Magneto-Rheological (MR)

Fluids
Harish Hirani
Associate Professor
Department of Mechanical Engineering
Indian Institute of Technology DELHI

Lubrication & Bearings http://web.iitd.ac.in/~hirani/

 Used in Japan's National Museum of Emerging Science &
China's Dong Ting Lake Bridge to counteract vibrations caused
by earthquakes and gusts of wind

MagnetoRheological
Fluids

Dr. H. Hirani
Mechanical Engnieering, IIT Delhi
¾RHEOS (Greek word) = to FLOW (English word)

¾RheoLOGY= Science of material flow under external load

conditions

¾MAGNETOrheological FLUID= Fluid, whose apparent

viscosity increases, with application of MAGNETIC field.

Liquids that harden or change

shape when they feel a magnetic
field
 Soft magnetic
particles

Carrier
liquid
Particle Sizes !!!!!
Application of magnetic
field, polarizes and
align magnetic particles.
Particle chain formation
limits particle
movement, which in
turn limits the
movement of the fluid.
 MR Fluids:
¾Consist micron (1-10 μm) sized, magnetically
polarizable (soft magnets) dispersed in a carrier
liquid such as mineral, silicone oils, kerosene,
water.
ƒParticles > 10 μm~ unstable against settling

2(ρ P − ρ f )gai2
Stoke' s settling velocity =
9η
MR Fluids:
¾Consist micron (1-10 μm) sized, magnetically
polarizable (soft magnets) dispersed in a carrier
liquid such as mineral, silicone oils, kerosene,
water.
ƒParticles > 10 μm~ unstable against settling
2(ρ P − ρ f )gr 2
Stoke' s settling velocity =
9η
ƒParticles < 1 μmÆ destabilizing
effect of Brownian motion
dominates
 Required Particles’ properties
Permeability: degree of magnetization of a material that
responds linearly to an applied magnetic field.
μ0 (=4π×10−7 N/A2) is
known as permeability of
free space.
 Required Particles’ properties….
Relative Permeability
Iron 2000
Nickel 100
Permalloy (78.5% nickel, 21.5% iron) 8000-
25,000
Mu metal (75% nickel, 2% chromium, 5% copper, 20,000-
18% iron) 100,000
 Required Particles’ properties….
The applied field where the data (called a magnetization curve)
crosses zero is the coercivity.
Saturation Limit: The limit of applied field at which all the
magnetic domains align with the field, and the magnetic-curve
flattens out.
Coercivities of soft and hard magnets
Material Coercivity
Permalloy, Ni81Fe19 0.5-1

Co 20

Ni 150
Alnico, a common refrigerator
1500-2000
magnet
NdFeB 10,000
SmCo5 40,000
 Approx % Composition
Saturation
Maximum
Material Fe Ni Co Mo Other flux density
permeability
B gauss
Iron 99.91 --- --- --- --- 2,000 21,500
Purified iron 99.95 --- --- --- --- 10,000 21,500
Permalloy 21.2 78.5 --- --- 0.3 Mn 100,000 10,700
Mu metal 18 --- --- --- --- 100,000 6,500

Particle size
Permeability
Saturation
Non-magnetic carrier fluid
How many particles ???????
MR Fluids:
¾20-50% by vol. Magnetic particles (higher vol.
Increase “off state” viscosity).
 140

120

100
Yield Stress (kPa)
at 100 (1/s)

80
MRF36L
MRF36S
60 MRF36M1
MRF36M2

40

20

0
0 20 40 60 80 100 120 140

Magnetic Field, H (kA/m)

 MR Fluid Properties
Newtonian fluid, τ = ηγ& η is plastic viscosity
non - Newtonian fluid, τ = τ o + ηγ&
In addition to plastic viscosity, elastic viscosity (τ 0 / γ& )

Apparent viscosity η ′ = τ &

γ

Fluids do not flow until

the applied shear stress
crosses a threshold value
called the “yield stress”.
 90

80 10% by Volume Iron particle

70
Off-state viscosity of MR fluids (Pas)

36% by Volume Iron particle

60

50

40

30

20

10

0
0 250 500 750 1000
Shear Rate (1/s)

Special consideration for Apparent viscosity η ′ = τ &

γ
high shear rate application
 MR-FLUID…………..
¾ Make device smart by changing system’s
properties( stiffness, damping, viscosity, shear
modulus) in a desirable manner. Sy ~ 0-100 kpa
ƒ Useful in active control of vibration & motion, i.e.
engine mount, shock absorbers, seat dampers,
variable resistance equipment, etc.

Motion damping is perhaps the most practical use

for MR technology today
MR Fluids:
¾20-50 times stronger than ER fluids, lower
sensitivity to impurities.
Property MR fluids ER fluids
Max. yield stress τ0 50-100 kpa 2-5 kpa
Maximum field ~250 kA/m ~4 kV/mm
Apparent plastic viscosity η 0.1-10 pa-s 0.1-10 pa-s
Operable temp. range -40-150 oC +10-90 oC
Stability Unaffected by Cannot tolerate
most impurities impurities
Density 3-4 g/cm3 1-2 g/cm3
Maximum energy density 0.1 Joules/cm3 0.001 Joules/cm3
Power supply (typical) 2-50 V, 1-2 A 2000-5000 V, 1-10 mA
Properties of three different types of MR fluids
MR fluid MRF-132LD MRF- MRF-336AG
240BS
Fluid base Synthetic oil Water Silicone oil
Operable temp. range oC -40-150 0-70 -40-150
Density (g/cc) 3.055 3.818 3.446
Weight percent solids 80.74% 83.54% 82.02%
Coefficient of thermal expansion 0.55-0.67×10-3 0.223×10-3 0.58×10-3

Specific heat @ 25oC 0.80 0.98 0.68

(J/g oC)
Thermal conductivity (w/w oC) 0.25-1.06 0.83-3.68 0.20-1.88
Flash point (oC) > 150 >93 > 200
Viscosity @ 10s-1/50s-1 0.94/0.33 13.6/5.0 8.5
(Pa-sec)
 Geometries for MR Fluid
• Most devices that use MR fluids can be
classified as having:
– Fixed poles (Pressure driven flow mode)
• Servo-valves, dampers and shock absorbers
– Relatively moveable poles (Direct-shear/sliding mode).
• Clutches, brakes, chucking and locking devices.
Both of these configurations can be described by assuming MR fluid
is dispersed between two parallel plates. In the sliding plate (or
shear) mode the MRF is stationary and the walls/electrodes move. In
the fixed plate (or flow) mode the walls/electrodes are stationary and
the fluid moves.

Squeeze-film modeÆ Low motion and high force applications

 Small element of
Fluid with sides
dx, dy, and dz
⎛ ∂τ ⎞ ⎛ ∂p ⎞
Force balance : pdy.dz + ⎜⎜τ + dy ⎟⎟dx.dz = ⎜ p + dx ⎟dy.dz + τdx.dz
⎝ ∂y ⎠ ⎝ ∂x ⎠

∂τ
Shear flow mode =0
∂y
∂τ ∂P
Pressure flow mode =
∂y ∂x
 Application of MR Fluid in Brakes?
In friction brakes, two surfaces are pressed
together with a normal force to create a
friction torque.
• Disk brake: Flat surface ⊥ to axis of rotation, and
normal force is axial.
• Drum brake: Cylindrical surface with normal force in
radial direction
 At least one the friction surface is metal (cast iron or
steel) and other is usually a high friction material,
referred to as lining. Sacrificial.
b
Maximum contact pressure, Maximum bulk temperature,
pmax t m, max
Coefficient of
a
Friction material friction, µ psi kPa °F °C
Molded 0.25-.045 150-300 1030-2070 400-500 204-260
Woven 0.25-0.45 50-100 345-690 400-500 204-260
Sintered Metal 0.15-0.45 150-300 1030-2070 400-1250 232-677
Cork 0.30-0.50 8-14 55-95 180 82
Wood 0.20-0.30 50-90 345-620 200 93
Cast iron; hard steel 0.15-0.25 100-250 390-1720 500 260
a
When rubbing against smooth cast iron or steel.
b
Use of lower value will give longer life.
 Properties of Braking materials
Operating in Oil
Friction materiala Coefficient of friction, µ
Molded 0.06-0.09
Woven 0.08-0.10
Sintered Metal 0.05-0.08
Paper 0.10-0.14
Graphitic 0.12 (avg)
Polymeric 0.11 (avg)
Cork 0.15-0.25
Wood 0.12-0.16
Cast iron; hard steels 0.03-0.16
a
When rubbing against smooth steel or cast iron.

Brake wiping mechanism !!!!!

 MRF Bearing cum Brake

91

81

71 200 RPM
Amplification factor

1200 RPM
61

51 T i=I
41 AF =
31 T i =0
21

11

1
0 0.2 0.4 0.6 0.8 1 1.2
Current, A

3/14/2014 27
 ωr
τ = τ yd + η
h

ηω r ⎞ ηω r
r2 r3
⎛ ⎛ ⎞
T = 2 ∫ 2π rh ⎜ τ yd + ⎟dr + ∫r 2πrw ⎜⎝ τ yd + h ⎟dr
r1 ⎝ h ⎠ 2
⎠

T = 2πhτ yd ( 4
) ( ) ( 2
)w 3 3
r − r + ηπω r2 − r1 + πwτ yd r3 − r2 + ηπω r3 − r2
2
2

3
1
2 3 3 2 2

3 h
( )
 MR Brake
Title: Magnetorheological brake operating under
shear, squeezing and valve mode.

Inventor: H. Hirani and C. Sarkar

Application number: 2530/Del/2013

3/14/2014 29
 Application of MR Fluid in Dampers?
• The practical necessities often
require attenuation of the vibrations.
– Passive Damper
– Active Damper
– Semi-active Damper
 Application of MR Fluid in Engine Mount?

Basic Function: To connect the

Engine firmly to Chassis / Frame.
Vibration isolation, to reduce
vibrations transmitted from the
engine to the frame.

Damper Isolator
Attacks the source of vibration Prevents the transmission of
and reduces the movement of vibration from the vibration
vibration source. source to another part.
Mount Advantages Disadvantages
Passive Easy to design, availability, Can’t change response
shows better performance at as per change in input
tuned frequency frequency.

Active:Electromecha Ability to adapt to varying Costs.Failure of any

nical actuators, operating conditionsÆ component brings
piezoelectric elements Optimizing the mount system to stand still
along with closed loop effectiveness under all condition.
feed back system. conditions.

Semi-active: Even though the actuation or Cost higher than the

combination of the feed back system fails it passive type of mount.
active and passive functions as a passive mount
isolator serving the purpose.
 Dynamic Stiffness

Frequency

Dynamic Stiffness of an ideal engine mount

 Application of MR Fluid in Engine Valves
• Ex: In most of engines, the valve timings and lift are
optimized for one set of operating conditions.
– engine operates in various load and speed
conditions. Consequently, to optimize the engine
performance in any condition and any circumstance,
a need exists for a device that permits variable
valve actuation.
– Variable lift/timing (VVA) to exploit benefits:
• Fuel economy
• Elimination of throttling
• Reduction in emission.
Reference: SAE 1999-01-0329, SAE 2003-01-0029, SAE
2003-01-0036, SAE 2003-01-0052, SAE 2004-01-1386, ..
Natural frequency ….
9000 rpm

Tribo-Pairs:
• Cam-pushrod
• pushrod-rocker arm
• rocker arm-rocker
shaft
• rocker arm-valve
• valve-valve-guide
• valve-seat
• push rod – guide
 Variable Lift Valve Mechanism

Valve lift vs crank rotation

11
10
Valve lift, mm

9 1.7 Amp current

8 1 Amp current
7 0 amp
6
5
0 120 240 360 480 600 720 840 960 108
0
Crank rotation, degrees
3/14/2014 Total slides = 27 38
 Computer

Optical Displacement
sensor
Delta
converte Dc
r Valve Power
supply
4 Stroke
Maximum valve lift Vs Product of speed and Current
AC Motor Diesel

Maximum Valve lift(mm)

engine
9
8.5
8
Electro Magnet
7.5 Experimental values
7 Least square fit
6.5
6
5.5
0 200 400 600 800

Product of Cam speed(Rpm) and

Current(Amps)

Valve_Lift =
0.0021(N.I) + 6.6646

3/14/2014 39
 Thank U
Variable spring stiffness ……….