Desenvolvimento e validação de um protótipo de cilindro mestre de embreagem para veículos comerciais

Abstract

This work studied the development and validation of a clutch master cylinder for commercial vehicles. The product was designed to be able to replace a model already on the market that would be discontinued. Using finite element methodology, it was possible to optimize the design of the cylinder housing and reduce its mass by 51%. The project also involves manufacturing and installing prototypes in a vehicle from its application framework to carry out functional tests. With the aid of instrumentation, it was possible to collect important data to analyze the functioning of the system, such as hydraulic pressure, clutch fork stroke, pedal force and pedal travel. The collected parameter values and cylinder operation met the project requirements. To validate the durability of the prototype, a cyclic test bench was developed. Data collected in vehicles was used on the bench, helping to achieve true-to-real-condition behavior. The first samples tested supported low cycling, and after some fine adjustments, the best sample reached the mark of 320 thousand cycles. Although the durability validation requirement for the OEM market is 4 million cycles, it was possible to make great progress with the project and guide the next steps. [resumo fornecido pelo autor]