AltoEngineering-Design

ALTO PRODUCTS
ENGINEERING / DESIGN
PROCESSES
08 July 2011
ALTO DESIGN AND
DEVELOPMENT PROCESS
CUSTOMER CLUTCH
INPUT DESIGN
RESEARCH
FRICTION
CLUTCH
MATERIAL
VALIDATION
DEVELOPMENT
Alto Clutch Design Process
• Customer Completes Application Data Sheet
• Engineering Calculates: Qc = (R)(t)(Coil)(DT)
o Required Dynamic and Static Coefficients (E)
o Max. Torque and Apply Force or Pressure
o Number of Required Friction Surfaces
o Thermal Dynamics of the Clutch and Oiling System
o Metal Tooth Contact Surface Strength KE = 1/2Iw2
t = (Fa)(µ)(Rm)(Ns)
• Engineering Designs Clutch:
o Necessary Frictional Properties for the Specific
Application
o Selects Friction Material or Initiates the Design
and Development of New Materials
o Perform Finite Element Analysis (FEA) to
Confirm Design Functionality
o Friction Disc Groove Patterns are Designed to:
 Manage Oil Flow
 Reduce Thermal Degradation
 Eliminate Noise/Shudder
 Soften Shift Feel
o Reaction Disc Surface Finishes are Designed to:
 Eliminate Noise/Shudder
 Prolong Clutch Pack Life Through the
Reduction or Elimination of Mechanical
Degradation
o Reaction Disc Surface Treatments Such As:
 Nitride Heat Treat
 Black Oxide Coating
 Phosphate Coatings
o Help Lube the Engagement/Reduce Noise
o Prevent Corrosion
ALTO DESIGN AND
DEVELOPMENT PROCESS
CUSTOMER CLUTCH
INPUT DESIGN
RESEARCH
FRICTION
MATERIAL
DEVELOPMENT
Alto Friction Material Development
• Alto Formulates and Creates Test Hand Sheets In-
House
• Hand Sheets are Saturated In-House
• Friction Material Designs are Analytically Tested:
o Gurley Densometer
K2 Compression Modulus
%
@ 100 ° C in Cognis II Fluid
100 12.0 o Precision Thickness
Friction Material Pressure (MPa)
10.0 Perm. ...

80
8.0
Sample: SDC_3585_M_Resin_3_24, 9.7000 mg o Compression Modulus
60
6.0 Sample: Arofene_295_E_50_Resin_3_24, 11.3000 mg o ThermoGravimetric
4.0
Analysis (TGA)
40 2.0 Sample: 50% 295 Resin_50% Tung Oid_3_23, 7.6000 mg
0.0
Sample: Tung Oil M odified Phenolic Resin_3_24, 10.1000 mg
o Differential Scanning
0% 10% 20% 30% 40% 50% 60%
Lab: METTLER
100 200 300 400 500 600
Displacement %
700 800 900 °C
STARe SW 9.20
Calorimetry (DSC)
• Friction Material Designs are Analytically Tested:
o Digital Microscope
o Scanning Electron
Microscope (SEM-EDS)
o Inductively Coupled
Plasma (ICP)
o Total Organic Content
(TOC)
Alto Friction Material Summary
• Based on Alto’s Friction Development Efforts, the Alto
Friction Material Library Consists Of:
o Several Series of Friction Materials which range in:
 Heat/Energy Capacity,
 Application Specific Requirements, and
 Frictional Properties
o Within each Series there are Numerous Grades of
Friction Materials.
Alto Friction Material Design
• Friction Material Design and Development:
• Analytical testing consist of: Compression
Modulus Testing
K2 Compression Modulus
@ 100 ° C in Cognis II Fluid
12.0
Friction Material Pressure (MPa)
10.0 Perm. Set
8.0
6.0
4.0
2.0
0.0
0% 10% 20% 30% 40% 50% 60%
Displacement %
• 4500 Series
o Moderate Energy Materials
o High Dynamic and Static Coefficient
o Used in Industrial and Automotive Transmission Applications
• 4550 Series
o High Energy Materials
o Good Slipping Material for Torque Converter Applications
o High Unit Loading Capabilities Seen Typically in Sintering, Heavy
Duty (i.e. Mining), and Differential Applications
• 4570 Series
o Used in Automotive Transmission, Industrial, On/Off Highway, and
Motorcycles
• 4580 Series
o Used in Motorcycle Applications
ALTO DESIGN AND
DEVELOPMENT PROCESS
CUSTOMER CLUTCH
INPUT DESIGN
RESEARCH
FRICTION
CLUTCH
MATERIAL
VALIDATION
DEVELOPMENT
Alto Clutch Plate Validation
• After the Analytical Test are Completed and the

Properties of the Material are Favorable:
o Alto Performs Society of Automotive
Engineers (SAE) Testing
o Submit Products for Field Testing
o Collect Customer Feedback
LOOKING AHEAD
SHIFT… YOUR THINKING
 100%
FRICTION
AUTOMATED
SUCCESS MATERIALQUALITY
THROUGH DEVELOPMENT
INSPECTION
CONTINUOUS FOR TOMORROW’S
& PRODUCT
IMPROVEMENT ANDHANDLING
TECHNOLOGIES
CONSTANT INNOVATION
THANK YOU FOR YOUR TIME & CONSIDERATION

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ALTO PRODUCTS

10.0 Perm. ...

10.0 Perm. Set

• After the Analytical Test are Completed and the

THANK YOU FOR YOUR TIME & CONSIDERATION

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