reynolds number (* denotes critical Reynolds number)

r:

Radius (* denotes radius at critical Reynolds number)

Q:

Flow rate

T:

Torque

Z:

Module

α :

Transverse operating pressure angle (degrees)

β :

Operating helix angle (°)

γ :

Gear ratio

ν :

Kinematic viscosity

μ :

Dynamic viscosity

ρ :

Density

ω :

Rotational velocity (rad/s)

ψ :

Cone angle

ζ :

Chamfer angle

s:

start of approach

S:

Sleeve

D:

Drag

t:

end of approach

M:

Mesh

m:

mean

V:

windage

l:

Pinion

I:

Index

C:

Cone

o2:

Gear outside radius

w2:

Gear operating pitch radius

o1:

Pinion outside radius

w1:

Pinion operating pitch radius

A:

Tooth tip

P:

Pitch point

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Author information

Authors and Affiliations

  1. Faculty of Engineering and IT, University of Technology, Sydney, P. O. Box 123, 15 Broadway, Ultimo, NSW, 2007, Australia

    Paul D. Walker & Nong Zhang

  2. NTC International, Unit F, 2 Hudson Avenue, Castle Hill, 2154, Australia

    Ric Tamba & Simon Fitzgerald

Authors
  1. Paul D. Walker
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  2. Nong Zhang
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  3. Ric Tamba
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  4. Simon Fitzgerald
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Corresponding author

Correspondence to Paul D. Walker.

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Walker, P.D., Zhang, N., Tamba, R. et al. Simulations of drag torque affecting synchronisers in a dual clutch transmission. Japan J. Indust. Appl. Math. 28, 119–140 (2011). https://doi.org/10.1007/s13160-011-0030-4

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  • DOI: https://doi.org/10.1007/s13160-011-0030-4

Keywords

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