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Procedia Engineering 97 (2014) 1220 – 1226

12th GLOBAL CONGRESS ON MANUFACTURING AND MANAGEMENT, GCMM 2014

Implementation of Magneto-rheological dampers in bumpers of

Automobiles for reducing impacts during accidents
T.Imthiyaz Ahameda,R.Sundarrajana,*,G.T.Prasaatha,V.Raviraja
a
Department of Mechanical Engineering, Sri Sairam Engineering College, West Tambaram, Chennai 600 044, India.

Abstract

This paper deals with the idea of implementing the magneto Rheological bumper in the front overhang of the four wheeler,
which reduces the loss and deformation of vehicle during accident. It includes the basic characters and properties of the magneto
rheological fluids (MR) and implementation of MR damper in bumpers of four wheelers. Research results of the past decades in
Magneto Rheological fluids and their applications are reviewed. The whole paper includes MR fluids as active component in
Impact reducing system. It is one of the important materials used by major engineers in designing components like brakes,
dampers, clutches. Here Magneto rheological techniques are used to reduce the impacts which are occurred during collision of
vehicles. Here the vibration is arrested by controlling the intensity of Magnetic field. Vibration produced during impact is
partially absorbed by the magnetic field and remaining by spring action. This paper discusses about the conventional bumpers
and replacing it with magneto rheological bumpers which we called as Impact Reducing System. It also deals with fabrication
and assembly of Magneto Rheological Dampers in bumpers.

©2014
© 2014TheThe Authors.
Authors. Published
Published by Elsevier
by Elsevier Ltd.
Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the Organizing Committee of GCMM 2014.
Selection and peer-review under responsibility of the Organizing Committee of GCMM 2014

Keywords:Magneto Rheological Fluid; Dampers; Smart Materials; Vibrations; Collision ;Viscosity.

* Corresponding author. Tel.: +919994684093;

E-mail address: sundarrajrv@gmail.com.
1877-7058 © 2014 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the Organizing Committee of GCMM 2014
doi:10.1016/j.proeng.2014.12.400
 T. Imthiyaz Ahamed et al. / Procedia Engineering 97 (2014) 1220 – 1226 1221

1. Introduction

Magneto-rheological fluids have existed for over fifty years. However, it is only now that they are stable and have
many attractive features such as high yield stresses and low viscosity. They are adequate in demanding applications
such as automotive damping [1].In recent years large scale magneto-rheological dampers have reached more
attention in the area of structural response control [2].A mathematical model was presented elsewhere [3] to
represent the device force-displacement and force-velocity behaviour of an MR damper that includes variability on
the damper geometry, viscosity of the fluid without magnetization, and level of shear stress of the magnetized MR
fluid. Magneto-Rheological Fluid technology has been successfully employed in various low and high volume
automotive applications. Good understanding of specific design constraints is required to define and to optimize a
magneto-rheological device [4].Magneto-rheology is the change of rheological behaviour under an external
magnetic field. The external magnetic field forces the ferromagnetic particles to form a chain-like structure, which
resists the free fluid motion, and the fluid behaviour becomes controllable with the external magnetic field [5].
MR fluids are suspensions of micron-sized, magnetically polarizable particles in a carrier medium such as mineral
or silicon oil. The volume fraction of the particles is between 20% and 60% [6]. MR fluids belong to the group of
non-Newtonian fluids and their description as a Bingham model is generally recognised [7].The boundary
lubrication performance of typical electro and magneto-rheological fluids are compared for friction and wear. It is
found that the MR species seems to have advantages over the ER variety [8].MR dampers have the advantage of
being safe from faults, they consume low power, the force is controllable, they respond rapidly, and so on, but their
non-linear force/displacement and hysteretic force/velocity characteristics are very complex[9,10].
Apart from that the fluidsÿ rheological properties can alternate continuously and reversibly in matter of milli-
seconds, characteristics which have inspired the design of a large variety of MR devices [11],[12].There are several
MR damper models proposed in the literature using a range of techniques. Models obtained by a deterministic
approach include the Bingham, Bouc-Wen, phenomenological model and others, [13], [14] and [15].Magneto-
rheological (MR) damper is an intelligent damper, which is used as automobile suspension for vibration semi-active
control. A single piston rod MR damper with an accumulator was designed in order to satisfy with the demand of a
certain automobile front suspension. The damper structural parameters were obtained by integrated optimal design
combining magnetic circuit and structure [16].
In most of the accidents, the bumper system is the first vehicle part that receives the collision and which may to
some extent protect the car body and passengers. This system comprises three main parts: fascia, energy absorber,
and bumper beam [17].Bumper beams are one of the key structures in passenger cars for which careful design and
manufacturing should be considered in order to achieve good impact behaviour [18] and [19].The bumper beam is
the main structure for absorbing the energy of collisions. Suitable impact strength is the main expectation for such a
structure [20] and [21]. Bumper beams are one of the main structures of passenger cars that protect them from front
and rear collisions [22].Car traffic has increased dramatically. Although additional traffic regulations such as speed
limits or other restrictions were imposed to reduce accidents, crashes can be seen every day. Many result in vehicle
damages or injuries of occupants or other people involved [23].Bumper beam absorbs the accidental kinetic energy
by deflection in low-speed impact and by deformation in high-speed impact. The new bumper design must be
flexible enough to reduce the passenger and occupant injury and stay intact in low-speed impact besides being stiff
enough to dissipate the kinetic energy in high-speed impact.[24].
There are some investigations of new material development, property improvement, and FEA of bumper beam
structures by researchers and car manufacturers. These parties are mainly interested in substituting the conventional
material with lighter and stronger material [25].Renault used SMC in a passenger car bumper in 1972 instead of
steel [26] and General Motors (GMs), used the sheet molding compound (SMC) beam in Pontiac Bonneville
Cadillac Seville and Cadillac Eldorado instead of steel which was used in previous models [27].the current trends in
bumper design focus on aerodynamic efficiency where the designed curve should be embraced with the same style
in other parts of the bumper system[28].Selecting a suitable material in bumper beam development is crucial and
bad selection may cause poor performance, frequent maintenance or failure. Proper material selection for bumper
beam requires information about type of loading (axial, bending, torsion or their combination), mode of loading
(static, dynamic, fatigue, impact), operating environment (temperature, humidity, chemical conditions),
manufacturing process, cost (raw material, manufacturing, assembly) [29].Development of new material to comply
with safety and environmental regulations, and development of various intelligent pre-crash systems to prevent or
decrease the injury by fully automated controlled of car safety mechanism [30].
1222 T. Imthiyaz Ahamed et al. / Procedia Engineering 97 (2014) 1220 – 1226

Nomenclature

τ0 Yield stress due to applied magnetic field ,N/mm2

H Magnetic field strength ,A/m
γ Shear rate, s-1
η Plastic viscosity,pa.s
∆P Total pressure drop,
∆PȠ viscous pressure loss,
∆Pτ Field dependent yield stress pressure loss,
Ƞ Fluid viscosity,
Q Flow Rate,
L Pole Length,
w Pole Width,
g Fluid Gap,
τγ Field dependent yield stress.

2. Magneto rheological fluid

Major constituents of MR fluid are oil and iron particles which vary in percentages according to the
specifications. Iron particles are coated with anti-coagulant materials. When this combination of fluid is in inactive
state, it acts as typical natural oil. When magnetic field is applied in the vicinity areas of fluids, micro-sized iron
particles that are distributed throughout the fluid make themselves align according to the applied magnetic flux lines.
It occurs when iron particles moves from one magnetic pole to the other and perpendicular to each paramagnetic
pole surface.MR fluids are quite similar to electro rheological (ER) fluids and Ferro fluids in composition: all three
fluids are a non-colloidal suspension of polarizable particles While MR and ER fluids usually contain carbonyl iron
on the order of a few microns in size, Ferro fluids use nanometre-sized iron oxide particles. Ferro fluid particles are
too small to demonstrate any yield strength; instead they tend to be only attracted to and flow toward a magnetic
field. MR fluids, on the other hand, demonstrate very high yield strengths when a field is induced, usually on the
order of 20 to 50 times the strength of ER fluids.
With absence of applied magnetic field (off state), MR fluids behave as a Newtonian-fluid. Applying an external
magnetic field through the fluid activates MR fluids, causing the micron-sized particles to form magnetic dipoles
along the magnetic lines of force.

Fig 1: Off State Magnetic Fluid particles (Left) aligned in a applied Magnetic Field (Right)
 T. Imthiyaz Ahamed et al. / Procedia Engineering 97 (2014) 1220 – 1226 1223

The dipoles align parallel to the induced magnetic flux lines to form chain-like structures of iron particles between
the north and South Pole. The ferrous particles that form each of the chains resist the movement of iron particles
from their respective flux lines and the resistance level showed by the particles is directly depends on the amount of
applied magnetic field. The reluctance of the ferrous dipole chains to move result in a restriction of the fluid flow.
The flow restriction resulting from the alignment of the ferrous dipoles causes a change in the apparent viscosity of
the fluid. The term “apparent” is used to modify the fluid because the carrier fluid’s physical viscosity does not
change – rather, the MR mixture acts as if it is thickening due to the resistance of the dipole chains. The apparent
viscosity can be varied infinitely between its off-state and saturation state, even becoming a near-solid. At
saturation, the ferrous dipoles are fully aligned and any additional field intensity will cause no change in the
apparent viscosity.MR fluid also develops a yield stress as it thickens, based on the amount of mechanical energy
required to yield the ferrous dipole chains.

2.1 Properties of Magneto rheological fluids

Typical magneto rheological fluids consists of mixture of magnetisable (mainly iron), micron sized particles
suspended in liquid such as synthetic oil, water or ethylene glycol, mineral oil. These liquid which carries the
particles are called Carrier Liquid. The carrier fluid creates dispersion medium and ensures that the particles in the
fluid are homogeneous. Different types of additives, stabilizers and surfactants are used to reduce the effect of
Gravitational settling of suspended and dispersed particles. It also increases stability of particles suspended, enhance
lubrication property and varies the initial viscosity of the MR fluids. Aim of using stabilizers is to maintain the
particles suspended in the fluid and the surfactants used are adsorbed on the surface of the magnetic particles in
order to induce the effect of polarization in the suspended particles upon the application of a magnetic field.

Table 1 . Properties of MR fluids

Properties Values
Initial viscosity 0.2 – 0.3 [Pa.s] (at 250C)

Density 3 – 4 [g/cm3]
Magnetic field strength 150 – 250 [kA/m]
Yield point 50 – 100 [k.Pa]
Reaction time Few milliseconds
Current intensity 2 – 25 V, 1–2 A
Work temperature -50 to 150 [oC]

Generally, the magnetisable particle’s diameter ranges from 3 to 5 microns. Functional MR fluids are usually
made with larger particles. As the size of the particles increases, suspension stability of particles becomes very low.
Carbonyl irons of commercial quantities are limited to sizes which are greater than 1 or 2 microns. It is very easy to
use smaller particles, but difficulty level of manufacturing smaller particles is very high. Availability of smaller
ferromagnetic particles is only in the form of oxides, like pigments that can be seen in magnetic-recording media.
MR fluids created using pigments found in magnetic-recording media are quite stable. The reason for this stability is
that the particles are only 30 nanometres in diameter. One main disadvantage is the strength of fluid created by these
particles are limited to 5 Kpa because of their lower saturation magnetization property. It also has a high value of
plastic viscosity because of increased surface area. When the MR fluid is inactive state (i.e.) in the absence of an
applied magnetic field, MR fluids are closely shows the properties similar to Newtonian liquids. In many
engineering usages, Model of Bingham plastic is very useful in explaining the required, field-dependent fluid
properties. One of the best example for Non-Newtonian fluid is Bingham plastic. The yield stress of Bingham
exceeds well before flow can begin. From there onwards, Linearity is maintained in the rate of shear vs. shear stress
graph curve. Mathematical expression for total theoretical yield stress is given by the following equation
τ = τ0(H) + ηγ.

Various complex prototypes of magneto-rheological fluid systems are created so far.Generally,MR fluids have
capability to flow freely and also has a consistency which is very much closer to that of motor oil.
1224 T. Imthiyaz Ahamed et al. / Procedia Engineering 97 (2014) 1220 – 1226

Fig 2.MR fluid model without outer magnetic field (1 – carrier liquid, 2 – suspended magnetisable particles)

However, in the presence of an applied magnetic field, the iron particles acquire a dipole moment aligned with
the external field which causes particles to form linear chains aligned to the magnetic field. This phenomenon can
solidify the suspended iron particles and restrict the fluid movement. Consequently, yield strength is developed
within the fluid. The degree of change is related to the magnitude of the applied magnetic field and it can occur in a
few milliseconds [31].

Fig 3. Damper with MR fluid

3. Design and Implementation of MR damper in the front bumper

There are two components present in the Pressure driven flow mode for the occurrence of pressure
drop. The important reason for drop in pressure is because of viscous drag and due to the field dependent yield
stress. The Mathematical expression which convinces the above statement is as follow,

∆P = ∆PȠ + ∆Pτ = 12 Ƞ Q L + cτγL

g3w g

Fig 4. MR fluid Damper assembly

 T. Imthiyaz Ahamed et al. / Procedia Engineering 97 (2014) 1220 – 1226 1225

As per our design, the MR damper should be placed at the bottommost portion of the fork arrangement. The
suspension spring is placed over these dampers. The other end of the fork is connected to the bonnet of the vehicle.
By designing so, the majority of vibrations (in terms of 50 percentage to 60 percentage) are absorbed by the MR
damper and the remaining are absorbed by the spring in fork arrangement. If a vehicle is met with an accident, the
front portion which contains the bumper with damper arrangement absorbs most of the impact. .
Suppose if we have placed the spring at the front it may easily get deformed in case of accident. Also the spring
has the capability of sticking together because of heat generated during friction. and the whole system get affected.
This is an arrangement of single unit. Like these 5 units are connected parallel by two steel plates to form a full
bumper arrangement .this not only save engine but also save driver's life.

4. Conclusion

Vehicle collisions are occurred in different possible modes. It may be head-on collision, rear end collision, and side
collision and roll overs. Of these modes, head-on collision is mostly occurred one and causes severe damage to both
vehicle and passengers. We cannot totally avoid these types of vehicle collisions. Instead of preventing these
accidents which is not possible, collision effects can be reduced by providing Bumpers in the front side of vehicles.
Thus in this paper, effects of collision is much reduced by implementing the several units of Magneto Rheological
dampers in bumpers of vehicles when it is compared with that of vehicles installed with normal bumpers. Thus the
development of smart materials will be an essential task in many fields such as energy, transportation, safety
engineering and military technologies.

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