2nd ICAI 2022

International Conference on Automotive Industry 2022

Mladá Boleslav, Czech Republic

Determination of Forging Press Clutch Loss Jiří Dekastello 1 , Jan Hlaváč 2 University of West Bohemia 1, 2 Faculty of Mechanical Enginnering, Department of Machine Design Univerzitní 2732/8, 301 00 Plzeň Czech Republic e-mail: jdekaste@kks.zcu.cz 1 , jhlavac@kks.zcu.cz 2

Abstract This paper describes different approaches to determine energy losses of clutch engagement on mechanical forging press. Mechanical forging press is a machine used to produce forgings which are widely used in drivelines and chassis groups of all cars. In the case of non-continuous cycle operation, the mechanism of the press is repeatedly started which is connected with considerable energy losses in case of conventional press drive. The clutch losses are caused by the physical nature of the impact of the bodies and the efficiency of the clutch engagement. The machine manufacturers determine the clutch losses by empirical calculations based on a long-term experience with press operations. However empirical calculations are only approximate so it is appropriate to use a modern simulation software. With its help, the mechanical design of the clutch can be optimized to increase its efficiency. With regard to the stress of the coupling components and their service life, it is necessary to look for their optimal design. Keywords: forging press, energy consumption, friction clutch, energy JEL Classification: C61, L61, L62 1. Introduction Forging crank press is used to produce precise forgings widely used in automotive industry. Due to mass production every energy saving is important. The more important energy loss in drive side of press is clutch. Therefore it is our aim to study clutch with aim to reduce its loss (Varela, 2019). In the forging press drive the clutch is used to engage drive and machine side of machine. Clutch engaging is frequent due to intermittent operation. Intermittent operation is used to provide sufficient time to operate with forgings. While the forgings are operated used energy user energy is charged back to flywheel. Every engaging of clutch is connected with slip - energy loss. It is possible to optimize drive and clutch to reduce this loss. To be able to reduce this loss it is important to prepare reliable simulation model describing clutch behaviour (Amandyk, 2019, p. 114-123). 1.1 Forging press Typical crank press uses flywheel drive. Flywheel serves to accumulate the energy absorbed by the impact during forming. A typical arrangement is shown in Figure 1 (Hlaváč, 2022, p. 1–13). The press (Figure 1) consists of a machine part which is kinetically identical for all crank presses and the energy balance of most presses

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