In the domain of automotive transmissions, dual mass flywheels (DMFs) mark a significant technological advancement. Designed as an upgrade over conventional single flywheel, the DMFs help in maintaining the right momentum and weight in the crankshaft of motor engines. Based on the vehicle type as well as the engine specifications, the demand for DMFs vary. Leading dual flywheel manufacturers in India typically have a wide range of flywheels in their portfolio – to ensure that precise buyer requirements are met, and the longevity of auto motors is enhanced. Here's an overview of all that you need to know about these dual mass flywheels:
What Exactly Is A Dual Mass Flywheel?
The dual mass flywheel, just as its name suggests, has two separate flywheels. These flywheels are designed for independent rotation – with springs that ensure efficient vibration-damping. One of the flywheels is attached to the automotive engine, while the other is fixed to the clutch assembly section. Typically used in vehicles with manual gearboxes, a high-quality DMF can go a long way in preventing torsional vibrations from damaging the car engine.
In a single flywheel setup, the noise and vibrations directly go into the powertrain. This, in turn, has a negative impact on the overall transmission life as well as the driving experience. The spring system between the two flywheels of the DMF serve as excellent vibration dampener tools. When the vibration becomes lesser, gear-changing becomes significantly smoother – while there is additional care in the car engine starting/idling stages.
Understanding How Dual Mass Flywheels Function
The top flywheel companies in India design DMFs to work as a buffer system to eliminate additional jerks and noise. While these flywheels are similar in terms of functionality to a vehicle’s built-in shock absorbers – there is a key difference. DMFs work as a torsional damping system on a spinning/rotating motion. The flywheels (which are the two masses), along with the spring system, averages out the torque and rotation from the gearbox & engine. As a result, the car motion becomes smoother, with much lower stop-starts.
In cars with manual gearboxes, with single (or solid) flywheels, there remains a risk of the clutch or the tires slipping accidentally. A dual mass flywheel has the capacity to absorb the vibration generated by such ‘shocks’. DMFs are also commonly used in vehicles that have continuously variable transmission (CVT) and semi-automatic gear systems. When properly maintained (driving habits play a big part here), DMFs can have excellent longevity.
Dual Mass Flywheel: Components
In the internal combustion engine (ICE) of automobiles, the vibration can affect the transmission line or driveline. A dual mass flywheel helps in passively damping out these rotational vibrations by isolating the transmission system. Since the low-end torque is enhanced by DMFs, it becomes easier to drive at low engine velocities. The rattling sounds (generated from the gearbox) and average body boom are effectively lowered too.
At this juncture, a quick look at the main components of DMFs would be in order. First, there is the primary mass, which is highly flexible and is used to create an inertia (with the crankshaft). The secondary mass, made of cast iron, is machined – and it receives the engine torque from the primary mass. The cover of the DMF is attached to the primary mass via welding. Plain bearings or ball bearings are used in these flywheels (ball bearings typically take up more space). Torque is transferred to the clutch from the engine via the drive plate. Other important components of DMFs include coil springs, friction control plates and friction washers.
Advantages Of Dual Mass Flywheels
Leading dual flywheel manufacturers in India, like Crescent Foundry, ensure that their customised DMFs have the capability to work as mechanical ‘sponges’. While the individual flywheels are solid material, the spring system between them takes the sting out of the vibrations due to gear-changing, acceleration, and engine idling. In other words, the spring between the primary mass and secondary mass absorbs roughness in the driveline (in varying degrees).
By switching to dual mass flywheels, noise and vibration-related problems can be reduced to a large extent. Drivers are able to leverage the power and the torque of the engine – without having to worry about probable damages in the powerline or the transmission system. This is a significant advantage, particularly for automobiles with 2 or 3-cylinder engines. There are proven fuel-efficiencies associated with the use of DMFs as well.
Reliability Of Dual Mass Flywheels
With growing adoption of dual mass flywheels, concerns over their reliability and maintenance are coming sharply into focus. When sourced from a reputed manufacturer – these flywheels can deliver top-notch longevity, but only if they are used in the recommended manner. In particular, unstable driving on a frequent basis (frequent braking, moving while the engine is idling, etc.) creates excess stress and mechanical fatigue on DMFs, resulting in glitches cropping up. There is also a lot of pressure on the flywheels when the auto engine is working at high gear levels.
The dual mass flywheel operates just like any other component of an automobile. As such, they also need to be inspected regularly – to identify probable problems. In many cases, it is advisable to replace DMFs at the time of clutch replacements. Fortunately, there are plenty of telltale signs that give users a heads-up on the condition of the DMFs they are using.
Problems In Dual Mass Flywheels; Know The Symptoms
When the DMF starts to malfunction, the overall engine performance and vehicular operations can be adversely affected. That makes it imperative for users to keep an eye out for the (pretty apparent) symptoms that indicate something is not quite right with the flywheels. This ensures that repairs or replacements, as required, will get done on time.
For starters, gear-changing becomes problematic when there is a failure in the DMF. The clutch pedal also loses its softness (this can be easily felt in cars with manual transmission systems). There can be issues while starting the car engine as well. In case the clutch is slipping, or vibrations are being felt on the automobile floor – that is a telltale sign of the DMF springs getting jammed. In addition, perhaps the biggest indications of glitchy DMFs are the unnatural sounds (banging or rattling) from the bellhousing system of cars.
DMF Maintenance & Replacement
The top flywheel manufacturers typically guide users on the maintenance requirements of dual mass flywheels. Following these recommendations is important – particularly since getting a new replacement generally involves significant costs. The problem signs become noticeable when vehicles are in neutral transmission gear and/or have touched their maximum operating temperature.
Given that the average lifespan of the clutch and the dual mass flywheels is roughly the same – it is generally a good idea to replace both at the same time. However, not paying attention to the warning signs of DMF damage (as highlighted earlier) can lead to problems earlier.
The Final Word
DMF technology is evolving rapidly. This is hardly surprising, since these flywheels have good fatigue-resistance and perform very well as shock absorbers to protect the automobile engines from excess vibrations. The problem of too much noise is also eliminated. Earlier, there were concerns over the manufacturing and the installation time of dual mass flywheels. Thanks to recent technology advancements, these problems are getting eased. The maintenance requirements are going down as well – helping users get more value out of these flywheels.
With environmental concerns on the upswing, the demand for smaller vehicle engines – that are at par with larger engines in terms of power and torque – is growing rapidly. This, in turn, is pulling up the demand for dual mass flywheels as well. When sourced from a reliable manufacturer, a DMF can also improve the fuel efficiency of vehicles by up to 22%. The top flywheel companies from India adhere to stringent manufacturing & quality standards – to deliver an optimal mix of performance, efficiency and safety to users. Given that flywheels offer several advantages but can be costly to repair, it is important to understand the maintenance requirements of DMFs as well. Dual flywheels are highly effective in damping vibrations and noise (even at relatively low/idle speeds). As such, they are likely to become more popular in the foreseeable future.
