No abstract

Magnetorheological energy absorbers (MREAs) provide adaptive vibration and shock mitigation capabilities to accommodate varying payloads, vibration spectra, and shock pulses, as well as other environmental factors. A key performance metric is the dynamic range, which is defined as the ratio of the force at maximum field to the force in the absence of field. The off-state force is typically assumed to increase linearly with speed, but at the higher shaft speeds occurring in impact events, the off-state damping exhibits nonlinear velocity squared damping effects. To improve understanding of MREA behavior under high-speed impact conditions, this study focuses on nonlinear MREA models that can more accurately predict MREA dynamic behavior for nominal impact speeds of up to 6 m s−1. Three models were examined in this study. First, a nonlinear Bingham-plastic (BP) model incorporating Darcy friction and fluid inertia (Unsteady-BP) was formulated where the force is proportional to the velocity. Second, a Bingham-plastic model incorporating minor loss factors and fluid inertia (Unsteady-BPM) to better account for high-speed behavior was formulated. Third, a hydromechanical (HM) analysis was developed to account for fluid compressibility and inertia as well as minor loss factors. These models were validated using drop test data obtained using the drop tower facility at GM R&D Center for nominal drop speeds of up to 6 m s−1.

SynopsisParticle-level simulations are employed to investigate the rheological properties of bidisperse magnetorheological fluids. These suspensions are treated as nonlinearly magnetizable, neutrally buoyant, non-Brownian spheres immersed in a nonmagnetizable Newtonian continuous phase. We examine the effects of particle size ratio, composition, and field strength on the dynamic yield stress. The dynamic yield stress of bidisperse suspensions is larger than that of monodisperse suspensions at the same particle volume fraction. The smaller particles cause the larger particles to form more chainlike aggregates than those formed in monodisperse suspensions.

A key challenge when designing linear stroke magnetorheological energy absorbers for high-speed impact is that high piston speeds in linear stroke magnetorheological energy absorbers induce high Reynolds number flows in the magnetic valve of the magnetorheological energy absorber, so that achieving high controllable dynamic range can be a design challenge. So far, the research on magnetorheological energy absorbers has typically assumed that the off-state force increases linearly with piston velocity. But at the higher piston velocities occurring in impact events, the off-state damping exhibits nonlinear velocity squared damping effects. This problem was recognized in our prior work, where it was shown that minor losses are important contributing factors to off-state damping. In this study, a nonlinear analytical magnetorheological energy absorber model is developed based on a Bingham-plastic nonlinear flow model combined with velocity squared dependent minor loss factors. This refined model is denoted as the Bingham-plastic nonlinear flow model with minor losses. From this Bingham-plastic nonlinear flow model with minor losses, an effective design strategy is presented for conventional magnetorheological energy absorbers. The Bingham-plastic nonlinear flow model with minor losses is validated via computational fluid dynamics simulation, so that magnetorheological energy absorber performance can be analytically verified before being manufactured. The magnetorheological energy absorber is fabricated and tested up to an effective piston velocity of 5 m/s by using the high-speed drop tower facility at the GM R&D Center. Comparison of our analysis with measured data is conducted, and the effective design of the magnetorheological energy absorber using the Bingham-plastic nonlinear flow model with minor losses is validated.

Experimental results illustrate an enhancement in the field-induced yield stress of magnetorheological (MR) fluids caused by the presence of nonmagnetizable particles. Particle-level simulations in three dimensions show similar behavior. However, the enhancement does not appear in simulations in which the spheres are confined to a monolayer. A mechanistic explanation of these observations is currently lacking. Nonetheless, the ability to enhance the MR response by replacing magnetizable particles with nonmagnetizable particles offers several advantages for applications.