Title: Experimental and numerical fatigue-based design optimisation of clutch diaphragm spring in the automotive industry

Authors: Alper Karaduman; Betül Sultan Yıldız; Ali Rıza Yıldız

Addresses: Valeo Automotive Systems, R&D Department, Bursa, 16245, Turkey; Department of Automotive Engineering, Bursa Uludag University, 16059, Bursa, Turkey ' Department of Electrical and Energy, Bursa Uludag University, 16059, Bursa, Turkey ' Department of Automotive Engineering, Bursa Uludag University, 16059, Bursa, Turkey; TUSAŞ-TAI R&D Center, Bursa Uludağ, 16059, Bursa, Turkey

Abstract: In the present study, the fatigue behaviour of a clutch diaphragm spring is investigated experimentally and numerically. Differential evolution optimisation algorithm and response surface methodology are used to define optimal variables of the diaphragm springs under constraints both minimum stress and required clamp load. The required clamp load is checked by the chi-square theorem vs. to target clamp load curve. Ten design variables are considered for creating a design of experiment with two steps, including finger shape optimisation with eight variables, load, and stress optimisation with two variables as the aim of maximum fatigue definition. One hundred seventy-five different designs are analysed numerically. As a result of the optimisation study, the optimum design is provided an endless lifetime subject to the required load, minimum stress, and minimum weight. The optimum design is manufactured and tested experimentally.

Keywords: optimum design; differential evolution algorithm; diaphragm spring; fatigue analysis.

DOI: 10.1504/IJVD.2019.109875

International Journal of Vehicle Design, 2019 Vol.80 No.2/3/4, pp.330 - 345

Received: 03 Dec 2019
Accepted: 23 Jun 2020

Published online: 28 Sep 2020 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article