DESIGN, DEVELOPMENT AND

TESTING OF AN INNOVATIVE
LOW COST MAGNETO
RHEOLOGICAL FLUID BASED

DYNAMIC VIBRATION
ABSORBER
Presented by : Under the guidance of:
Ganga Nair B180452ME Dr. Jagadeesha T
Nathan Job Antony B180497ME Dr. G Varaprasad
Akshay Kumar B170887ME
Sebin Sabu Mathew B180838ME
Department of
Mechanical Engineering

11/04/2023 NIT CALICUT i

 01

TABLE OF CONTENTS
INTRODUCTION
3-5

02 LITRATURE REVIEW

OBJECTIVES, METHODOLOGY,
6-8

03 WORKPLAN 9-11

04 MATHEMATICAL MODELLING AND SIMULINK

MODELLING
12-16

05 SIMULATION OF DAMPER
17-26

06 EXPERIMENTAL SETUP AND CAD MODEL

27-33

07 INNOVATIONS AND ADDITIONS TO THE

MODEL 34-38

08 CONCLUSION, WORK TO BE DONE, REFERENCES 39-42

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 INTRODUCTION
Unchecked machine vibration can:

• Cause heavy damage in machinery in case of vibration

matching the natural frequency of the structure.

• Cause machinery to consume excessive power and may

damage product quality.

• Accelerate rates of wear (i.e. reduce bearing life) and

damage equipment.

• Create noise, cause safety problems and lead to

degradation in plant working conditions.

Vibration reduction is a key component in the

performance of Mechanical Engineered structures for
safety of their users. Fig.1 Wind Turbine Farms rotating at different wind
speeds and directions

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MR DAMPER BASED DYNAMIC VIBRATION ABSORBER

Dynamic Vibration Absorbers are:

• 2° systems which absorbs vibration preventing damage to
primary body
• Can be tuned to frequencies

Types of
DVA

Fig 2 . Amplitude ratio vs Frequency ratio

Active Passive Semiactive

Applications
• Vibration control of heavy machines
• Vibration absorber in machines using VFD’s
• Vibration control of transmission cables
• Control of torsional oscillation of crankshaft
• Control of noise in aircraft cabin
Fig 3 . (a)Active, (b)Passive, (c)Semi active DVA

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INTRODUCTION Utilisation of smart materials like ER or MR fluids enables tuning of DVA to
wide range of frequency.

UTILISING MR-FLUID Magneto rheological fluid is a type of smart material whose rheological
properties (eg. Viscosity) can be rapidly altered by applying a magnetic field .
This property can be utilised to create a damper whose damping ratio (or force
applied) can be controlled.

Advantages of using MR Fluids: MR Dampers

• High yield stress with less power input
• Operates at a wide range of temperatures
• Very small response time
• Relatively less affected by chemical impurities
• Non toxic and environmentally safe
• MR fluid as damping fluid
• Fluid properties varied with magnetic field generated
by the circuit in the piston
• Magnetic field controlled by a control system

Fig 4. Working mechanism of Fig 5. Variation of viscosity with Fig 6. Model of MR Damper Fig 7. Modes of operation
MR fluid magnetic field

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 REVIEW OF LITERATURE
Title of Paper Insights Illustrations and Findings
Felix Weber, Hans Distl, ● Design of MR DVA as a passive
Sebastian Fischer, DVA with MR Damper in parallel
Christian Braun “MR
Damper Controlled ● Adaptive Control algorithm using
Vibration Absorber for by specifying semi- active control
Enhanced Mitigation of force
Harmonic Vibrations”

Fig 8. graphs of various DVA Setup Outputs

KUMBHAR MAHADEV • Design of experimental setup.

BAPU, “Design, • Fabrication, dimensions etc.
Development and Testing
• Experiments to be conducted
of a Pendulum Type DVA
for SDOF System
Subjected to Base
Excitation”

Fig 9. Experimental setup for a

pendulum type DVA

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 REVIEW OF LITERATURE
Title of Paper Conclusion Illustrations and Findings

Debangshu Paul, Abdullah • Mathematical models for MR

Moinuddin, “Finite Fluids can utilise Bingham
Element Analysis And Plastic, Bi-viscous, Carreau
Simulation of A Magneto-
Rheological Damper” • Variation of force on the piston
International Journal for vs current in the coil
Innovative Research in
Science & Technology, vol • Dynamic Viscosity vs Shear rate
1, (2014) and its relationship on current Fig 10. Magnetic Field in Damper duct, Force vs Current function,
axisymmetric model of damper

Nguyen Q-H and Choi S- • MR Damper uses combination

B, “Optimal Design of modes.
Methodology of • Flow mode
Magnetorheological Fluid • Shear Mode
Based Mechanisms” , • Valve mode (a) (b)
Journals of Intelligent
Material Systems and Fig 11. Modes of
Structures, 2012 operation : (a) Shear
(c) Mode (b) Squeeze
Mode (c) Valve Mode

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 Objectives

Design of a Complete Dynamic

Design of complete DVA Vibration Neutralizer Set Up

Optimised control system for

MR Damper Analysis of Experimental Data

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 Literature review
Understand the application (vibration profile and any possible constraints)
currently available technology
Scope for improvement

Mathematical model & Control System Part modelling & Analysis Properties of Study & Characterisation of MR Fluids
Using Matlab and Simulink modelling to Parameters Using Ansys and COMSOL to model Damper and MR Fluid by synthesising varied compositions to understand
develop a transfer function and control system DVA, to obtain the preferred design, dimensions etc. variation of MR effect with composition and to identify
for further experimentation the desirable composition for our application

Update parameters & model

Design experimental set up
To closely resemble the real application and to
match optimised properties from simulated model

Simulate any suggested

Fabricate control system Fabricate experimental setup Synthesis Optimised MR Fluid

updation in model
Perform relevant experiments
to simulate real application and identify any set
backs or improvements

Analyse results
Understand the consequence, compare simulation &
experimental results, suggest any updation in model METHODOLOGY
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MATHEMATICAL MODELLING

fd

The equations of motion of the two masses may be

written as:

¨ 1=𝑚𝑒 𝜔 2 𝑠𝑖𝑛 𝜔 𝑡 − 𝑘1 𝑥1 − 𝑘2 ( 𝑥 1 − 𝑥2 ) − 𝑓
𝑚1 𝑥 𝑑

-- -- -- 2

Fig 16 .Simple DVA diagram

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SIMULINK MODEL OF MR DAMPER
Simulation Theoretical

Fig 17 . Simulink model of an MR Damper Fig 18. Force vs displacement and velocity curves for different currents in MR
Damper. (From simulation and from literature)
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SIMULINK SIMULATION

Fig 20 . Bode Plot for the system with and without MRDVA

Fig 19 . Simulink model of an MR DVA using Bingham Plastic Model

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 Design and
Fabrication of
Setup
VIII SEMESTER

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 2. Structural Frame
Experimental Setup –
4. Auxiliary mass
Testing DVA
4. Auxiliary spring

4. MR Damper

3. Primary mass

3. Primary spring

1. Base Excitation System

6. Dimmer

5. Tachometer

Fig. 20 Setup for testing Dynamic vibration

Absorber and comparison to the diagram used to
model it
Fig 19 MR DVA Setup and its components
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 EXPERIMENTAL SETUP – Design iterations

Fig 21. CAD models of experimental set-ups

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Final Design
• Designed and modelled experimental set
up for the testing of MR DVA.
>Made multiple iterations of the experimental setup.
>Identified parts required and created BOM
>Conducted FEM analysis to study the load bearing
capacity of the connector plates.
>Contacted and placed order from manufacturer of
parts

Fig 22. CAD Model of Experimental Set-Up along with

BOM
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 PART DRAWINGS

Fig. 23 2D drawings of the experimental set-up in SolidWorks

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FEM ANALYSIS of Connector Plates

Fig 24. FEM Analysis of the Connector Plates

Analysis of Sliders in the experimental setup. FOS was always above 15

and deflection did not exceed 2 mm.

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COMPONENTS OF THE SETUP

Fig 25. Components of MR DVA Setup

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Base Excitation System

Fig 26 Base Excitation System

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 Sliding Plates

Fig 28 Masses with damper holders

Fig 28 Measuring the weights of the masses

Fig 27 Fabrication of the Slider Plates

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Selection of Springs
REQUIREMENTS Calculating parameters
• Inner diameter = 22 mm = 30 turns
• Stiffness of spring (K) = 1.781 N/mm (G = 81370 Mpa)
• Free length = 15 cm
Pitch (P) = = 5.5 mm
Assumptions Solid Length = 96 mm
• Consider oil hardened and tempered spring steel wire Max. Compression = - = 54 mm
• Diameter of spring wire = 3 mm wire

Checking if conditions are met

• Spring index (C)= 8.33 (5<C<12; Condition met) Table 4. Spring Specifications
  K (N/mm) Free Length Solid Number of Inner dia Outer
• Critical ratio = 50/150 = 0.33 (mm) length active coils (mm) dia (mm)
(mm)
• Lf/Dm = 150/25 = 6
• This is in the Stable region. So no buckling
Spring1(1) 3.562 150 51 15 22 28

Spring1 (2) 1.781 150 96 30 22 28

Spring2(1) 1.37 194 128 30 36 44

Spring2(2) 1.37 194 121.5 38.5 22 28

Spring2(3) 0.68 194 63 19 36 44

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 Testing of the springs
Table 5 Testing results of springs from UTM

Spring name Stiffness Stiffness Remarks

from UTM calculated
experiment during
design
Spring 1 (2) a 1.6122 1.781 𝑘1
Fig 28 Testing of springs from UTM
Spring 1 (2) b 1.6122 1.781 𝑘1
Spring 1 (3) a 1.3364 1.781 𝑘1
Spring 1 (3) b 1.5027 1.781 𝑘1
Spring 2 (1) a 2.5375 1.37 𝑘2
Spring 2 (1) b 2.5979 1.37 𝑘2
Spring 2 (2) a 1.0594 1.37 𝑘2
Spring 2 (2) b 1.2815 1.37 𝑘2

Fig 29 Stress vs Strain Graph of springs

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Selection of bearings

Fig 30. Linear bearing in position

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 CAD Design

Mounts
Spring
Fig 31 CAD model of Spring Mounts

Fig 33 Final Assembled Spring Mount

Fig 32 Springs (left) Final machined Spring mount (right)

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 Table 5. Damper details and specification
Selection of Damper

Fig 34 MagneshoX MR Damper

Fig 35 Dimensions of MagneshoX MR Damper

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 Final Setup
Fig 36 Final Fabricated Experimental Set Up

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 Experimentation and
Results

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Experimental Schematic Diagram

Power Supply Unit Laser Sensor 1

Laser Sensor 2

DAQ

Fig 37 Schematic Experimental Diagram

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 Running of DVA
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 Experiment No.1:
Experiments on the damper setup was performed for two sets of masses as mentioned in design of experiments.
Set 1: m1 = 1.3 kg, m2 = 0.9 kg;
Set 2: m1 = 4 kg, m2 = 0.9 kg;
Objective
1. Confirmation of the natural frequency of the primary system.
Experimental Procedure: The SDOF system comprising of only the base plate and the primary mass will be subjected to
harmonic base excitation with a fixed amplitude. The displacement of primary mass was then observed at different cam rotation
speeds using the laser sensor. Data was captured for about 10 secs. The data generated plotted as Amplitude Ratio versus
Frequency (Hz).
• Natural frequency calculated from the frequency at which maximum amplitude was achieved

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 Results of Experiment 1
Fig 38 Displacement vs Time Graph of Input Vibration

Fig 39 Amplitude vs Frequency Curve for Primary Mass Fig 40 Comparison of Primary mass (Green) vs Input
Vibration ( Blue)
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 Experiment No.2:
Objective
1. Check vibration reduction capability of passive DVA

Experimental Procedure: The 2-DOF system will be subjected to harmonic base excitation
with given amplitude and the system response Xp is to be observed at different cam rotation
speeds. The passive system is designed to provide vibration absorption at the natural
frequency of the SDOF system. This is to be verified.

Fig 41 Sensor data obtained for 1.3 kg mass with vibration neutralizer

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 Experiment No.3:
Objective
1. Obtain MR Damper parameters to fit it into mathematical model

Experimental Procedure: The damper is subject to compression with a linear actuator and F vs x and F vs v curves are
plotted, with the help of a Load cell and accelerometer. This will help obtain Force as a function of I. This data can
then be put into the mathematical model.

Fig 42 Damper test setup using UTM

Fig 43 Force vs Displacement Plot for MR damper
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Parameter Estimation of MR Damper

The hyperbolic tangent function model was The non-linear square fitting technique was
used to represent our MR damper. The used in MATLAB to estimate the parameters
equations of which are given below: of the MR Damper, using the data obtained
from UTM, the results of which are given
below.
Table 6 Results of Estimated Parameters
And the coefficients are expressed according to the
current input as:

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 Experiment No.4:
Objective: Find optimum damping at various input frequency
DEPENDANT VARIABLE: INSTRUMENTS
1) Time taken to reach steady state Instrument: accelerometers attached to
2) Final amplitude of primary mass vibration primary mass to determine amplitude
FACTORS OR INDEPENDENT VARIABLES Instrument: accelerometer/LVDT
1) Current provided to damper
Range: 0-2A
Levels: By changing the input current using Power Supply Unit
2) Amplitude and frequency of Input signal (Motor)
Range: 25 Hz (Max)
Levels: 1. Speed control using DC Motor Control Unit and measured
using tachometer
2. Amplitude and input signal determined by the cam design
3) Secondary Mass
Levels: Adjusting secondary mass

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 Result of Experiment 4
Fig 44 Amplitude vs Frequency curve for MRDVA at different currents

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 Table 7 Optimum Current for Different Frequencies

Result of Experiment 4
Frequency (Hz) Best current % Decrease wrt % Decrease wrt
primary mass passive DVA
alone
10 Passive 92.7% -
11 0.3 A 87.65% 28.8%
12 1A 78.26% 60.55%
13 1A 75.6% 83.3%
14 1A 70.65% 89.7%
15 1A 71.13% 92.5%
16 1A 70.1% 91.92%
17 1A 69.7% 88.48%
18 0A 74.23% 82.3%

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 Experiment No.5:
Objective: To measure the time response spring damper system with different current
input to the damper.
Experimental Procedure: The damper is paired with two springs of stiffness 1.78 N/mm. It
is then compressed to maximum compression and released. Time required to reach is
measured.
Table 8 Response time for different currents

Current to Damper Time required to

move 3mm
0A 1.58825

0.1 A 1.611

0.3 A 3.2475

Fig 45 Time response of currents 0 A (blue), 0.1 A 0.4 A 128.1

(green), 0.3A (pink), 0.4A (yellow)
and 0.5 A (red).

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 absorbers
Passive vibration
Fig 45 Vibration Neutralizer Set-up

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Passive vibration absorbers

Fig 46 Vibration Neutralizer Theoretical Model Fig 47 Theoretical Frequency Response Plot
• Vibration neutralizer is designed to reduce amplitude at
natural frequency

• So,

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 Experimental vibration neutralizer

Fig 48 Amplitude vs Frequency Plot (Experimental vs Theoretical )
The experimental vibration absorber is similar to the
theoretical model.
This helped us verify the stiffness and mass values used
Fig 49 Amplitude vs Frequency Plot ( m1= 1.3Kg)
The highest peak for SDOF system at its natural frequency has
been minimised and replaced with two peaks by the passive
DVA system.
This is seen very clearly form the experimental graph

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 Additional Work
Done

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 Details
DAMPRO MR Fluid
Fig 49. Graphs of MR Damper properties

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STATIC MAGNETIC FIELD ANALYSIS – BH Curve
• MR Fluid does not have a linear B-H relationship
• Add B-H relationship as interpolation function in COMSOL

Using Bingham-Papanastasiou
model \

Fig 50. Surface Magnetic field intensity and flux density

Table 9. Magnetic Field intensity for different number of turns and current

Current through Max magnetic No. of turns Max magnetic flux

coil (A) (N = flux density (T) (I = 0.1 A) density (T) Figure 51 Velocity of flow plot
430)
0.1 0.03 100 6.9e-3

0.2 0.06 200 0.01

1 0.3 430 0.03

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 Force on the Piston (Damping Force)

Table 2. Variation of dependent variables with current in coil

Current Velocity Highest Magnetic Flux

Load (N)
(A) (m/s) density (T)

0 -405.61 0.15 0
0.05 -414.78 0.15
0.1 -423.65 0.15

• Load increases with increase in current

• Load calculated as line integral of load (z) in along the boundary of the piston
• Direction of load is shown in the arrow diagram

Fig 52. Force on Piston (b) Arrow line

diagram (c) Line load diagram
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 MODELLING DAMPER

Fig. 53 MR DVA CAD models incorporating Self Agitator Piston

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 Incorporating energy harvester which
Energy harvester eliminates the need for external power
source

Piezoelectric Energy Harvester

1) Cantilever

Fig 56 Cymbal Type Piezo energy harvester Model

Fig. 54 Schematic diagram of the proposed variable-damping MR

fluid energy harvester
2) Cymbal

Fig. 55  Illustration of PZT transducers lining the interface of DVA and Fig 57 Cantilever Type Piezo energy harvester Model
primary mass.

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 Experimentation with fluid

Fig 58. Anton Paar Rheometer with MRD extension

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Conclusion

• A prototype of MR Fluid based DVA has been designed and fabricated. Corresponding
experimental setup has been developed.
• Testing of the setup was done by collecting data for different rpm, by varying current
input.
• Passive DVA without a damper can clearly eliminate the frequency it is tuned to, here,
the natural frequency of the primary system. Adding the MR damper improves range of
vibration absorption by eliminating additional peaks that may be present in passive
system.
• Different current reading give minimum amplitude at different frequencies. This is
studied and noted, allowing us to give optimum current input by considering this and the
time response.

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PUBLICATIONS
1. N.B Ganga, S.S Mathew, J.A Nathan, T. Jagadeesha, “Modelling and
Simulation of Magneto Rheological Fluid in a Damper using COMSOL”,
Second International Conference on Future Technologies 2021, NIT
Puducherry. Link Conference proceedings will be published in Springer
series entitled : Lecture notes in Mechanical Engineering. ( Scopus indexed)
Status:
Submitted paper and presented in conference, Awaiting publication.
2. N.B Ganga, S.S Mathew, J.A Nathan, T. Jagadeesha, “Design and Validation
of a Dynamic Vibration Neutralizer”, Third International Conference on
Recent Advances in Mechanical Engineering Research and Development
2022, Institute of Technical Education and Research, Bhubaneswar.
Conference proceedings will be published in Materials Today: Proceedings
(Elsevier). ( Scopus indexed)
Status: Submitted paper,
Awaiting acceptance
3. N.B Ganga, S.S Mathew, J.A Nathan, T. Jagadeesha, “Experimentation and
Parameter Estimation of a Magneto-Rheological Damper”, Third
International Conference on Recent Advances in Mechanical Engineering
and Systems Engineering 2022, STEM Research Society. Conference
proceedings will be published in Materials Today: Proceedings (Elsevier).
11/04/2023 NIT CALICUT 51
( Scopus indexed)
Deliverables
PATENT

Patent on “ Innovative Dynamic Vibration Absorber using

MRF Technologies” under the name of Ganga Nair, Nathan
Job Antony, Sebin Sabu Mathew, Krishna Karthik Peri, Dr.
Jagadeesha T, Dr. Varaprasad G and Dr. Srinivas M
Status: Approved by R&C, Applied for Patent

RESEARCH GRANT

Research Grant of Rs. 1,00,000 received under UG/PG Innovation

Project Funding Scheme 2021 vide sanction no R&C/UG
res/Order/2021-4 dated 14/09/2021, approved by Hon Director, NIT
Calicut.

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 [1] A. Roszkowski, M. Bogdan, W. Skoczynski, B. Marek “Testing Viscosity of MR Fluid in Magnetic Field.”

REFERENCES
Measurement Science Review 8 (3), 58-60 (2008)

[2] D. A. Pohoryles, P. Dufour, "Adaptive control of structures under dynamic excitation using magneto-
rheological dampers: an improved clipped-optimal control algorithm". Journal of Vibration Control 21, 2569–
2582.

[3] C. Ciocanel, M. H. Elahinia, Kevin E. Molyet, N. G. Naganathan "Design analysis and control of a
magneto-rheological fluid based torque transfer device", International Journal of Fluid Power, 9:319-24, 2008

[4]Kumbhar, S. B., Chavan, S. P., Gawade, S. S., "Adaptive Tuned Vibration Absorber Based on Magneto-
rheological Elastomer-Shape Memory Alloy Composite," Mechanical Systems and Signal Proc., 100, pp.
208223-208232, 2018

[5] Nitin Ambhore , Shyamsundar Hivarale , Dr. D. R. Pangavhane, “A Study of Bouc-Wen Model of
Magnetorheological Fluid Damper for Vibration Control “, International Journal of Engineering Research &
Technology, Vol. 2 Issue 2, 2013

[6] Quoc-Duy Bui, Quoc Hung Nguyen 3, Tan Tien Nguyen, Duc-Dai Mai, “Development of a
Magnetorheological Damper with Self-Powered Ability for Washing Machines” Appl. Sci. 2020

11/04/2023 NIT CALICUT 53

 THANK YOU

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INNOVATIONS IN DAMPER MODEL
SELF AGITATOR PISTON
• Provide a stirring effect.

• Piston twists slightly as it moves to and

fro.
Fig . 40. Self Agitator Piston views
• Blades on the ends of the piston

Fig. 39 Sedimentation curve for 50% CI-

based MR fluid in three different carrier
oils
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 INNOVATIONS IN DAMPER MODEL
Electromagnetic Induction method

• Permanent magnet at the end of the piston surrounded by induction coils.

• As the piston moves back and forth it induces current in the coil.

Fig 41. Schematic of the proposed self-powered shear-mode magnetorheological (MR) Fig 42. Schematic diagram of Energy Harvester component
damper.

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Modelling Magneto rheological properties - static

Governing Equations

Where,

Here,

• To add magneto-rheological properties to the model, we add a Yield

Stress vs Magnetic Field Strength graph

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