Magneto Rheological Fluid.

CHAPTER-1
INTRODUCTION

1.1 Introduction:

Science and technology have made amazing developments in the design of electronics
and machinery using standard materials, which do not have particularly special properties.
Imagine some materials have the ability to change shape or size simply by adding a little bit of
heat, or to change from a liquid to a solid almost instantly when near a magnet; these materials
called smart materials. Smart materials have one or more properties that can be dramatically
altered. Most everyday materials have physical properties, which cannot be significantly altered;
for example if oil is heated it will become a little thinner, whereas a smart material with variable
may turn from a liquid state which flows easily to a solid. Each individual type of smart material
has a different property which can be significantly altered, such as viscosity, volume or
conductivity.

MRFT stand for Magneto-Rheological Fluid Technology. The essential components of

MRFT are MR fluid and a magnetic field to control the viscous property of the fluid. The basic
principle of MRFT is that very small suspended particles having magnetizing properties are
introduced in the base fluid. When a magnetic field is applied to this fluid, these particles form a
chain aligned in the direction of the field which creates a resistance to the fluid flow. Resulting,
an increase in the fluid viscosity takes place. Thus in the presence of magnetic field the MR fluid
converts into a semi solid with an increase in its yield strength. This work phenomenon takes
only milliseconds to occur. MR fluids thus act similar to Bingham fluids used in many
engineering applications. In the absence of magnetic field, the MR fluid behaves like newtonion
fluids.

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1.2 Rheology of the MR fluid

Rheology is the study of the deformation and the flow of the liquid. Basically three
factors viscosity, shear stress and rate of strain are considered in the study of flow and
deformation. In most of the fluid applications viscosity is an important property. In case of
general fluids, viscosity changes with change in other physical properties such as shear stress,
temperature etc.

In most applications these physical properties cannot be controlled as they are governed by the
working environment and hence the viscosity also cannot be controlled.

1.3 MR fluid components

Magneto Rheological (MR) fluids are basically non colloidal suspensions of micro sized
magnetisable particles in an inert base fluid along with some additives. Thus there are basically
three components in an MR Fluid.

1.3.1 Base fluid.

The base fluid is an inert or non magnetic carrier fluid in which the metal particles are
suspended. The base fluid should have natural lubrication and damping features. For better
implementation of MRF technology the base fluid should have a low viscosity and it should not
vary with temperature. This is necessary so that MRF effect i.e. variation of viscosity due to
magnetic field becomes dominant as compared to the natural viscosity variation. Due to the
presence of suspended particles base fluid becomes thicker. Commonly used base fluids are
hydrocarbon oils, mineral oils and Silicon oils.

1.3.2 Metal particles.

For proper utilization of this technology we need such type of particles which can
magnetized easily and quickly therefore we use metal particles. Metal particles used in the MR-
technology are very small. Size of the particle is approximate of the order of 1μm to 7μm.
Commonly used metal particles are carbonyl iron, powder iron and iron cobalt alloys.

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Metal particles of these materials have the property to achieve high magnetic saturation
due to which they are able to form a strong magnetizing chain. The concentration of magnetic
particles in base fluid can go up to 50%. (approx.)

1.3.3 Additives.

It is necessary to add certain additives to MR fluid for controlling its properties. These
additives include stabilizers and surfactants . Surfactants serve to decrease the rate of settling of
the metal particles. While the functions of additives are to control the viscosity of the fluid,
maintain friction between the metal particles and to reduce the rate of thickening of the fluid due
to long term use of the fluid thus additives also increase the life of the MR fluid. Commonly used
additives are ferrous oleate and lithium stearate.

All the three components of an MR fluid define its magneto rheological behavior.
Changing any one component will result in change in the rheological and magneto rheological
properties of the MR fluid. An optimum combination of all the three components is necessary to
achieve the desirable properties of an MR fluid.

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CHAPTER-2

WORKING PRINCIPLE OF MR FLUID TECHNOLOGY

The MR fluid is a smart fluid whose properties can be controlled in the presence of
magnetic field. In the absence of magnetic field, the rheological properties of the MR fluid are
similar to that of base fluid except that it is slightly thicker due to the presence of metal particles.
In the absence of magnetic field, these metal particles align themselves along the direction of
flow however when a magnetic field is applied each metal particles becomes a dipole aligning
itself along the direction of magnetic field. Thus a chain like structure is formed along the line of
magnetic flux which offers mechanical resistance to the flow resulting in an increase in the
viscosity of fluid .This mechanical resistance created due to the chain column imparts yield
strength to the fluid, making it stiff like a semi-solid. This stiffness and hence the yield strength
depends on the strength of the magnetic field and also the quality and quantity of metal particles.

The MR effect is reversible. When the magnetic field is removed the fluid returns to its
original condition. The MR fluids with their controllable properties are found to be useful in the
implementation of smart fluid concept. Where the fluid motion is controlled by varying its
viscosity with the help of magnetization .The simpleness of MR fluid technology, the
controllability and the quick response of the rheological properties makes it a smart fluid with
application areas where fluid motion is controlled by varying the viscosity.

Fig.2.1(a).MR Fluid model without outer magnetic field.

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Fig.2.1(b). MR Fluid model with outer magnetic field.

2.1 Modes of Magneto Rheological fluids

According to the type of fluid flow, there are following three modes of MRF operation:

2.2.1 Valve mode (Flow mode).

2.2.2 Shear mode

2.2.3 Squeeze mode

2.1.1 Valve mode (Flow mode).

In this mode of MRF operation, fluid flow through the two fixed surfaces and magnetic
field is applied perpendicular to the direction of flow. The resistance of the fluid can be
controlled by controlling the intensity of magnetic field. This mode of MRF technology is used
in various types of dampers and shock absorbers and has vast application in automobile industry.

The pressure drop in this mode is the summation of pressure developed due to fluid viscosity
ΔPv and pressure developed due to the magnetic field ΔPm.

ΣP = ΔPv + ΔPm

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Fig.2.2.1 Valve mode (Flow mode).

2.1.2 Shear mode.

In this mode, the fluid flows between surfaces having relative motion and a magnetic
field is applied perpendicular to the direction of flow. Shear mode of MRF operation Shear mode
of MRF technology is used in various types of brakes and clutches of the vehicles.

In this mode, the total shear force developed is a summation of the force developed due
to the viscosity of the fluid (Fv) and the force developed due to the magnetic field (Fm).

Σ F = Fv + Fm

Fig.2.2.2 Shear mode.

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2.1.3 Squeeze mode.

This mode is used for low motion and high force applications. This mode is a recent
development as compare to the other two. In this mode of MRF technology externally applied
force is absorbed with the help of MR fluid. The yield stress developed through this mode is
approximately ten times of the stress developed in either valve or shear mode. Working of the
squeeze mode is clearly shown in below figure.

Fig.2.2.3 Squeeze mode.

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CHAPTER-3

APPLICATIONS

The application set for MR fluids is vast, and it expands with each advance in the
dynamics of the fluid.

3.1 Mechanical engineering.

Magneto Rheological dampers of various applications have been and continue to be

developed. These dampers are mainly used in heavy industry with applications such as heavy
motor damping, operator seat/cab damping in construction vehicles, and more.

As of 2006, materials scientists and mechanical engineers are collaborating to develop stand-
alone seismic dampers which, when positioned anywhere within a building, will operate within
the building's resonance frequency, absorbing detrimental shock waves and oscillations within
the structure, giving these dampers the ability to make any building earthquake-proof, or at least
earthquake-resistant.

3.2 Military and defense.

The U.S. Army Research Office is currently funding research into using MR fluid to enhance
body armor. In 2003, researchers stated they were five to ten years away from making the fluid
bullet resistant. In addition, HMMWVs, and various other all-terrain vehicles employ dynamic
MR shock absorbers and/or dampers.

3.3 Optics.

Magneto Rheological finishing, a magneto rheological fluid-based optical polishing method,

has proven to be highly precise. It was used in the construction of the Hubble Space Telescope's
corrective lens.

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3.4 Automotive.
 Shock absorbers.
 Suspension
 Magneto Rheological damper
 Magne ride active suspension
 Driveshaft
 Drive trains.
 Engine mounts.

If the shock absorbers of a vehicle's suspension are filled with Magneto Rheological Fluid
instead of a plain oil or gas, and the channels which allow the damping fluid to flow between the
two chambers is surrounded with electromagnets, the viscosity of the fluid, and hence the critical
frequency of the damper, can be varied depending on driver preference or the weight being
carried by the vehicle - or it may be dynamically varied in order to provide stability control
across vastly different road conditions. This is in effect a Magneto Rheological damper. For
example, the magne ride active suspension system permits the damping factor to be adjusted
once every millisecond in response to conditions.

General Motors (in a partnership with Delphi Corporation) has developed this technology for
automotive applications. It made its debut in both Cadillac (Seville STS build date on or after
1/15/2002 with RPO F55) as "magne ride" (or "MR") and Chevrolet passenger vehicles
(All Corvettes made since 2003 with the F55 option code) as part of the driver selectable
"Magnetic Selective Ride Control (MSRC)" system in model year 2003. Other manufacturers
have paid for the use of it in their own vehicles, for example Audi and Ferrari offer the magne
ride on various models.

General Motors and other automotive companies are seeking to develop a Magneto
Rheological Fluid based clutch system for push-button four wheel drive systems. This clutch
system would use electromagnets to solidify the fluid which would lock the driveshaft into
the drive train.

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Porsche has introduced magneto rheological engine mounts in the 2010 Porsche GT3 and
GT2. At high engine revolutions, the magneto rheological engine mounts get stiffer to provide a
more precise gearbox shifter feel by reducing the relative motion between the power train and
chassis/body.

As of September 2007, Acura (Honda) has begun an advertising campaign highlighting its
use of MR technology in passenger vehicles manufactured for the 2007 MDX model year.

3.5 Aerospace.
 Helicopter cockpit seats.

Magneto rheological dampers are under development for use in military and commercial
helicopter cockpit seats, as safety devices in the event of a crash. They would be used to decrease
the shock delivered to a passenger's spinal column, thereby decreasing the rate of permanent
injury during a crash.

3.6 Human prosthesis.

 Semi active human prosthetic legs.

Magneto rheological dampers are utilized in semi-active human prosthetic legs. Much
like those used in military and commercial helicopters, a damper in the prosthetic leg decreases
the shock delivered to the patients leg when jumping, for example. This results in an increased
mobility and agility for the patient.

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3.7 Advances in the 2000s

Studies published beginning in the late 2000s which explore the effect of varying
the aspect ratio of the ferromagnetic particles have shown several improvements over
conventional MR fluids. Nanowire-based fluids show no sedimentation after qualitative
observation over a period of three months. This observation has been attributed to a lower close-
packing density due to decreased symmetry of the wires compared to spheres, as well as the
structurally supportive nature of a nanowire lattice held together by remnant magnetization.
Further, they show a different range of loading of particles (typically measured in either volume
or weight fraction) than conventional sphere- or ellipsoid-based fluids.

Conventional commercial fluids exhibit a typical loading of 30 to 90 wt%, while

nanowire-based fluids show a percolation threshold of ~0.5 wt% (depending on the aspect
ratio).They also show a maximum loading of ~35 wt%, since high aspect ratio particles exhibit a
larger per particle excluded volume as well as inter-particle tangling as they attempt to rotate
end-over-end, resulting in a limit imposed by high off-state apparent viscosity of the fluids. This
range of loadings suggest a new set of applications are possible which may have not been
possible with conventional sphere-based fluids.

Newer studies have focused on dimorphic magneto rheological fluids, which are
conventional sphere-based fluids in which a fraction of the spheres, typically 2 to 8 wt%, are
replaced with nanowires. These fluids exhibit a much lower sedimentation rate than conventional
fluids, yet exhibit a similar range of loading as conventional commercial fluids, making them
also useful in existing high-force applications such as damping. Moreover, they also exhibit an
improvement in apparent yield stress of 10% across those amounts of particle substitution.

Another way to increase the performance of magneto rheological fluids is to apply a

pressure to them. In particular the properties in term of yield strength can be increased up to ten
times in shear mode and up five times in flow mode. The motivation of this behavior is the
increase in the ferromagnetic particles friction, as described by the semi empirical magneto-
tribological model by Zhang et al.

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3.8 Limitations

Although smart fluids are rightly seen as having many potential applications, they are
limited in commercial feasibility for the following reasons:

 High density, due to presence of iron, makes them heavy. However, operating
volumes are small, so while this is a problem, it is not insurmountable.
 High-quality fluids are expensive.
 Fluids are subject to thickening after prolonged use and need replacing.
 Settling of ferro-particles can be a problem for some applications.

Commercial applications do exist, as mentioned, but will continue to be few until these problems
(particularly cost) are overcome.

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CHAPTER-4

CASE STUDIES

4.1 Magnetic Rheological Brake

The automotive industry has a commitment to build safer, cheaper and better performing
vehicles. For example, the recently introduced “drive by wire” technology has been shown to
improve the existing mechanical systems in automobiles. In other words, the traditional
mechanical systems are being replaced by improved electromechanical systems that are able
to do the same tasks faster, more reliably and more accurately. The proposed brake is a
Magneto Rheological Brake (MRB) that potentially has some performance advantages over
Conventional Hydraulic Brake(CHB) systems. A CHB system involves the brake pedal,
hydraulic fluid; transfer lines and brake actuators (e.g. disk or drum brakes).

When the driver presses on the brake pedal, the master cylinder provides the pressure in
the brake actuators that squeeze the brake pads onto the rotors, generating the useful friction
forces (thus the braking torque) to stop a vehicle. However, the CHB has a number
limitations, including,

(i) delayed response time (200–300 ms) due to pressure build up in the hydraulic
lines,
(ii) bulky size and heavy weight due to its auxiliary hydraulic components such as
the master cylinder,
(iii) brake pad wear due to its frictional braking mechanism, and
(iv) low braking performance in high speed and high temperature situations. The MR
brake operates in a direct-shear mode, shearing the MR fluid filling the gap
between the two surfaces (housing and rotor) moving with respect to one another.

Rotor is fixed to the shaft, which is placed in bearings and can rotate in relation to
housing. Resistance torque in the MR brake depends on viscosity of the MR fluid that
can be changed by magnetic field. MR brake allows for continuous control of torque.

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When there is no magnetic field the torque is caused by viscosity of carrier liquid,
bearings and seals.

Fig.4.1(a) Basic configuration of the proposed MR brake

Fig.4.1(b).Basic illustration of the proposed MR brake

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A basic configuration of a MRB was proposed for automotive applications. a rotating

disk (3) is enclosed by a static casing (5), and the gap (7) between the disk and casing is filled
with the MR fluid. A coil winding (6) is embedded on the perimeter of the casing and when
electrical current is applied to it, magnetic fields are generated, and the MR fluid in the gap
becomes solid-like instantaneously. The shear friction between the rotating disk and the
solidified MR fluid provides the required braking torque. In this paper, we propose a MR
actuator for the brake in each wheel. The actuator consists of a rotating disk immersed in a MR
fluid, enclosed in an electromagnet. In principle, the brake torque can be controlled by changing
the DC current applied to the electromagnet. Magneto Rheological Fluid a compound containing
fine iron particle in suspension - stiffens in the presence of a magnetic field. Two important
characteristics of MR fluids are:

(i) they exhibit linear response, i.e., the increase in stiffness is directly
proportional to the strength of the applied magnetic field and
(ii) they provide fast response, i.e., MR fluid changes from a fluid state to a near-
solid state within milli-seconds of exposing a magnetic field.

4.2 Magnetic Rheological Suspension

Now day’s people require high quality for everything. Certainly, the comfort in the moving
vehicle is peoples concern, so it is desirable to have high performance suspension system for
vehicles. In the environment of a moving vehicle, passengers often feel uncomfortable due to the
vibration of the vehicle body. To improve the ride comfort, effective vibration control of vehicle
suspension is very important. Shock absorbers in most vehicles rely on a hydraulic fluid, a
sliding piston and other parts that suffer wear and tear. In addition, the characteristics of a
conventional shock absorber are either fixed, or else cannot be rapidly varied on demand. MR
fluid is the enabling technology to design entirely new suspension systems that avoid these
limitations, leading to improvements such as reduced wear and tear and more reliability through
the life cycle

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Fig.4.2(a).The Model of Vehicle.

Magneto rheological dampers of various applications have been and continue to be

developed. These dampers are mainly used in heavy industry with applications such as heavy
motor damping, operator seat/cab damping in construction vehicles, and more. Seating equipped
with MR dampers is the only product that offers both safety and health benefits for drivers.
Unlike standard air suspended seats, which compromise shock and vibration control, the MR
technology is the only solution that automatically adapts to both the drivers body weight and
continually changing levels of shock and road vibration, improving driver responsiveness and
control while reducing fatigue and risk of injury. MR-based suspension systems use the fluid in
specially designed dampers, which take the place of standard dampers (shock absorbers).

If the shock absorbers of a vehicle's suspension are filled with Magneto Rheological Fluid
instead of plain oil, and the whole device surrounded with an electromagnet, the viscosity of the
fluid, and hence the amount of damping provided by the shock absorber, can be varied
depending on driver preference or the weight being carried by the vehicle - or it may be
dynamically varied in order to provide stability control. One of the deliverables of the
development for the Magneto rheological shock absorber was a direct comparison between the
MR damper and a conventional hydraulic damper.

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Fig.4.2(b).Commercial Linear MR Fluid-based Damper

This second shock absorber was also used to test the principal of replacing the conventional
coil-spring with a gas-spring. A conventional shock absorber unit was designed with a
conventional hydraulic damper unit. The unit flows all of the fluid through the damping valves
which allows for much larger valves than is common in piston ported dampers. This in turn
reduces fluid shear and improves damping response. The flow path was kept was long and very
turbulent so the shock absorber is not sensitive to fluid viscosity temperature changes.

The MR fluid damper contains MR fluid, bearing & seal, annular orifice, coil, diaphragm and
accumulator. For accumulator, there is nitrogen gas with pressure 20-bar acting on the damper.
The diaphragm is used to separate the nitrogen and the MR fluid. Also, the coil produces the
electromagnetic field by the current passing through it. The annular orifice allows the MR fluid
passing up and down. And also, the bearing & seal is used to prevent the friction. The MR fluid
valves and associated magnetic circuit are fully contained within the piston. These magnetically
controlled valves regulated the flow of MR fluid within the damper. Current is carried to the
electromagnetic coil via the leads through the hollow shaft. When the current through the valves
the MR fluid will change the state into solid. Then the damping force will increase. By changing
the current, the damping force can be changed so that the damping can be controlled.

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ADVANTAGES
 It can used in Dampers & shock absorber.

 It is high quality fluid.

 Easy to control.

 Have higher magnitude of yield stress.

 Low power requirements for control.

DISADVANTAGES
 It is not insurmountable

 It is expensive.

 Fluids are subject to thickening after prolonged use and need replacing.

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CONCLUSION

Magneto rheological fluid technology has a wide scope in the coming era. This
technology is very useful in those places where controlled fluid with varying viscosity is
required. The main features of MRF technology are fast response, simple interface between
electrical input and mechanical output and intelligent controllability.

The geometric design method of a cylindrical MR fluid brake is presented theoretically in

this paper. Based on a commercially available Magneto Rheological Fluid, a new automotive
brake system was proposed. The model of the proposed MRB was presented, an optimum MRB
design with two rotating disk was proposed. This allows easy implementation of advanced
braking control features with a smaller number of components, simplified wiring, improved
braking response and generally optimized layout. Magneto Rheological dampers of various
applications have been and continue to be developed.

This technology is simple and involves less moving parts. Hence MRF based products
require less maintenance and have comparatively longer life. The main drawback of MRF
technology is that the MR fluid becomes thick after prolonged use and needs to be replaced, also
due to presence of high density metal particles, the weight of MRF products is high. At present
automobile industries are using this technology. Some other fields where this technology can be
used are in aero space and medical field. There is a vast scope for research in MRF technology.
MRF systems need to be made more sensitive, possibly by introducing the uses of sensors and
feedback system i.e. closed loop systems The life span of MRF devices in terms of the total
energy dissipated from the equipment need to be increased. An improved MRF technology
would make it the smart technology of future.

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REFERENCES

[1]. Deepak Baranwal, Dr. T.S. Deshmukh, International Journal of Emerging Technology
and Advanced Engineering, Vol. no.:Volume 2, Issue 12, December 2012.
[2]. Mr. Vinayak D.Dabade, Prof. Y. R. Patil, Prof.M.V. Kharade, Prof. P.R.Patil, Smart
materials;Magneto Rhelogical Fluids.
[3]. Mukund A. Patil, Ashutosh S. Zare “Theoretical Studies on Magneto rheological
Fluid Brake”

[4]. M. Kciuk, R. Turczyn “Properties and application of magneto rheological fluids”, Journal
of achievement in material and manufacturing engineering, Vol.18, Issue 1-2 Sept.2006

[5]. J.D. Carlson, What makes a good MR fluid, in: 8th International Conference on Electro
rheological (ER) and Magneto rheological (MR) Suspensions, Journal of Intelligent
Material Systems and Structures, No. 13, 2002.

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