Minimization of release bearing load loss in a clutch system for high-speed rotations using the differential evolution algorithm

Abstract Diaphragm spring is a critical part of a clutch system because it affects the release bearing load characteristics directly and that determines the quality of disengagement. Bearing load provides required clamping for coupling however it may vary significantly during the engagement/disengagement process. A significant drop in bearing load may be experienced especially for high engine velocities for certain bearing displacement due to centrifugal forces occurring on the fingertips of diaphragm springs. The falling in release bearing load is undesirable for comfortable driving and clutch performance. This problem has not been addressed clearly in technical literature. In this study, the diaphragm spring for a C-segment passenger car is optimized using a differential evolutionary algorithm, and an optimized diaphragm was manufactured for testing. The load-bearing characteristics of the optimized diaphragm were compared with those of the currently available diaphragm spring. Loss of bearing load occurring in high-speed rotations was significantly reduced for the optimized diaphragm. Parameters influencing the performance were identified using parameter influence analysis, and a robust disengagement behavior was actualized using the optimization process.