Abstract
Online control of braking performance of magneto-rheological (MR) brake by bridling the apparent viscosity of MR fluid and by amending magnetic field is considered as an effective and smart option to replace the conventional disc brake. The magnetic field procreated by electromagnet in MR brake is reliant on dimensions and material properties of MR brake (casing, rotor and MR fluid region). Extensive works have been reported on enhancing the magnetic properties of MR fluid to achieve maximum braking performance; however, scarce works are available that reflects that the dimensions of MR brake influence the braking performance. Prior works on MR brakes focus on designing for meticulous outer dimensions of brakes, and thus, their results find little utility to a new designer. Therefore, the objective of the present work is to propose a methodology to determine the dimension of MR brake for a given outer dimensions, which shall provide maximum braking performance. The, braking performance is evaluated by assessing the effective torque and brake density. Magneto-static analysis using ANSYS is employed for determining the magnetic field in the MR region, and thereafter, the braking torque is calculated. From the obtained results, curve fit equations are proposed to estimate the values of (i) MR brake casing thickness, (ii) height of the MR brake to rotor, (iii) thickness of core, and (iv) thickness of MR fluid region, for achieving maximum torque. To validate the proposed methodology, MR brake with two different electromagnets and rotors is developed. The static performance of MR brake is evaluated by measuring the braking torque for different currents using a torque wrench and the dynamic performance of the MR brakes is performed on an MR brake test setup. The dynamic performance is evaluated by measuring viscous torque. Finally, the comparisons of the theoretical and experimental results are performed and the obtained results are presented.
Similar content being viewed by others
References
Park EJ, Luz LF, Suleman A (2009) Multidisciplinary design optimization of an automotive magnetorheological brake design. Comput Struct 86:207–216
Sohn JW, Jeon J, Nguyen QH, Choi SB (2015) Optimal design of disc-type magneto-rheological brake for mid-sized motorcycle: experimental evaluation. Smart Mater Struct 24:1–11
Lijesh KP, Kumar D, Hirani H (2017) Synthesis and field dependent shear stress evaluation of stable MR fluid for brake application. Ind Lubr Tribol 69(5):655–665
Karakoc K, Park EJ, Suleman A (2008) Design considerations for an automotive magnetorheological brake. Mechatronics 18:434–447
Poznić A, Zelić A, Szabó L (2012) Magnetorheological fluid brake basic performances testing with magnetic field efficiency improvement proposal. Hung J Ind Chem 40(2):107–111
Sarkar C, Hirani H (2015) Development of a magnetorheological brake with a slotted disc. Proc Inst Mech Eng Part D J Automob Eng 229:1907–1924
Lijesh KP, Deepak K, Hirani H (2017) Effect of disc hardness on MR brake performance. Eng Fail Anal 74:228–238
Bhau K, Satyajit RP, Suresh MS (2015) Synthesis and characterization of magneto-rheological (MR) fluids for MR brake application. Eng Sci Technol 18:432–438
Jun JB, Uhm SY, Ryu JH, Suh KD (2005) Synthesis and characterization of monodisperse magnetic composite particles for magnetorheological fluid materials. Coll Surf A Physicochem Eng Aspects 260:157–164
Nguyen PB, Choi SB (2012) A bi-directional magnetorheological brake for medical haptic system: optimal design and experimental investigation. Adv Sci Lett 13:165–172
Park EJ, Stoikove D, da Luz LF, Suleman A (2006) A performance evaluation of an automotive magnetorheological brake design with a sliding mode controller. Mechatronics 16:405–416
Assadsangabi B, Daneshmand F, Vahdati N, Eghtesad M, Bazargan LY (2011) Optimization and design of disk-type MR brakes. Int J Automot Technol 12(6):921–932
Shamieh H, Sedaghati R (2016) Design optimization of a magneto-rheological fluid brake for vehicle applications. In: ASME 2016 conference on smart materials, adaptive structures and intelligent systems. American Society of Mechanical Engineers
Li WH, Du H (2003) Design and experimental evaluation of a magneto- rheological brake. Int J Adv Manuf Technol 21(7):508–515
Sumukha M H, Sandeep R, Vivek N, Lijesh K P, Kumar H, Gangadharan KV (2017) Design and development of magneto-rheological brake for optimum casing thickness. In: International conference on innovative mechanisms for industry applications (ICIMIA), pp 704–709
Shivaram AC, Gangadharan KV (2007) Statistical modeling of a magneto-rheological fluid damper using design of experiments approach. Int J Smart Mater Struct 16:1310–1314
Sarkar C, Hirani H (2013) Theoretical and experimental studies on a magnetorheological brake operating under compression plus shear mode. Smart Mater Struct 22(11):115032
Resiga SD (2009) A rheological model for magneto-rheological fluids. J Intell Mater Syst Struct 20(8):1001–1010
Wang DM, Hou YF, Tian ZZ (2013) A novel high-torque magnetorheological brake with a water cooling method for heat dissipation. Smart Mater Struct 22(2):025019
Tao R (2001) Super-strong magnetorheological fluids. J Phys Condens Matter 13(50):R979
Hartman N, Rimmer RA (2001) Electromagnetic, thermal, and structural analysis of RF cavities using ANSYS. Proc Part Accel Conf 2:912–914
Piłat A (2004) FEMLab software applied to active magnetic bearing analysis. Int J Appl Math Comput Sci 14:497–501
Lijesh KP, Hirani H (2015) Development of analytical equations for design and optimization of axially polarized radial passive magnetic bearing. J Tribol 137:011103
Acknowledgements
Authors acknowledge the funding, technical, instrumentation support, and experimental facility from the Center for System Design Lab: A Centre of excellence at NITK Surathkal.
Author information
Authors and Affiliations
Corresponding author
Additional information
Technical Editor: Pedro Manuel Calas Lopes Pacheco.
Rights and permissions
About this article
Cite this article
Lijesh, K.P., Kumar, D. & Gangadharan, K.V. Design of magneto-rheological brake for optimum dimension. J Braz. Soc. Mech. Sci. Eng. 40, 161 (2018). https://doi.org/10.1007/s40430-018-1089-5
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s40430-018-1089-5