Abstract: A microstructural constitutive theory of ER suspensions was formulated in this investigation. The framework was based on the internal variable theory and the mechanism analysis. The ER suspension consists of fine particles with high dielectric constant and the supporting fluid. Under the action of the electric field, the polarized particles will aggregate together to form the chain-like structures along the direction of the electric field. As the size and orientation of the particle aggregates are volatile, and they adjust according to the applied electric field and strain rate, the energy conservation equation and the force equilibrium equation were thus established to determine the orientation and size of the aggregates. Following that, a three-dimensional, explicit form of the constitutive equation was derived based on the interaction energy and the dissipation function of the system. The response of the system under the action of a simple shearing load was considered and discussed in detail. It is found that the shear-thinning viscosity of an ER suspension is well approximated by the power-law ∞(Mn)^-0.82.

Key words: electrorheological fluid, internal variable theory, constitutive theory