Design optimization of a viscous clutch with an electrorheological fluid

Abstract The article describes design optimization of a viscous disc clutch with an electrorheological (ER) fluid. The design optimization is conducted based on mathematical models of ER fluid and clutch geometry. As important issues for the optimal design, the assumed values are: the torque transferred by the clutch, the dimensions of the clutch and the steady-state operating temperature of the clutch. The assumed design variables are: the angular velocity of the input shaft, the number of working gaps of the clutch and the selected dimensions of the clutch. The aim of the design optimization is to search for design variables such as the angular velocity of the input shaft, the number of working gaps of the clutch and the selected dimensions of the clutch, for which the clutch transfers the highest possible torque, while the dimensions of the clutch are small and the steady-state operating temperature is low. The design optimization is conducted searching at least two different objective functions created taking into account the volume, the transferred torque and the steady-state operating temperature of the clutch. Two numerical methods are used: the Monte Carlo method and the Genetic Algorithm method. The optimization calculations are performed for two sets of design variables, consisting of three and eight elements, and a final prototype designed via the optimization is depicted with the principal design parameters.