Design and Manufacturing Aspects of Magneto-Rheological Fluid (MRF) Clutch
Design and Manufacturing Aspects of Magneto-Rheological Fluid (MRF) Clutch
Design and Manufacturing Aspects of Magneto-Rheological Fluid (MRF) Clutch
Abstract
This paper describes a research work concerned with design method and manufacturing
details of a Magneto-rheological Fluid (MRF) Clutch which has a multi-layered disks and
micro-size (1 milli meters) gaps of MR fluid for automotive applications. Magneto-
rheological Fluid devices are finding a wide variety of applications to meet the new market
demand. An MR fluid will be in a free-flowing liquid state in the absence of magnetic
field, but under a strong magnetic field its viscosity can be increased by more than two
orders of magnitude in a very short time (milli seconds) and it exhibits solid-like
characteristics. Various devices working with MR fluids include Clutches, Brakes,
Hydraulic valves, dampers, robotic arms. The micro-size gap works for the reduction of
magnetic resistance, amount of power supply and size of the total system. The
controllability of MR fluids provides an adjustable torque transmission and slippage for the
applications. Three-dimensional solid modeling is performed for clutch design and
manufactured. The benefits with using MRF are fast response, simple interface between
electrical power input and mechanical power output and of course the excellent
controllability of the fluid. MRF clutches are known as good Torque transmitting devices.
Magneto rheological fluid is one of the smart materials which are gaining importance in
current scenario.MR fluids find applications in dampers, brakes etc. nowadays. Viscosity of
MR Fluids can be temporarily increased or decreased within a fraction of second, so that we
can vary the torque whenever we require. This property makes MR Fluid a perfect material for
clutch operations. Convectional friction clutch has high heat generation, frequent maintenance
and replacement of clutch plates. The aim of this work is to develop a magneto rheological
clutch (MRC) system that has performance advantages over the conventional friction clutches.
The proposed clutch system consist of rotating discs immersed in a MR fluid and enclosed in
an electromagnet which the yield stress of the fluid varies as a function of the magnetic field
applied by the electromagnet. The controllable yield stress causes friction on the rotating disk
surfaces thus transferring the torque.
1. Introduction
MR devices are playing a vital role now a days. Magneto-rheological fluid (MRF)
clutches are used in several automotive systems such as auxiliary engine devices, active
differentials, and automatic transmissions. MR Fluids are magnetically polarizable
particles suspended in viscous fluids. They have the ability to change their rheological
properties as shear modulus and viscosity reversibly in milliseconds when subjected to
varying magnetic fields. While the magnetic particles are randomly distributed in the liquid
when no magnetic field is applied, they form chains in the presence of a magnetic field,
and as a result rheological properties of the fluid increase. Typically, the magnetizable
particles are metal or metal oxide particles with size of on the order of few microns.
Magneto- rheological fluids are the suspensions of micron sized, magnetizable particles
(iron, iron oxide, iron nitride, iron carbide, carbonyl iron, chromium dioxide, low-carbon
steel, silicon steel, nickel, cobalt, and combinations there of in an appropriate carrier liquid
(non-magnetizable) such as mineral oil, synthetic oil, water or ethylene glycol. The carrier
liquid serves as a dispersed medium and ensures the homogeneity of particles in the fluid.
Nowadays there are a lot of researchers are undergoing on developing smart materials. These
smart materials can perform same function done by the conventional materials much smarter
and economical. Magneto rheological fluids are such kind of smart material. It has a large area
of application and lots of researchers are pursuing on that. MR fluid is very responsive to
magnetic field, with an estimated time of less than 10 micro seconds and requires relatively
low power to operate. Nowadays the traditional mechanical system are being replaced by
improved electro mechanical systems that are able to do the same tasks faster, more reliably
and more accurately.
on the application of a magnetic field. So when we give a magnetic field the fluid gets
solidified and it makes a rigid joint between the input and output shafts and transfer the
torque. And if there is no electric field, the fluid is purely a liquid and input shaft freely
rotates in that fluid.
Magneto rheological (MR) fluids are materials that respond to an applied field with a
dramatic change in their rheological behavior. The essential characteristic of these fluids is
their ability to reversibly change from a free-flowing, linear, viscous liquid to a semi-solid
with controllable yield strength in milliseconds when exposed to a magnetic field.
2.1Chemical composition
A typical MR fluid consists of 20%–40% by volume of relatively pure, soft iron particles,
typically 3–5 microns, suspended in a carrier liquid such as mineral oil, synthetic oil, water, or
glycol. A variety of proprietary additives similar to those found in commercial lubricants are
commonly added to discourage gravitational settling and promote particle suspension,
enhance lubricity, modify viscosity, and inhibit wear.
2.2Physical properties
MR fluids made from iron particles exhibit maximum yield strengths of 30–90 kPa for applied
magnetic fields of 150–250 kA/m (1 Oe . 80 A/m). MR fluids are not highly sensitive to
moisture or other contaminants that might be encountered during manufacture and use.
Further, because the magnetic polarization mechanism is not affected by the surface chemistry
of surfactants and additives, it is a relatively straightforward matter to stabilize MR fluids
against particle-liquid separation in spite of the large density mismatch.
The ultimate strength of the MR fluid depends on the square of the saturation magnetization
of the suspended particles.
2.4 MR FLUID
MR fluids are created by adding micron-sized iron particles to an appropriate carrier fluid
such as oil, water or silicon. Their rheological behaviour is nearly the same as that of the
carrier fluid when no external magnetic field is present. However, when exposed to a
magnetic field, the iron particles acquire a dipole moment aligned with the applied magnetic
field to form linear chains parallel to the field. This reversibly changes the free flowing liquid
to semisolids that have a controllable yield strength, which depend son the magnitude of the
applied magnetic field. The magnetic field dependent fluid characteristics of MR fluids can be
described by a simple Bingham plastic model. As illustrated in Fig.1, in this model, the total
shear stress is given by
τ=τy(H)+ηγ (1)
Where τy is the yield stress due to the applied magnetic field H, ηis the constant plastic
viscosity, which is considered equal to the no-field viscosity of the fluid, and γ is the shear-
strain rate. Here, the plastic viscosity is defined as the slope between the shear stress and
shear-strain rate as shown in fig.1, which is the traditional relationship for
Newtonian fluids.
True behaviour of MR fluids exhibits some significant departures from the Bingham model in
the absence of a magnetic field (i.e., lp ¼ lpð_c;HÞ).. However, if used properly Eq. (1)
provides a useful basis for the design of MR fluid-based devices, and the simple Bingham
model is still very suitable for the initial design phase.
Material whose rheological properties can be varied by application of magnetic fields belong
to a specific class of so called smart materials because they can respond, via solid state
electronics and modern controlled algorithms, to change in their environment. These materials
in the fluid responds to applied magnetic fields and are thus referred to as magneto rheological
materials. Such materials can be utilized in devices or can be incorporated in traditional
composites to form advanced intelligent composite structures, whose continuum magneto-
rheological response can be actively controlled in real time. Applications that can be benefit
from materials whose rheology can be continuously, rapidly and reversibly varied are
numerous.
The viscosity of controllable fluids in the absence of a field is most significantly a function of
the carrier oil, suspension agents, and particle loading. Rheological figure of merits of
controllable fluids benefit from low fluid viscosity, but be balanced with other fluid
requirements such as temperature range and particle resuspendability. Because of the
inclusion of the suspension agents and changes in particle microstructure during shear, most
MR fluids exhibit significant shear thinning.
3. MR Fluid Characteristic
Fig.1: Activation of MR fluid: (a) no magnetic field applied; (b) magnetic field applied ;(c) Ferrous
particle chains have formed .
The viscous fluid can be a non-magnetic liquid, usually oils. Additionally surfactants are
used to allow for high particle volume fractions of the MR fluids that can yield higher
variations in the rheological properties, and increase the fluid’s stability against
sedimentation. Figure 1 illustrates a schematic diagram of MR fluids with and without a
magnetic field applied. Depending on the type of the magnetic particles, viscous fluids and
their volume rate, the rheological properties of MR fluids vary. The viscosity of MR fluids
can vary between 0.2 to 0.3 pascals at 25° C. MR fluids are being considered in variety of
energy dissipation and transfer devices such as shock absorbers, clutches, brakes, and
engine mounts.
The yield stress developed within the MR fluid is a function of the applied magnetic
field. However, once this yield stress is exceeded, the behavior of the MR fluid deviates
from that of a Bingham-Plastic. This is attributable to the breakdown of the chains of
particles under the forces of the fluid flow, and results in a shear-stress/shear-rate
characteristic that is highly non-linear. When used in a damping device, the result is a
damper whose force/velocity characteristic is non-linear, but can be changed by the way
the magnetic field is applied .They are field responsive in nature and the magneto-
rheological response of these Fluids is in the fact that the polarization is induced in the
suspended particles by the application of an external magnetic field.
This allows the fluid to transform from freely flowing liquid state to solid-like state
within milliseconds, because the magnetically dispersed particles attract each other to form
fibril/chain-like structures along the direction of magnetic field. The chain-like structures
resist the motion of the Fluid and increase viscous characteristics.
The variation of yield stress with magnetic field strength and also the variation of
Magnetic induction with Magnetic flux density are shown in figure2 and figure 3.
Having great potential for engineering applications due to their variable rheological
behavior, MR fluids find applications in dampers, brakes, shock absorbers, suspensions,
clutches and engine mounts. The key defects that affect their applications are
sedimentation (gravitational settling), poor dispersion stability and corrosion of the
suspended magnetic particles. In order to resolve these, a variety of proprietary additives,
similar to those found in commercial lubricants are commonly added to MR fluid to
enhance lubricity, modify viscosity and inhibit wear.
MR fluids are increasingly being considered in variety of devices such as shock absorbers,
vibration insulators, brakes or clutches. The activation of MRF clutch’s built-in magnetic field
causes a fast and dramatic change in the apparent viscosity of the MR fluid contained in the
clutch. The fluid changes state from liquid to semi-solid in about 6 milliseconds. The result is
a clutch with an infinitely variable torque output.
Bansbach, proposed a double-plate and a multi-plate MRF torque transfer apparatus with a
controller that adjusts the input current. The apparatus is proposed to be placed between the
engine of a car and its differential. Gopalswamy suggested a MRF clutch to minimize
reluctance for fan clutches. Gopalswamy also studied a controllable multi-plate MR
transmission clutch. This clutch was also designed to be placed between the engine and
differential. Hampton described a design of MRF coupling with reduced air gaps and high
magnetic flux density. Carlson proposed a MR brake with an integrated flywheel.
The MR fluid is located in the gap between the input and output plates, with the diameter of
51.94 mm. These plates are connected to 30 mm diameter input and output shafts. The shafts
are supported by deep groove ball bearings, which are press-fitted into the side caps. The
electromagnet circuit of this clutch consists of an electromagnetic coil, which is wound
around an electromagnetic core. This assembly is located inside a 152.4 mm outer diameter
casing with 6.35 mm wall thickness, which is also acting as a return path for the magnetic
field. Two O-rings are located in the grooves machined on the circumferences of plates to
prevent leakage of MR fluid. The MRF clutch is activated by a power supply connected to
two ends of the electromagnet. The total width of the clutch is 31.75 mm.
A magneto rheological fluid clutch consists of a input shaft that rotates and which carries
an input clutch plate and a housing with front and rear covers. The bearings are provided
which support the housing on the input shaft. The Magneto rheological fluid is filled in the
gaps between the plates of input and output shaft through which the torque is transferred.
An electromagnetic coil is placed radially outside the nonmagnetic spacer, which generates
a variable electric current to effect variable magnetic field across the input clutch plate and
through the magneto rheological fluid enabling variable torque transmission between input
clutch plate and the core. A multi plate torque transfer device that is a MRF clutch is
designed and developed which is shown in the figure 4.
A uniform magnetic fields is generated from the magnetic circuit in the housing .
The output shaft is 79 mm in diameter and fits in the outer disc/housing assembly with a 1
mm gap on either side for the MR fluid. A stationary electromagnetic coil is placed around
the clutch with a steel shell enclosure to direct the magnetic field to the active regions of
the clutch. The electromagnetic coil has 750 turns.
Fig.6.MRF
Figure 4 shows a cross section of the MRF clutch and figure 5, shows the 3D model of
the MRF clutch. Figure 7 shows the manufactured MRF Clutch Assembly.
The gap for MR fluid is 1mm between each plate. Spacers are located in between each
set of input and output plates to set the MR fluid thickness fixed and to arrest the
disposition of plates. Two alignment bearings are fixed to arrest the off-axis rotation of the
clutch pack and also to position the centers of both shafts. The magnetic circuit of the
clutch composes of an electromagnetic coil made of copper wire which has 750 windings.
The clutch pack and the electromagnet circuit are placed inside a 152.4 mm outer diameter
casing, which also acts as a return path for the magnetic field. The total length of the clutch
is 119mm.Shaft and the output plates are made to glide on to the spline of the inner casing.
5 . DESIGN OF MR CLUTCH
A basic configuration of MR Clutch for automotive is shown in fig 2. In addition, some of the
key practical design considerations were also included during the design process, e.g. sealing
of the MR fluid and the viscous torque generated within the MR Clutch due to MR fluid
viscosity.
The main goal of the magnetic circuit analysis is to direct the maximum amount of the
magnetic flux generated by the electromagnet onto the MR fluid located in the gap. This will
allow the maximum torque to be generated .The magnetic circuit in the MR clutch consists of
the coil winding in the electromagnet, which is the magnetic flux generating ‘‘source” and the
flux carrying path. The path provides resistance over the flux flow, and such resistance is
called reluctance (Ɽ). The total reluctance of the magnetic circuit is the sum of the reluctances
of the wire and the gap, which consists of the MR fluid and the clutch disk.
The flux generated (φ) in a member of the magnetic circuit can be defined as
φ = ni/R = mmf/R
Where,
Ɽ = 1/Uav
In Eq. (2), where ‘n’ is the number of turns in the coil winding and ‘I’ is the current applied;
in Eq. (3), μ is the permeability of the member, A is its cross-sectional area, and l is its length.
Recall that in order to increase the torque, the flux flow over the MR fluid needs to be
maximized. This implies that the reluctance of each member in the flux path of the flux flow
has to be minimized, which in turn implies that l can be decreased or/and l and A can be
increased. Since the magnetic fluxes in the gap (φ) can be directly calculated as the ratio
between the MMF and the total reluctance of the magnetic circuit.
In terms of structural considerations, there are two critical parts: the shaft and the clutch disk.
The shaft should be non ferromagnetic in order to keep the flux far away from the seals that
enclose the MR fluid (to avoid from MR fluid being solidified). Stainless steel is a suitable
material for the shaft due to its high yield stress and availability. For the clutch disk material,
already chosen AISI 1018 has a high yield stress. The remaining parts are not under any
considerable structural loading. Thermal properties of the materials are another important
factor. Due to the temperature dependent permeability values of the ferromagnetic materials
and the MR fluid viscosity, heat generated during shearing should be removed as quickly as
possible. In terms of material properties, in order to increase the heat flow from the clutch
disk, a material with high conductivity and high convection coefficient has to be selected as
materials for the non-magnetic clutch components. Aluminium is a good candidate material
for the thermal considerations.
5.3 Sealing
Sealing of the MR clutch is another important design criterion. Since MR fluid is highly
contaminated due to the iron particles in it, the risk of sealing failure is increased. In addition,
in the case of dynamic seals employed between the static casing and the rotating shaft, MR
fluid leakage would occur if the fluid was repetitively solidified around the vicinity of the
seals. In this work, the dynamic seals were kept away from the magnetic circuit by
introducing a non-ferromagnetic shaft and clutch disk support outside the circuit which holds
the magnetic clutch disks. Also the surface finishes were improved and the tolerances were
kept tight for better interface between the seals and the counterpart surfaces.
Coil is another important design criterion, as it is the source (i.e. mmf) in the magnetic circuit.
The current density that can be applied to the electromagnet coil is limited, which depends on
the cross-sectional area of the coil, its material, and the saturation flux densities of the
magnetic materials used in the MR clutch. When the saturation flux value of a magnetic
material has been reached, it will behave as non-magnetic material (i.e. μr becomes 1),
affecting the corresponding reluctance in the magnetic circuit. Thus, it is beneficial to keep
the flux in the unsaturated region for that material In order to maximize the amount of applied
current density, the dimensional space of where the coil is located is also optimized along
with the other dimensional parameters. In addition, a wire size that can generate the highest
current density was selected: AWG 21 (Ø 0.77 mm).
6 .WORKING
These materials in the fluid responds to applied magnetic fields and are thus referred to as
magneto rheological materials. Such materials can be utilized in devices or can be
incorporated in traditional composites to form advanced intelligent composite structures,
whose continuum magneto-rheological response can be actively controlled in real time.
Applications that can be benefit from materials whose rheology can be continuously, rapidly
and reversibly varied are numerous. The most common MR materials are of liquid state. The
controllable rheological response of such fluids results from the polarization induced in the
suspended particles by application of an external magnetic field. The interaction between the
resulting induced dipoles causes the particles to form columnar structures, parallel to the
applied field.
These chains like structure restrict the flow of the fluid, thereby increasing the viscous
characteristics of the suspension. The mechanical energy needed to yield these chains like
structures increase as the applied magnetic field increase resulting in a field dependent yield
stress. In the absence of an applied field, the controllable fluids exhibit Newtonian like
behaviour. MR fluid is filled in the casing and the fluid is there between the disc and the
aligned electro magnets. The electro magnets are arranged so that the field of the magnet is
directly focussed towards the fluid area. The electro magnet in the assembly is worked by
using a 12 volt battery.
MR fluid is composed of particles suspended in a carrier fluid such as oil. When a magnetic
field is applied the magnetic particles will align and form chains and solid like structures
within the fluid.
In disengaged phase the MR fluid filled between the shafts are not magnetically excited and
the magnetically polarisable particle will be dispersed in carrier fluid in random manner as
shown in fig.4.So whenever the shaft is rotating the fluid could not provide the resistance to
shear due to low viscosity and is sheared off easily. Thus the power from the shaft will not be
transmitted to the output shaft.
During engaged phase MR fluid is excited by passing current through the electromagnetic
from a battery. Magnetic field will be generated in the region of MR fluid. This causes
suspended magnetically polarisable particles in MR fluid to become magnetic dipoles and
attract each other and align according to the magnetic field as shown in fig.5. This results in
an immediate stiffening of the MR material and helps in transferring torque.
Now under commercial development are very large MF fluid dampers designed for seismic
damage mitigation in civil engineering structures such as buildings and bridges.
Book makers could publish rippling magnetic texts in Braille that blind readers could actually
scroll and edit. It might even be possible to train student surgeons using synthetic patients
with MR organs that flex and slices like the real thing. New developments in MR fluid
technology allow the use of permanent magnets which has lots of advantages. The question
often arises asking if it is possible to use a permanent magnet to bias a MR fluid valve or
device at a mid-range condition. Current could then be applied to the accompanying
electromagnetic coil to cancel the magnetic field and open the valve.
Alternatively, a reverse current could be applied to the coil to add to the magnetic field taking
the device to a higher–range condition. One motivation for creating such a system is to
provide a fail-safe mode of operation wherein the device remains in a locked condition when
power is lost. Another motivation may be energy conservation in systems intended to remain
closed or locked for extended periods of time and then only open momentarily.
Magneto-liquid mirror telescopes that bend and deform to cancel the twinkling of starlight.
Prosthetic limbs for humans (a prosthetic knee based on Lord Corporation MR fluid
technology is already available.)
Active engine mounts that reduce vibration and quiet noise before it can get into a vehicle.
Shock absorbers for payloads in the space shuttle.
Active hand grips that conform to the shape of each individual hand or fingers.
9. CONCLUSION
By this project, a magneto rheological clutch design has been introduced as a viable
alternative to the current conventional friction clutches. Since the MRC is an
electromechanical device, it has several advantages over conventional one, such as reduced
actuation delay, ease of software control, temperature reduction. The design process was
started with an analytical model of the MRC.
Then the MRC device was designed with a focus on magnetic circuit optimization and
material selection. From that design considerations we develop a working model of MRC.
And it is found that the MRC have quicker response time than that of conventional clutches .
The exploitation of hybrid magnetic circuits offers the possibility to reverse the operational
states of MR clutches. If the clutch is engaged in the usual operational state, this engagement
can be maintained simply by the supply of electric energy. Only for a short disengagement of
the clutch, electric energy in terms of the coil current has to be supplied.
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