The Application of Big Flake Graphite in Clutch Facings Production
In the production of clutch facings, the choice of clutch facings friction materials is pivotal for ensuring the optimal performance of a clutch system. Big Flake Graphite has emerged as a significant component in clutch facings mixtures and mixes, bringing with it a unique set of characteristics.
I. Technical Parameters of Big Flake Graphite in Clutch Facings
- Particle Size
- Big Flake Graphite typically has a relatively large particle size, with an average diameter ranging from 0.1 – 1 mm. This large flake size contributes to its unique properties in the clutch facings mixture. For example, larger flakes can provide better lubrication paths between the clutch components during operation.
- Carbon Content
- High – quality Big Flake Graphite used in clutch facings usually has a carbon content of over 95%. The high – purity carbon is essential for its excellent thermal and electrical conductivity, as well as its lubricating properties. A higher carbon content also means better chemical stability within the clutch facings friction materials.
II. Advantages
- Superior Lubrication
- Big Flake Graphite offers outstanding lubricating properties. In clutch facings, it can reduce the friction coefficient effectively. Tests have shown that in a clutch facings mix with 8% Big Flake Graphite by mass, the friction coefficient can be decreased by about 12 – 18% compared to a mix without it. This results in smoother clutch engagement and disengagement, reducing the wear and tear on the clutch facings. In a durability test of 80,000 clutch operation cycles, clutches with Big Flake Graphite – containing facings exhibited a 25 – 35% reduction in wear compared to those without it.
- High – Efficiency Heat Dissipation
- Graphite, including Big Flake Graphite, has a high thermal conductivity of around 120 – 160 W/(m·K) in the in – plane direction. In clutch facings production, this property is crucial. During clutch operation, a substantial amount of heat is generated due to friction. Big Flake Graphite in the clutch facings mixture can rapidly transfer this heat away. In a high – load driving simulation, clutch facings with 12% Big Flake Graphite maintained a temperature 15 – 25°C lower than those without it. This efficient heat dissipation helps to maintain the stability of the friction coefficient and the mechanical properties of the clutch facings friction materials, thus enhancing the overall performance and reliability of the clutch.
- Chemical Inertness
- Big Flake Graphite is highly chemically stable. It is resistant to most common chemicals and does not react readily with other components in the clutch facings mixture. In an environmental exposure test lasting for 6 months, clutch facings with Big Flake Graphite showed no significant change in their friction and wear properties when exposed to various chemicals and humidity levels. This chemical stability ensures the long – term durability of the clutch facings.
III. Disadvantages
- Low Mechanical Strength
- Big Flake Graphite has relatively low compressive strength. When the proportion of Big Flake Graphite in the clutch facings mix is increased, the overall compressive strength of the clutch facings may be compromised. For instance, when the content of Big Flake Graphite in the clutch facings mix reaches 25% by mass, the compressive strength of the clutch facings can decrease by 8 – 12%. This reduction in strength can be a concern in applications where the clutch facings need to withstand high – pressure loads, such as in heavy – duty vehicles.
- Cost – Intensive
- Big Flake Graphite is more expensive than some traditional additives used in clutch facings production. The price of high – quality Big Flake Graphite can range from \(400 – \)1200 per ton, depending on its purity and flake size. This high cost can increase the production cost of clutch facings. A cost – benefit analysis indicates that replacing a common additive with Big Flake Graphite in the clutch facings mix can lead to a 15 – 25% increase in production cost per unit. This cost factor may limit its widespread use in price – sensitive markets.
- Dispersion Challenges
- Due to its large flake size, Big Flake Graphite is difficult to disperse evenly in the clutch facings mixture. Uneven dispersion can lead to inconsistent properties within the clutch facings. In laboratory experiments, when Big Flake Graphite was mixed into the clutch facings mixture without proper processing, about 25% of the samples showed significant variations in friction coefficient across the surface of the clutch facings. Specialized mixing techniques and equipment are often required to ensure uniform dispersion, which adds to the complexity and cost of the production process.
In summary, Big Flake Graphite provides significant advantages in clutch facings production in terms of lubrication, heat dissipation, and chemical stability. However, its low mechanical strength, high cost, and dispersion difficulties must be carefully considered. Manufacturers need to find the optimal balance and adopt appropriate production methods to fully utilize the benefits of Big Flake Graphite in producing high – performance clutch facings friction materials.