1、 FORD LABORATORY TEST METHOD BJ 115-02 Date Action Revisions 2001 07 24 Revised Editorial no technical change A. Cockman 1995 05 15 Printed copies are uncontrolled Page 1 of 8 Copyright 2001, Ford Global Technologies, Inc. CLUTCH FRICTION EVALUATION Application This test method evaluates the durabil
2、ity of clutch friction plates by measuring wear, breakaway torque, coefficients of friction, and speed coefficient ratios during varying test cycle operations. Materials and Apparatus Required Friction Plates - No. XP -192219 (BW-4400) and XP -142976 (SD-1777) Source: Borg Warner Corp. 700 25th Ave.
3、 Bellwood, IL 60104-1908 (708) 547-2600 Separator Plates - No. XP -143218 Source: Steel Part Corp. P.O. Box 700 Tipton, IN 46072-0620 (317) 523-4248 Heptane Cleaning solvent. Non-Metallic Brush or Scouring Pad Micrometer Depth Micrometer Test Fluid - Candidate Fluid Thermocouple - size 0.58 +/- .02
4、mm diameter O-Rings Precision Seal No. 265 and 272. Temperature Recorder FORD LABORATORY TEST METHOD BJ 115-02 Page 2 of 8 Copyright 2001, Ford Global Technologies, Inc. Timer Print - 134 - D8 Source: Greenings & Associates, Inc. 18465 Mt. Elliot Ave. Detroit, MI 48224 Conditioning and Test Conditio
5、ns All test values indicated herein are based on material conditioned in a controlled atmosphere of 23 +/- 2 C and 50 +/- 5 % relative humidity for not less than 24 h prior to testing and tested under the same conditions unless otherwise specified. Procedure General Operation Using friction plates w
6、ith waffle-groove SD-1777 and BW-4400 friction material, run twelve 4-plate packs, 200 cycles each, for evaluations and three 4-plate packs, 20,000 cycles for durability, according to the procedure below. One pack is considered to be four steels and two friction plates arranged according to Figure 1
7、 and referred to as the 4-plate pack. All torque trace information must be obtained using digitized data acquisition and must be acquired at no less than 1000 points per second. Cleaning Procedure Prior to each durability test, the fixture must be cleaned. After removing the front cover, the spacer,
8、 retainer ring and hub are removed. These parts are cleaned with heptane, scrubbed with a non-metallic bristle brush or non-metallic scouring pad and rinsed. The inside of the test housing, attached ports and thermocouple connections are flushed with heptane using a squeeze bottle. Thoroughly clean
9、all crevices and ports in the housing where lubricant is likely to be trapped. Air blow dry the cleaned parts and test housing. Assembly Procedure 1. Inspect rotating shaft seal (National No. 4471887) for deterioration and replace if necessary. Indication of seal failure or loss of flexibility is th
10、e escape of air past the seals. If this seal is replaced, also replace lip seals No. 1366236 and 3-21196 (both supplied by Greening & Associates, Inc.). 2. Install clutch plate hub, snap ring, and clutch plate retainer. 3. Inspect clutch plates prior to testing using the following procedure. (a) Fin
11、d the thickest spot of each plate and arrange the plates so the thick spots are distributed around the pack, for minimum thickness. FORD LABORATORY TEST METHOD BJ 115-02 Page 3 of 8 Copyright 2001, Ford Global Technologies, Inc. (b) Identify each plate by marking the top tooth with a number, one thr
12、ough six in the sequence shown in Figure 1. This number will be at the top when each plate is installed for test. (c) Mark a tooth at approximately 120 each way around from the numbered tooth on each plate. (d) Measure and record average overall pack thickness under a 14 kg load. (e) Measure plate t
13、hickness as follows: At each of the three locations, 120 apart, measure at two places, one near the inside, and one near the outside diameter. These measurements will be labeled “initial“. (f) Use micrometer, and keep the entire anvil within the friction contact area for each measurement. (g) After
14、the durability test repeat these measurements in the same order and at the same places, beginning at the numbered tooth. These measurements are labeled “final“. (h) Subtract the “final“ measurements from the “initial“ measurements. Wear limit at any of the six places is 0.1524 mm. Average wear per p
15、late is not to exceed 0.0762 mm. 4. Presoak clutch plates in test fluid for 5 minutes minimum and then install clutch plates in the test head in the order prescribed with plate rounded side facing operator. 5. Install packs into test head. Thermocouple is to be located at the mid point of the back t
16、o back plates of the 4-plate pack. 6. Install two spacers only between the cover and the outermost clutch plate to locate the thermocouple at the center of the test pack. 7. Check clutch plate pack free movement. Clearance is 0.70 +/- 0.13 mm. This measurement, conveniently made with a depth microme
17、ter, is made between the head and outermost clutch plate while the pack is pressed into the head with finger pressure (about 1 kg) at the sites of measurements. 8. Install thermocouple between the 4 and 5 oclock position to within 1.0 mm of steel clutch plate annulus O.D. (without touching clutch pl
18、ate). 9. Install new O-rings on cover, if necessary. Print 134-D8 O-rings are Precision Seal No. 265 and No. 272 or equivalent. 10. Attach cover and fasten with ring-bearing support and cover retainer, print 134-D18. FORD LABORATORY TEST METHOD BJ 115-02 Page 4 of 8 Copyright 2001, Ford Global Techn
19、ologies, Inc. Lubrication Installation Attach reservoir line to housing port at 12 o-clock position. Close all other housing ports. Pour 305 +/- 5 mL for SD-1777 and 650 +/- 5 mL for BWA-4400 of test lubricant into reservoir. Open valve at 11 oclock position to allow air venting during filling. Clos
20、e this valve when oil begins to overflow. Test Start-Up 1. Connect torque, pressure, motor speed, and thermocouple transducers. Calibrate torque, pressure, and speed signals. Note: If compression type load cell is used, calibrate torque with lever arm tare included in calibration. 2. Set apply air p
21、ressure at 275 +/- 5 kPa for SD-1777 and 480 +/- 5 kPa for BWA-4400. 3. Set release air pressure at 75 +/- 0.7 kPa. 4. Opening cooling fluid valve. 5. Set timer to provide the following test cycle sequence: Event Duration,s Cumulative Time,s Operation 1 10.0 (T1)* 0 to 10.0 Highspeed (HS) motor on (
22、force released) 2 5.0 (T1+T2)* 10.0 to 15.0 Motor off, force applied 3 5.0 (T4)* 15.0 to 20.0 Motor off, force released 4 0.5 20.0 to 20.5 Static Drive (SD) motor on to engage static drive 5 5.0 20.5 to 25.5 SD motor off, force released 6 0.5 25.5 to 26.0 SD motor off, force applied 7 5.0 26.0 to 31
23、.0 SD motor on, force applied 8 5.0 31.0 to 36.0 SD motor off, force released *- Reference SAE Friction Nomenclature Specification (SAE J1646) 6. Start temperature recorder. FORD LABORATORY TEST METHOD BJ 115-02 Page 5 of 8 Copyright 2001, Ford Global Technologies, Inc. 7. Start timer (this engages
24、motor) 8. Check for leaks, operation of transducers and cycling event times. Test Start-up After Unscheduled Shutdown 1. Ascertain and correct cause of shutdown. Record length of time of shutdown, reason for shutdown and reasoning for continuing testing. 2. Repeat Test Start-up sequence. Test Operat
25、ion 1. Continue to repeat test cycle sequence for 20,000 cycles. See Test Start-up, Step 6. 2. Maintain average candidate fluid temperature during operation at 135 +/-2 C. 3. Record static breakaway torques after clutch pack has been released (allowed to separate) for a 5 second soak time. Static br
26、eakaway speed to be 4.37 +/- 0.1 RPM. 4. Two static breakaway measurements are required. Measure the first static breakaway .25 seconds after beginning of zero time. Zero time begins at threshold torque plus 5 Nm positive torque. Static breakaway torque shall be the mean of torques obtained during 5
27、0 ms interval centrally located about the .25 +/- .02 second point. Report the first torque as well as the maximum torque measured between zero time and the .25 +/- .02 second time. Evaluation Required Recordings 1. Record fluid temperature continuously. 2. Record apply pressure, and motor speed at
28、5 cycles to confirm proper test operation. 3. Record torque, apply pressure, and motor speed during test cycle sequence at intervals indicated in Table I. Test Results Required for Review 1. Torque, apply pressure and motor speed records. See Required Recordings Steps 2 and 3. 2. Friction Data Requi
29、rement Sheet - see Table 1. FORD LABORATORY TEST METHOD BJ 115-02 Page 6 of 8 Copyright 2001, Ford Global Technologies, Inc. 3. Graph Static Breakaway, Low Speed Dynamic, Dynamic Coefficients and Stop Times per Table 1 as function of cycles. 4. Temperature chart obtained. See test start-up Step 7. 5
30、. Provide all torque traces required per Table 1. Test Criteria (Evaluation of 12 Packs and Durability of 3 Packs 1. All required coefficients shall be calculated using the mean of 5 measured values taken +/- 2 cycles around the specified cycle. The maximum and minimum torques of each range are to b
31、e reported with the coefficient of the specified cycle. 2. All 200 cycle midpoint dynamic coefficient measured at 1800 RPMs shall fall within a range of .140 - .160 for SD-1777 and .105 - .140 for BWA-4400. Midpoint dynamics torque is to be a mean of torques obtained during the 50 ms interval centra
32、lly located about the 1800 RPM speed. Upper and lower control limits to be established after review of data and data to be revisited annually for revisions. 3. All low speed dynamic peak coefficients, calculated from the dynamic torque trace, shall fall between .135 - .160 for SD-1777 and .120 - .15
33、5 for BWA-4400. The low speed dynamic measurement shall be the highest value for torque obtained within the last 50 ms of the torque measurement. The time of the measurement must be reported. 4. Between 200 and 20,000 cycles of operation, all static breakaway coefficient must fall between .120 - .15
34、0 for SD-1777 and .105 - .135 for BWA-4400. Static breakaway torques must be obtained after the clutch pack has been opened for 5 seconds following the dynamic engagement to allow the friction surfaces to attain temperature equalization. The static breakaway torque values are to be measured at .25 s
35、econds after the beginning of the static engagement. 5. All ratios of the low speed dynamic coefficient (formerly static coefficient) to the midpoint dynamic coefficient E/M, both obtained from the same dynamic engagement trace, shall fall between .90 and 1.0 for SD-1777 and 1.10 to 1.35 for BWA-440
36、0. Ratios between the static breakaway coefficient and the mid-point dynamic coefficient E/M, are to be “rate and report“. 6. Between 25 and 20,000 cycles of operation, all stop times must fall between .70 and .90 seconds for SD-1777 and .75 to 1.05 for BWA-4400. 7. A 50 cycle break-in is required f
37、or the BWA-4400 material at 15.7 KJ energy and apply pressure of 207 +/- 5 kPa. Stop times should be approximately .80 seconds. Chemicals, materials, parts, and equipment referenced in this document must be used and handled properly. Each party is responsible for determining proper use and handling
38、in its facilities. FORD LABORATORY TEST METHOD BJ 115-02 Page 7 of 8 Copyright 2001, Ford Global Technologies, Inc. Figure 1 TABLE 1 FRICTION TEST REPORT SHEET CYCLES DYNAMIC COEFFICIENT STATIC BREAKAWAY COEFFICIENT E/M RATIO B/M RATIO LOW SPEED DYNAMIC COEFFICIENT 5 R&R R&R 25 (SD-1777 only) X X X
39、100 X X 200 X X X X X AT 100 CYCLE INTERVALS TO 500 CYCLES X X AT 1000 CYCLE INTERVALS TO 20,000 CYCLES X X X X X GRAPH: A: Coefficient vs cycles for Static Breakaway, Dynamic and Low Speed Dynamic Engagements B: Stop Times vs Cycles NOTE: Data required at cycles indicated by X. SAE No. 2 Machine Se
40、t-up Paramaters FORD LABORATORY TEST METHOD BJ 115-02 Page 8 of 8 Copyright 2001, Ford Global Technologies, Inc. Perform evaluation at the following schedule: Cycle Rate: 3 per minute Cycle Make-up: (Dynamic) Motor on, clutch released 10 s Motor off, clutch applied 5 s Motor off, clutch released 5 s
41、 (Static) Motor off, clutch applied 5 s Motor on, clutch applied 0.5 s Motor off, clutch released 1 s SD-1777 BWA-4400 Temperature: 135 +/- 3 C 135 +/- 3 C Pressure: 275 +/- 5 kPa 477 +/- 5 kPa Velocity: 3600 rpm 3600 rpm Energy: 20740 +/- 100 J 32000 +/- 150 J Fill Volume: 305 mL +/- 5 mL 650 +/- 5 mL Total Cycles: 200 for each evaluation pack 20,000 for each durability pack
