Clutch Hub

Clutch Hub: The clutch hub places between clutch basket and pressure plate. The clutch plates are mounted on it. It has teethes in the centre hole which rotate with main shaft. It means it is connected with the engine.

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Drive (friction) plate

Drive (friction) plate: The friction plate is ring shaped and coated with fiber. It is a wear and tear part of clutch assembly. The friction plate surfaces interface between the clutch basket tangs (gaps) and pressure plate. It has teethes on the outside surfaces. These teethes fix on the cutouts between clutch hub tangs (gaps). It is coated with the same material as you see in brake pad (shoe).

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Clutch Plate

Clutch Plate: There are two types of plates in clutch plate. One is Drive (friction) plate another is Driven (Steel) plate

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How A Clutch Works

How A Clutch Works

In a normal condition a clutch is engaged with the engine. When a rider presses the clutch lever for changing gears, the coil springs in the clutch compressed and the pressure plate expands which allows the stake of clutch plates to move independently. The stake of clutch is arranged in such a manner that friction plate and steel plate alternate. It makes the engine and clutch to move at different speeds. Ultimately the clutch disengages power to transmission which allows rider to shift the gears.
There are two types of clutches: Wet clutch & Dry clutch

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Clutch

A clutch is that part of engine which engages or disengages power from the engine crankshaft to transmission. A clutch is mechanism by which you change the gears. In simple words, it turns on or off power to rear wheel. A clutch is made of clutch assembly which includes clutch plate, Clutch basket, Clutch hub, pressure plates, Clutch springs, lever and clutch cable.

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Hot Extrusion

Hot Extrusion: Hot extrusion is done at fairly high temperatures, approximately 50 to 75 % of the melting point of the metal. The pressures can range from 35-700 MPa (5076 - 101,525 psi). Due to the high temperatures and pressures and its detrimental effect on the die life as well as other components, good lubrication is necessary. Oil and graphite work at lower temperatures, whereas at higher temperatures glass powder is used.
Typical parts produced by extrusions are trim parts used in automotive and construction applications, window frame members, railings, aircraft structural parts.

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Cold Extrusion

Cold Extrusion: Cold extrusion is the process done at room temperature or slightly elevated temperatures. This process can be used for most materials-subject to designing robust enough tooling that can withstand the stresses created by extrusion. Examples of the metals that can be extruded are lead, tin, aluminum alloys, copper, titanium, molybdenum, vanadium, steel. Examples of parts that are cold extruded are collapsible tubes, aluminum cans, cylinders, gear blanks. The advantages of cold extrusion are:

•	No oxidation takes place.
•	Good mechanical properties due to severe cold working as long as the temperatures created are below the re-crystallization temperature.
•	Good surface finish with the use of proper lubricants.

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Extrusion

Extrusion is the process by which long straight metal parts can be produced. The cross-sections that can be produced vary from solid round, rectangular, to L shapes, T shapes. Tubes and many other different types. Extrusion is done by squeezing metal in a closed cavity through a tool, known as a die using either a mechanical or hydraulic press.
Extrusion produces compressive and shear forces in the stock. No tensile is produced, which makes high deformation possible without tearing the metal. The cavity in which the raw material is contained is lined with a wear resistant material. This can withstand the high radial loads that are created when the material is pushed the die.
Extrusions, often minimize the need for secondary machining, but are not of the same dimensional accuracy or surface finish as machined parts. Surface finish for steel is 3 µm; (125 µ in), and Aluminum and Magnesium is 0.8 µm (30 µ in). However, this process can produce a wide variety of cross-sections that are hard to produce cost-effectively using other methods. Minimum thickness of steel is about 3 mm (0.120 in), whereas Aluminum and Magnesium is about 1mm (0.040 in). Minimum cross sections are 250 mm² (0.4 in²) for steel and less than that for Aluminum and Magnesium. Minimum corner and fillet radii are 0.4 mm (0.015 in) for Aluminum and Magnesium, and for steel, the minimum corner radius is 0.8mm(0.030 in) and 4 mm (0.120 in) fillet radius.

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Forging Quiz

.

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CERAMIC AND CARBIDES DIE MATERIALS

CERAMIC AND CARBIDES DIE MATERIALS

Potential use of ceramics and carbides has been found be gaining interest for use in

warm and hot forging applications. Ceramic inserts and coatings are well established in

the machining industry for reducing tool wear and enhancing the tool per formance.

Some of the ceramic materials have marked improvements over the traditional hot work

die materials (Cr-Mo-W based steels) used in hot forging

 

 

 

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DIE MATERIALS FOR FORGING OF STEEL

DIE MATERIALS FOR FORGING OF STEEL

There are various tool steels which are used in forging. Although in hot and warm

forging, mainly hot work die steels are used due to their ability to retain their hardness at

elevated temperatures with sufficient strength and toughness to withstand the stresses

that are imposed during forging. There have also been some successful applications of

other materials such as ceramics, carbides and super alloys although their application is

limited due to design and cost of manufacturing. The selection of die material grade and

subsequent treatment affects the mode of failure and rate of tool failure. 

 

 

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Forging defects

Forging defects:

Though forging process give generally prior quality product compared other manufacturing processes. There are some defects that are lightly to come a proper care is not taken in forging process design.

A brief description of such defects and their remedial method is given below.

 Unfilled Section:

In this some section of the die cavity are not completely filled by the flowing metal. The causes of this defects are improper design of the forging die or using forging techniques.

Cold Shut:

This appears as a small cracks at the corners of the forging. This is caused manely by the improper design of die. Where in the corner and the fillet radie are small as a result of which metal does not flow properly into the corner and the ends up as a cold shut.

Scale Pits:

This is seen as irregular depurations on the surface of the forging. This is primarily caused because of improper cleaning of the stock used for forging. The oxide and scale gets embedded into the finish forging surface. When the forging is cleaned by pickling, these are seen as depurations on the forging surface.

Die Shift:

This is caused by the miss alignment of the die halve, making the two halve of the forging to be improper shape. 

 Flakes:

These are basically internal ruptures caused by the improper cooling of the large forging. Rapid cooling causes the exterior to cool quickly causing internal fractures. This can be remedied by following proper cooling practices.

Improper Grain Flow:

This is caused by the improper design of the die, which makes the flow of the metal not flowing the final interred direction.

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