Multi-objective optimization of an energy-efficient diaphragm spring for clutch applications.

Area of Science:

• Mechanical Engineering
• Automotive Engineering
• Materials Science

Background:

• Diaphragm springs are critical components in automotive clutches, requiring efficient and reliable designs.
• Existing design methods may not fully address multi-objective optimization for energy efficiency and material reduction.

Purpose of the Study:

• To develop a deterministic multi-objective framework for the energy-efficient design of diaphragm springs.
• To enable optimal-rational design synthesis using the direct feasible-set approach and similarity theory.

Main Methods:

• A deterministic multi-objective framework based on the direct feasible-set approach and similarity theory.
• Adaptive constraint management for identifying rational configurations.
• Nonlinear finite element analysis (FEA) for mechanical validation.
• Experimental validation including cyclic loading and thermal analysis.

Main Results:

• Synthesized configurations show up to +22% increase in compressive force and -12% reduction in material volume.
• FEA confirms mechanical admissibility with localized stress and strain.
• Experimental validation demonstrates stable nonlinear behavior, minimal force variation over 5000 cycles, and moderate thermal rise.
• Hysteresis analysis reveals a 25% reduction in mechanical energy dissipation per cycle, enhancing energy efficiency.

Conclusions:

• The deterministic framework provides a transparent and computationally efficient methodology for energy-efficient diaphragm spring design.
• The approach is validated by strong agreement between analytical predictions, FEA, and experimental results.
• The methodology can be extended to other nonlinear elastic components in transmission systems.