Numerical analysis on impurities aggregations of electrorheological fluids on anodes of electrorheological valves matrix

Micro-electrorheological valves are widely used in medical devices, precision instruments, general industrial equipment, and other fields. Although these valves matrix can also be applied in multiple loops of Fabry–Pérot sensors for power utilities, they face challenges such as uneven performance and insufficient operational sustainability, primarily due to the aggregation of impurities during the preparation of electrorheological fluids. To address these issues, this study proposes a multi-physics coupled numerical analysis method integrating electrical, hydrodynamic, and particle dynamics. Using this method, the working mechanisms of the electrorheological valve were analyzed, revealing the forces and dynamic states of particles within the system. Simulation experiments identified the promising cause of the problem: The coupling of non-uniform electric and flow fields inside the valve polarizes impurity particles in the electrorheological fluid, generating dielectrophoretic forces that drive long-term unidirectional particle migration and eventual sedimentation. Based on these findings, an improvement strategy is proposed to be used in alternating current (AC) applications to suppress particle polarization and mitigate sedimentation.