Magnetic Circuit Design and Multiphysics Analysis of a Novel MR Damper for Applications under High Velocity

Abstract

A novel magnetorheological (MR) damper with a multistage piston and independent input currents is designed and analyzed. The equivalent magnetic circuit model is investigated along with the relation between magnetic induction density in the working gap and input currents of the electromagnetic coils. Finite element method (FEM) is used to analyze the distribution of magnetic field through the MR fluid region. Considering the real situation, coupling equations are presented to analyze the electromagneticthermal-flow coupling problems. Software COMSOL is used to analyze the multiphysics, that is, electromagnetic, thermal dynamic, and fluid mechanic. A measurement index involving total damping force, dynamic range, and induction time needed for magnetic coil is put forward to evaluate the performance of the novel multistage MR damper. The simulation results show that it is promising for applications under high velocity and works better when more electromagnetic coils are applied with input currents separately. Besides, in order to reduce energy consumption, it is recommended to apply more electromagnetic coils with relative low currents based on the analysis of pressure drop along the annular gap.

A review on multi-physics numerical modelling in different applications of magnetorheological fluids

“…The same observation can be seen in other studies (Case et al, 2014; Singh et al, 2014; Zheng et al, 2014, 2015, 2017), in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015). However, the hysteretic behaviour was not shown in the results presented by Zheng et al (2014), which can be inferred from the instantaneous transition of force at maximum displacements in the work diagram, as shown in Figure 16.…”

“…The authors attributed that misrepresentation of hysteretic behaviour to the handicaps involved in the deforming mesh technique. The same observation can be seen in other studies (Case et al, 2014;Singh et al, 2014;Zheng et al, 2014Zheng et al, , 2015Zheng et al, , 2017, in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015).…”

A review on multi-physics numerical modelling in different applications of magnetorheological fluids

“…The same observation can be seen in other studies (Case et al, 2014; Singh et al, 2014; Zheng et al, 2014, 2015, 2017), in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015). However, the hysteretic behaviour was not shown in the results presented by Zheng et al (2014), which can be inferred from the instantaneous transition of force at maximum displacements in the work diagram, as shown in Figure 16.…”

“…The authors attributed that misrepresentation of hysteretic behaviour to the handicaps involved in the deforming mesh technique. The same observation can be seen in other studies (Case et al, 2014;Singh et al, 2014;Zheng et al, 2014Zheng et al, , 2015Zheng et al, , 2017, in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015).…”

An approach for characterizing twin-tube shear-mode magnetorheological damper through coupled FE and CFD analysis

“…5a, b. As current supply increases, the magnetic flux induced in the electromagnetic coil will also increase [34]. Due to this yield stress of the MR fluid increases.…”

A review on design and modelling methods of magnetic circuit cores for MR elastomers and MR fluids based system

“…The design of the magnetic circuit model is the next step of MRF calculation. The magnetic circuit model can be analyzed following the four-stage MRF damper [51], as shown in figure 9(b). Kirchhoff's second law is the main principle in the design of the magnetic circuit model and is stated as follows:…”

“…The FEM software is applied to optimize the MRF structure. The software includes ANSYS/ADPL/ (MAXWELL) Emag 2D [39,41,43,48,61,72,76,77,79,83,[89][90][91][92][93], ANSOFT/MAXWELL [85,94,95], FEMM [74,96], ANSYS/CFD FLUENT [45], COMSOL Multiphysics [51,97], SOLIDWORKS [75]. From the above analysis, the ANSYS software is the best choice for designing MRF structures.…”

A review on multi-physics numerical modelling in different applications of magnetorheological fluids

“…The same observation can be seen in other studies (Case et al, 2014; Singh et al, 2014; Zheng et al, 2014, 2015, 2017), in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015). However, the hysteretic behaviour was not shown in the results presented by Zheng et al (2014), which can be inferred from the instantaneous transition of force at maximum displacements in the work diagram, as shown in Figure 16.…”

“…The authors attributed that misrepresentation of hysteretic behaviour to the handicaps involved in the deforming mesh technique. The same observation can be seen in other studies (Case et al, 2014;Singh et al, 2014;Zheng et al, 2014Zheng et al, , 2015Zheng et al, , 2017, in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015).…”

An approach for characterizing twin-tube shear-mode magnetorheological damper through coupled FE and CFD analysis

“…5a, b. As current supply increases, the magnetic flux induced in the electromagnetic coil will also increase [34]. Due to this yield stress of the MR fluid increases.…”

A review on design and modelling methods of magnetic circuit cores for MR elastomers and MR fluids based system

“…The design of the magnetic circuit model is the next step of MRF calculation. The magnetic circuit model can be analyzed following the four-stage MRF damper [51], as shown in figure 9(b). Kirchhoff's second law is the main principle in the design of the magnetic circuit model and is stated as follows:…”

“…The FEM software is applied to optimize the MRF structure. The software includes ANSYS/ADPL/ (MAXWELL) Emag 2D [39,41,43,48,61,72,76,77,79,83,[89][90][91][92][93], ANSOFT/MAXWELL [85,94,95], FEMM [74,96], ANSYS/CFD FLUENT [45], COMSOL Multiphysics [51,97], SOLIDWORKS [75]. From the above analysis, the ANSYS software is the best choice for designing MRF structures.…”

A review on multi-physics numerical modelling in different applications of magnetorheological fluids

“…The same observation can be seen in other studies (Case et al, 2014; Singh et al, 2014; Zheng et al, 2014, 2015, 2017), in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015). However, the hysteretic behaviour was not shown in the results presented by Zheng et al (2014), which can be inferred from the instantaneous transition of force at maximum displacements in the work diagram, as shown in Figure 16.…”

“…The authors attributed that misrepresentation of hysteretic behaviour to the handicaps involved in the deforming mesh technique. The same observation can be seen in other studies (Case et al, 2014;Singh et al, 2014;Zheng et al, 2014Zheng et al, , 2015Zheng et al, , 2017, in which only the work diagrams were used to validate the models developed. In the study by Zheng et al (2014), where a coupled electromagnetic, thermal and fluid flow approach is presented, the performance of the damper was investigated at high piston velocity of 2 m/s and high amplitude of 0.34 m. It is believed that the hysteretic behaviour of the damper should be more remarkable under such high loads (Kim et al, 2015).…”

An approach for characterizing twin-tube shear-mode magnetorheological damper through coupled FE and CFD analysis

“…5a, b. As current supply increases, the magnetic flux induced in the electromagnetic coil will also increase [34]. Due to this yield stress of the MR fluid increases.…”

A review on design and modelling methods of magnetic circuit cores for MR elastomers and MR fluids based system

“…The design of the magnetic circuit model is the next step of MRF calculation. The magnetic circuit model can be analyzed following the four-stage MRF damper [51], as shown in figure 9(b). Kirchhoff's second law is the main principle in the design of the magnetic circuit model and is stated as follows:…”

“…The FEM software is applied to optimize the MRF structure. The software includes ANSYS/ADPL/ (MAXWELL) Emag 2D [39,41,43,48,61,72,76,77,79,83,[89][90][91][92][93], ANSOFT/MAXWELL [85,94,95], FEMM [74,96], ANSYS/CFD FLUENT [45], COMSOL Multiphysics [51,97], SOLIDWORKS [75]. From the above analysis, the ANSYS software is the best choice for designing MRF structures.…”