Magnetic Circuit Design

Research Article
Magnetic Circuit Design and Multiphysics Analysis of

a Novel MR Damper for Applications under High Velocity
Jiajia Zheng,
1
Zhaochun Li,
1,2
JeongHoi Koo,
3
and Jiong Wang
1
1
School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing 210094, China
2
School of Mechanical Engineering, Nanjing Forestry University, Nanjing 210037, China
3
Department of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH 45056, USA
Correspondence should be addressed to Jiong Wang; wjiongz@mail.njust.edu.cn
Received 16 November 2013; Revised 10 January 2014; Accepted 11 January 2014; Published 27 February 2014
Academic Editor: Weihua Li
Copyright 2014 Jiajia Zheng et al. Tis is an open access article distributed under the Creative Commons Attribution License,
which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
A novel magnetorheological (MR) damper with a multistage piston and independent input currents is designed and analyzed.
Te equivalent magnetic circuit model is investigated along with the relation between magnetic induction density in the working
gap and input currents of the electromagnetic coils. Finite element method (FEM) is used to analyze the distribution of magnetic
feld through the MR fuid region. Considering the real situation, coupling equations are presented to analyze the electromagnetic-
thermal-fowcoupling problems. Sofware COMSOL is used to analyze the multiphysics, that is, electromagnetic, thermal dynamic,
and fuid mechanic. A measurement index involving total damping force, dynamic range, and induction time needed for magnetic
coil is put forward to evaluate the performance of the novel multistage MR damper. Te simulation results showthat it is promising
for applications under high velocity and works better when more electromagnetic coils are applied with input currents separately.
Besides, in order to reduce energy consumption, it is recommended to apply more electromagnetic coils with relative low currents
based on the analysis of pressure drop along the annular gap.
1. Introduction
Magnetorheological fuid (MRF) is a kind of controllable or
smart fuids whose rheological properties can be dramatically
and reversibly varied by the application of an external mag-
netic feld in milliseconds [1]. Generally, MR fuid behaves
like an ordinary Newtonian fuid, when exposed to a mag-
netic feld, and the metal particles are guided by the magnetic
feld to form a chain-like structure and it becomes a grease
state. MRfuid technology has been investigated in or applied
to a variety of shock and vibration isolation systems, such
as shock absorbers, clutches, polishing devices, actuators [2],
hydraulic valves, gun recoil systems [3, 4], railway vehicles [5,
6], military suspension systems [79], and seismic isolation
systems for civil infrastructures [10, 11].
Magnetorheological dampers (MRDs) have been rela-
tively successful in most of the shock and vibration mitiga-
tion system. For the low-speed applications, fortunately, the
requirement for the damping force performances of the MR
damper is less demanding. Te traditional MR dampers with
annular gap [12] or utilizing bypass valves [11, 13, 14] could
provide a reasonable performance for the semiactive control
systems. However, the dynamic range of the conventional MR
dampers, which is ofen defned by the ratio of feld-on to
feld-of damper force, decreases signifcantly with increasing
piston speed (V > 3 m/s) due to the increase of the viscous
damping force (i.e., feld-of damper force) [15]. In order to
meet the requirements of the dynamic force range, Mao et al.
[16] proposed and experimentally tested an MR damper with
bifold valves. Bai et al. [15] proposed a biannular-gap MRD
with an inner-set permanent magnet to decrease the baseline
damper force (i.e., the negative current case for the biannular-
gap MRD) at high speed while keeping the appropriate
dynamic force range for improving shock and vibration miti-
gation performance. Becnel et al. [17] designed and tested an
MRdamper to control both the shock and loads and vibration
for crew seat of an EFV. Teir investigation results indicate
that the maximum damping force and dynamic range at
high velocity can be improved to some extent by changing
Hindawi Publishing Corporation
Advances in Mechanical Engineering
Volume 2014, Article ID 402501, 16 pages
http://dx.doi.org/10.1155/2014/402501
2 Advances in Mechanical Engineering
1 2 3 4 5 6
7 8 9 10 11 12
(2) Piston head
(1) Piston rod
(3) Wire-leaded hole
(4) Guide head
(5) Cylinder
(6) Rear sealing ring
(7) Rear cover
(8) MR uid
(9) Exciting coils
(10) Overow hole
(11) Front sealing ring
(12) Front cover
(a)
Jiont parts
Sealing ring
Force sensor Piston head
Piston rod
Cylinder
(b)
Figure 1: Novel MR damper: (a) schematic of the designed damper; (b) photograph of the designed damper.
the dimensions. However, for applications with higher speed,
more investigations on MR fuid fow exposed to extern-
al magnetic feld are needed to design high efcient MRDs,
which can provide maximum dynamic range as well as large
damping force.
In the impact bufer system, MR dampers have shown
promising advantages inreplacing the conventional hydraulic
absorbers [7, 8, 18]. Due to the controllable forces provided by
MRtechnologies, the lighter weapons could be designed with
increasing fring power and more mission fexibility [19, 20].
However, most researches on MR fuids or devices subjected
to impact loadings are focused on their behaviors. Little work
has been done considering the multiphysics coupling in
MR damper, which in fact is a highly nonlinear multidisci-
plinary problem with coupling from electromagnetic, fow
mechanism, thermal dynamic, structural force, and so on.
Particularly, optimal design and control of MR devices based
on multiphysics turn out to be more challenging.
Tis research aims to analyze a novel MR damper with
multicoil confguration which works under fring impact
loading conditions. Trough theoretical analysis of the mul-
tiphysics in MR damper, coupling equations are presented
to describe the real situation. Ten, the novel MR damper
with multistage coil is designed and manufactured in order
to obtain the optimal results of larger damping force, higher
dynamic range, and less induction time needed for magnetic
coil. Finally, by comparing the proposed measurement index,
the simulation results show that the novel damper is promis-
ing for applications under impact loading and high shear
rate and it works better when multiple coils are applied with
input currents. Besides, in order to reduce the total energy
consumption, it is recommended to apply multiple coils with
relative low current and reasonable control strategy enabling
the impact force bufered in a more smooth and steady way.
2. A Novel Magnetorheological Damper
Figure 1 displays the schematic and a photograph of the novel
MR damper. Te number of turns of each coil is 500 with
0.69 mm diameter copper wire. Te enameled wires come
from the wire-leaded hole 3 and wind around the groove
to form four parallel magnetic circuits. Tere are four wire-
leaded holes inside the piston, so each coil can be applied
with input current separately. Tus, the magnetic feld route
is composed of the cylinder, working gap, and piston head.
To make sure the magnetic fied lines go along the expected
route, the piston rod and guide head connecting the piston
head are made of aluminum and copper, respectively. Te
basic specifcations of the novel MR damper are shown in
Table 1.
When currents are applied to the coils of the MR damper,
the induced electromagnetic will provide damping force to
hinder the reciprocating movement of piston. By adjusting
the number of working coils as well as value of input cur-
rent or together, the MR damper can produce controllable
damping force. For the situation with no current on, the MR
damper acts as a conventional viscous damper.
3. Magnetic Circuit of the Novel MR Damper
For conventional MRdampers based on mixed or fowmode,
the magnetic felds generated by electromagnetic coils which
wind around the piston are distributed through the working
gap and perpendicular to the direction of MR fuid fow.
Advances in Mechanical Engineering 3
Table 1: Main parameters of the novel MR damper.
Maximum stroke
(mm)
Number of
coils
Turns of
coil
Gap width
(mm)
Inner diameter of
cylinder (mm)
Efective length of piston
head (mm)
500 4 500 1.5 40 40
Obviously, the novel MR damper with multicoil confgura-
tion increases the active length of damping channel to some
extent.
Since the four coils can be applied with current separately,
this confguration exhibits an advantage that the induction
time needed for the magnetic coil is much less [21]. Terefore,
for a limited time, the control strategy plays a greater role
on the damping force, which is mainly under the control of
applied magnetic feld.
3.1. Material Selection. In general, the maximum force avail-
able in an MR damper is limited by the magnetic saturation
in the efective area. Another important parameter for the
selected materials is the permeability. Tus, when designing
MR dampers, it is desirable to choose magnetic materials
with high magnetic saturation limit but avoid exceeding the
saturation limits in the preliminary design stage. In this study,
the piston head and cylinder are made of 45 number steel. Te
-relation of 45 number steel is shown in Figure 2, and the
magnetic saturationof 45 number steel occurs at the magnetic
feld density, , 1.7 T.
In selecting the working fuid, the MR fuid with low
zero-feld viscosity is preferred as it lowers the viscous
damper force, which will widen the overall dynamic range.
Yield stress is another important parameter to increase the
total damper force and large dynamic range as well. Here, we
select SG-MRF2035 (provided by China Ningbo Shangong
Center of Structure Monitoring and Control Engineering
Co., Ltd.) because it exhibits high yield stress (45 kPa) at the
saturation point (0.9 T) of magnetic induction density. Te
density and initial apparent viscosity (30
C, 500 s
1
) of the
chosen MR fuid are 3090 (kg/m
3
), 240 mPas, respectively.
Te operating temperature of the MR fuid ranges from 40
to 150
C and
relationship is shown in Figure 3.

3.2. Magnetic Circuit Analysis. A magnetic feld analysis is
performed to ensure that the designsatisfes the magnetic sat-
uration constraint and that the magnetic fux perpendicularly
passes through the MR fuid. Moreover, the key design para-
meters can be selected and validated based on the magnetic
feld analysis. Figure 4(a) shows the cross-sectional diagram
of the multistage MR damper, the detail dimensions of which
are shown in Table 2. An equivalent magnetic circuit is shown
in Figure 4(b) and the magnetic reluctance in the equivalent
magnetic circuit can be expressed as
1
=
2
(
2
)
,
2
=
ln (
)
2
0
,
0 1000 2000 3000 4000 5000 6000 7000
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
B
(
T
)
H(A/m)
Figure 2: - relationship of 45 number steel.
0.00 0.25 0.50 0.75 1.00 1.25 1.50
0
10
20
30
40
50
S
h
e
a
r

s
t
r
e
s
s

(
k
P
a
)
Magnetic induction (T)
Figure 3: Shear stress versus magnetic induction (MRF2035).
3
=
ln (1 + 2
)
2
0
MRF
4
=
2
((
+ 2
)
2

2
)
.
(1)
In order to decrease the magnetic coupling efect in the
magnetic poles between two adjacent coils, the shared active
D
p
D
b
D
h
D
c
t
w
L
f
L
c
L
s
t
g
(a) Cross-section diagram of the MR damper
2

3

4
1

2

3

4
3
R
m1
R
m1
R
m2
R
m2
R
m2
R
m3
R
m3
R
m3
R
m4
R
m4
R
m1
R
m1
R
m1
R
m1
R
m2
R
m3
R
m4
R
m4
F
m1
F
m2
F
m3
F
m3
+ +
(b) Te equivalent magnetic circuit model
Figure 4: Multistage MR damper.
length of the poles should be longer. So, the magnetic reluc-
tances in the shared parts between two coils are therefore
diferent.
1
,
2
,
3
, and
4
are given by
1
=
2 (
(
2
)
,
2
=
ln (
)
2
0
3
=
ln (1 + 2
)
2
0
MRF
4
=
2 (
((
+ 2
)
2

2
)
,
(2)
where
0
is the magnetic permeability of vacuum;
and
MRF
are the relative magnetic permeability of the solid materials
and the MR fuid, respectively. And
is the width of MR
working gap;
is the thickness of outer cylinder;
and
are the active lengths in the annular gap;
, and
are
the diameters of inner cylinder, piston head, and hole.
Table 2: MR damper dimensions.
Parameter Value
Inner cylinder diameter (
) 40 (mm)
Piston head diameter (
) 37 (mm)
Hole diameter (
) 6 (mm)
Cylinder thickness (
) 9 (mm)
Bobbin length (
) 40 (mm)
Bobbin height ( = (
)/2) 6.5 (mm)

Active length (
) 5 (mm)
Active length (
) 10 (mm)
Annular gap (
) 1.5 (mm)
Te magnetomotive force derived from the magnetic
circuit Kirchhofs second law is given by
=1
=1
=1
. (3)
Inthe formulas, magnetic fux
(),
is the
number of each coil turns, and
is the input current.

0.02 0 0.08 0.06 0.04
0
0.1
0.08
0.06
0.04
0.02
0.18
0.16
0.14
0.12
0.2
Surface: magnetic fux density, norm
Streamline: magnetic fux density
Max: 2.583
2.5
2
1.5
1
0.5
0
Min: 0 0.06 0.02 0.04
(a) Coil I
0.02 0 0.08 0.06 0.04
0
0.1
0.08
0.06
0.04
0.02
0.18
0.16
0.14
0.12
0.2
Surface: magnetic fux density, norm
Streamline: magnetic fux density
2
1.5
1
0.5
0
Min: 0 0.06 0.02 0.04
Max: 2.419
(b) Coil II
Figure 5: Magnetic fux density and distribution of magnetic feld lines.
According to the equivalent magnetic circuit, correspon-
ding expressions in diferent magnetic circuits are obtained
based on the formulas of Kirchhofs law:
1
=
2
+
1
,
3
=
2
+
2
,
3
=
3
+
4
,
1
(
1
+
2
+
3
+
4
)
1
=
1
(
2
+
2
) ,
2
= (
1
+
2
) (
2
+
3
) +
2
,
3
= (
2
+
3
) (
2
+
3
) +
3
,
4
(
1
+
2
+
3
+
4
)
4
=
3
(
2
+
3
) ,
(4)
where
1
,
2
,
3
,
4
,
1
,
2
, and
3
are the magnetic fux values
in the respective locations. Assuming that the magnetic feld
is uniform and perpendicular to the MR fuid section , the
magnetic feld density can be expressed as
( = 1, 2, 3, 4; = 1, 2, 3, 4, 5) , (5)
where represents the number of magnetic coils and is the
number of active working gaps. If the relative permeabilities
(
and
MRF
) are treated as constant, the magnetic feld
densities in the MRfuid sections can be determined by using
(1)(5).
However, the magnetic characteristics of the solid mate-
rials and MRfuid are highly nonlinear; it is difcult to obtain
the precise magnetic feld fromthe calculation of above equa-
tions. So, a magnetic circuit analysis using fnite element code
is shown in the subsequent section.
3.3. FEMAnalysis. Te magnetic circuit of the damper is ana-
lyzed by COMSOL Multiphysics. According to the axial sym-
metry, analysis for the three-dimensional magnetic circuit
is reduced to a two-dimensional 1/2-axisymmetric model.
Figure 5 shows the magnetic fux density and distribution of
magnetic feld lines when only one coil is applied with input
current. Obviously, the distribution of magnetic feld lines
covers the whole cross-section; however, the magnetic feld
distributions of coil I and coil II are totally diferent.
Figure 6(a) shows the magnetic feld density along the
middle of the working fuid gap by applying the frst coil with
current (1.5 A) and the case of the second coil applied with
current (1.5 A) is shown in Figure 6(b).
When coil I is applied with current (1.5 A), the maximum
magnetic feld density reaches 0.97 T in the frst active
length and it decreases exponentially along the annular gap.
However, in case of coil II, the magnetic feld density along
the working gap behaves more uniform, followed by 0.29 T,
0.42 T, 0.35 T, 0.16 T, and 0.1 T, respectively.
From(4), we knowthat the magnetic fux satisfed certain
distribution rule in the parallel magnetic circuit. Te -axis
in Figure 7 indicates the ratio between each magnetic fux
density along the active annular gap and the maximum
magnetic fux density when coil I and coil II are applied with
varying currents (0.25 A2.5 A) independently. Te magnetic
feld intensity in the working gap rises proportionally when
the input current increases and the internal relations among
the fve active regions can be regarded as a fxed linearity.
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
0.0
0.059
0.057
0.055
0.036
0.034.5
0.033
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
M
a
g
n
e
t
i
c

u
x

d
e
n
s
i
t
y

(
T
)
Working gap (m)
(a) Coil I
0.00 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
M
a
g
n
e
t
i
c

u
x

d
e
n
s
i
t
y

(
T
)
Working gap (m)
0.00
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
(b) Coil II
Figure 6: Magnetic fux density in the annular gap.
1 2 3 4 5
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
R
a
t
i
o
Number of active length
0.25 A
0.5 A
0.75A
1.0 A
1.25 A
1.5 A
1.75A
2.0 A
2.25 A
2.5 A
AVG
0.315
0.320
0.325
0.330
0.335
0.340
0.345
0.123
0.126
0.129
0.132
0.135
0.138
0.0500
0.0525
0.0550
0.0575
0.0600
0.0300
0.0325
0.0350
0.0375
(a) Coil I
0.67
0.68
0.69
0.70
0.71
0.72
0.73
0.74
0.835
0.840
0.845
0.850
0.855
0.860
0.865
0.3795
0.3810
0.3825
0.3840
0.3855
0.3870
0.240
0.243
0.246
0.249
0.252
1 2 3 4 5
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
R
a
t
i
o
Number of active length
0.25 A
0.5 A
0.75A
1.0 A
1.25 A
1.5 A
1.75A
2.0 A
2.25 A
2.5 A
AVG
(b) Coil II
Figure 7: Ratio of magnetic fux density along the annular gap.
Based on the distribution of magnetic feld density, the
others in the working gap can be expressed as.
Coil I
12
(
1
) = 0.329
11
(
1
) ,
13
(
1
) = 0.134
11
(
1
) ,
14
(
1
) = 0.057
11
(
1
) ,
15
(
1
) = 0.036
11
(
1
) .
(6)
Coil II
21
(
2
) = 0.708
22
(
2
) ,
23
(
2
) = 0.847
22
(
2
) ,
24
(
2
) = 0.382
22
(
2
) ,
25
(
2
) = 0.249
22
(
2
) ,
(7)
where
means the inductive magnetic feld density in the

th active working gap when the th coil is applied with input
current.
1.2
0.8
1
0
0.2
0.4
0.6
0 0.5 1 1.5 2 2.5
Fitting curve
Simulation data
95% prediction bounds
M
a
g
n
e
t
i
c

f
e
l
d

d
e
n
s
i
t
y

(
T
)
0.2
Current I (A)
B
11
(I
1
) = 0.02069I
5
1
0.241I
4
1
+ 1.042I
3
1
2.129I
2
1
+ 2.205I
1
0.001627
(0 A I
1
2.5 A)
Figure 8: Magnetic feld density
11
(
1
) ftting.
Besides, fromFigure 8, the numerical solutionof the rela-
tion between the magnetic feld density in the frst working
gap and input current (
1
) in the frst coil can be obtained as
11
(
1
) = 0.02069
5
1
0.241
4
1
+ 1.042
3
1
2.129
2
1
+ 2.205
1
0.001627
(0 A
1
2.5 A) .
(8)
Similarly, when only the second coil is applied with input
current (
2
), the ftting formula of the magnetic feld density
in the second working gap can be expressed as (Figure 9)
22
(
2
) = 0.0549
6
2
+ 0.1746
5
2
0.7811
4
2
+ 1.77
3
2
2.134
2
2
+ 1.367
2
0.0004509
(0 A
2
2.5 A) .
(9)
Due to the structural symmetry of pistonhead, whenapp-
lied with the same input current, the magnetic felds provided
by coil I and coil IV (coil II and coil III) also show sym-
metrical distribution. In order to enhance the magnetic feld
density in the working gap efectively, the current direction
of adjacent coils should be opposite. When the four coils are
applied with current independently at the same time, the
magnetic feld density
) is the vector sum of the cases

of single coil. Assuming the anticlockwise distribution of
1.2
0.8
1
0
0.2
0.4
0.6
0 0.5 1 1.5 2 2.5
Fitting curve
Simulation data
95% prediction bounds
M
a
g
n
e
t
i
c

f
e
l
d

d
e
n
s
i
t
y

(
T
)
0.2
Current I (A)
B
22
(I
2
) = 0.0549I
6
2
+ 0.1746I
5
2
0.7811I
4
2
+1.77I
3
2
2.134I
2
2
+ 1.367I
2
0.0004509
(0 A I
2
2.5 A)
Figure 9: Magnetic feld density
22
(
2
) ftting.
magnetic feld to be positive, the magnetic feld density
in
the working gap can be expressed as
=
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
{
4
=1
(1)
+
)
(=1)
12
(
1
) +
4
=2
(1)
++1
)
(=2)
2
=1
(1)
++1
) +
4
=3
(1)
+
)
(=3)
44
(
4
) +
3
=1
(1)
+
)
(=4)
4
=1
(1)
++1
)
(=5)
.
(10)
According to the symmetric distribution of magnetic fe-
ld, the substitution of (6)(9) into (10) gives
1
() = 0.00136 + 2.205
1
2.219
2
1
+ 1.042
3
1
0.241
4
1
+ 0.0207
5
1
0.9678
2
+ 1.511
2
2
1.253
3
2
+ 0.553
4
2
0.1236
5
2
+ 0.011
6
2
+ 0.34
3
0.53
2
3
+ 0.441
3
3
0.195
4
3
+ 0.0435
5
3
0.0039
6
3
0.079
4
+ 0.08
2
4
0.0375
3
4
+ 0.00867
4
4
0.000745
5
4
,
2
() = 0.000907 0.725
1
+ 0.730
2
1
0.343
3
1
+ 0.0793
4
1
0.0068
5
1
1.367
2
+ 2.134
2
2
1.77
3
2
+ 0.781
4
2
0.175
5
2
+ 0.0155
6
2
+ 0.522
3
0.815
2
3
+ 0.676
3
3
0.298
4
3
+ 0.067
5
3
0.0059
6
3
0.1257
4
+ 0.1265
2
4
0.0594
3
4
+ 0.0137
4
4
0.00118
5
4
,
3
() = 0.000328 0.295
1
+ 0.297
2
1
0.1396
3
1
+ 0.0323
4
1
0.0028
5
1
+ 1.158
2
1.807
2
2
+ 1.50
3
2
0.662
4
2
+ 0.148
5
2
0.0131
6
2
+ 1.158
3
1.807
2
3
+ 1.50
3
3
0.662
4
3
+ 0.148
5
3
0.0013
6
3
0.296
4
+ 0.297
2
4
0.1396
3
4
+ 0.0323
4
4
0.00278
5
4
,
4
() = 0.00091 0.126
1
+ 0.126
2
1
0.059
3
1
+ 0.0137
4
1
0.0012
5
1
+ 0.522
2
0.815
2
2
+ 0.676
3
2
0.298
4
2
+ 0.067
5
2
0.0059
6
2
1.367
3
+ 2.134
2
3
1.77
3
3
+ 0.78
4
3
0.175
5
3
+ 0.0155
6
3
0.725
4
+ 0.73
2
4
0.343
3
4
+ 0.079
4
4
0.0068
5
4
,
5
() = 0.0014 0.08
1
+ 0.08
2
1
0.038
3
1
+ 0.0087
4
1
0.00075
5
1
+ 0.34
2
0.53
2
2
+ 0.44
3
2
0.195
4
2
+ 0.0435
5
2
0.00386
6
2
0.968
3
+ 1.51
2
3
1.253
3
3
+ 0.55
4
3
0.123
5
3
+ 0.0109
6
3
+ 2.205
4
2.219
2
4
+ 1.042
3
4
0.241
4
4
+ 0.0207
5
4
.
(11)
4. Multiphysics Theoretical Analysis
As the piston head moves back and forth inside the damper
cylinder, the fuid is forced to pass through the annular
channel with large shear rate, causing signifcant heat gen-
eration. Te heat is transferred in both the axial and radial
directions. In the radial direction, the heat is conducted
through the cylinder house wall and converted to the air
outside the damper. Meanwhile, the MR fuid is forced to
fowthrough the annular gap under high pressure and slowed
down by the magnetic feld due to MR efect. In this study, a
commercial CFDpackage was used to verify MRfuid fowing
in this complex situation with heat transfer, electromagnetic
induction, and high shear rate.
4.1. Termal Analysis. Te heat in the MR damper is mainly
generated by two parts, one is from self-inductance of the
electromagnetic coil with fast-changing current, and the
other comes from the friction of the relative motion between
the piston and the cylinder. Terefore, it can be expressed as
= ()
()
+
2
() , (12)
where () is a sinusoidal input displacement, is the input
electric current, and is the wire resistance of the elec-
tromagnet. () represents the work input to the system
through reciprocation of the piston rod. For this analysis,
however, the input current applied to the damper is regarded
as constant for simplicity. Te nonlinear constitutive law for
the MR fuid damper is assumed to be as
() =
()
sgn (
()
), (13)
where is the damping coefcient and is a fractional
exponent that accounts for the nonlinearity in the MR fuid
damper. It should be noted that both and are functions of
input current and temperature . Generally, the range of is
0 < < 1. A value of one represents purely viscous behavior
and a value of zero corresponds to purely rigid plastic beha-
vior.
Meanwihle, there exists a heat exchange betweenthe mag-
netic shell and the ambient, and the exchange power
is
expressed as
[()
0
] , (14)
where is the convection heat transfer coefcient,
is the
outer surface area of the damper, () is the surface temper-
ature of the damper at any given time, and
0
is the ambient
temperature.
Considering the energy balance, the energy consumption
leads to rising temperature besides emission to the outside.
Te energy balance yields
=
()
, (15)
where ()/ is the rate of change of the temperature of the
system and
is the summation of the internal energies of

the materials contained within the system.
4.2. Force Analysis. Te MR damping relies on the enlarge-
ment of shear stress for vibration control. In an applied mag-
netic feld, the MR fuid presents Bingham fuid properties
with high viscosity and low liquidity; the constitutive equa-
tion can be expressed by
=
0
sgn ( ) + , (16)
where is the shear stress of the MR fuid,
0
is the magnetic
shear stress, which is the function of the magnetic feld, is
the shear strain rate, and is the of-feld viscosity of the MR
fuid.
Temperature efect on the performance of the MR fuid
damper is mainly based on the change of the MR fuids
viscosity and the apparent viscosity presents a nonlinear
decline when the temperature goes up [21]. Its characteristics
meet the hydraulic oil viscosity-temperature relationship.
Tat is,
(
0
)
, (17)
where
and
are the oil viscosities when the temper-

ature reaches and
0
, respectively; is the oil viscosity-
temperature coefcient. Considering the temperature efect
on the oil viscosity,
is introduced into the dynamic model

as a function of temperature. Based on (16) and (17), the
pressure drop calculation model [22, 23] on both ends can
be rewritten by
=
12
(
0
)
3
+
3
.
(18)
Accordingly, the damping force can be replaced by
V
=
[
[
3(
2

2
)
2
4
3
+

]
]
(
0
)
V
+ [
3 (
2

2
)
+ ]
,
(19)
where is the damping channel length; is the fow rate
through the channel; and is the piston head diameter; ,
, and V are the piston rod diameter, working gap width,
and velocity, respectively. Te former item describes viscous
damping associated with the speed and the latter indicates
Coulomb damping.
4.3. Fluid Analysis. Te description of yield stress leads to
complications in numerical simulation, due to its nondif-
ferentiability in the postyielding regions of the MR fuid.
However, one approach to the nondiferentiability problemis
frst to determine the bounds of the postyielding regions and
then to treat themas plug fow (a region in which the veloc-
ity is constant). But this approach assumes fully developed
fow and becomes far more complicated when dealing with
complex channel geometries [24]. Another approachemploys
a commercial fnite element sofware package and follows a
close approximation of the Bingham plastic behavior, pro-
posed by Case et al. [25]. Tus, in this model, the Navier-
Stokes equations are used to describe the fuid motion,
assuming fuid incompressibility and the apparent viscosity
subject to
=
0
+

tan ( )
2
+
2
.
(20)
Substituting (17) into (20), we can rearrange the apparent
viscosity
)
+

tan ( )
2
+
2
.
(21)
It can be seen that the MR fuid is modeled in the typical
manner for non-Newtonian fuids with variable viscosity
which takes temperature efect into consideration during the
long-stoke damping. is a small constant which eliminates
the discontinuity and is a scaling term for the slope.
5. Electromagnetic-Flow-Thermal
Coupling Analysis
5.1. Simulation Description. In the whole process of simula-
tion, it experiences much exchange of information among the
multiple physics. Both the apparent viscosity and fowfeld of
MR fuid change according to external magnetic feld. On the
other hand, the energy transmission and consumption inside
the damper infuence the MR fuid fow as well.
For the present long-stroke damper, coupled with electro-
magnetic, thermal dynamic, and fuid mechanism, the pro-
cess of the pistons moving inside the cylinder was simulated
by the sofware COMSOL Multiphysics. In order to simplify
the model and improve its accuracy, the dynamic model
assembled for this project uses 2D axisymmetric space. No-
slip wall boundary conditions are applied for both ends of the
damper cylinder and on the inner wall of the damper cylinder
house. Moving wall with the given velocity is applied on the
boundaries of the piston head and on the piston rod. Te
conjugate heat transfer is solved in the feld domain and the
damper cylinder house wall: heat transfer by convection and
conduction in the fuid domain heat transfer by conduction
only by the solid domain and the temperature feld is con-
tinuous between the fuid and solid domain. Te heat fux
boundary condition based on the Newtons cooling law is
applied on the outside boundaries of the cylinder house wall.
Te ends of the damper connected to the structures outside
are kept at constant temperature.
Te motion is modeled using the arbitrary Lagrangian-
Eulerian (ALE) deformed mesh. Te ALE handles the dyn-
amics of the deforming geometry and the moving boundaries
with a moving grid. Te Navier-Stoke equation for fuid fow
and heat equation for temperature variation are formulated
in these moving coordinates.
5.2. Results and Discussion. Te four-stage coils are designed
to apply current independently and the directions of adjacent
input current are kept opposite to enhance the damping force.
Figure 10 shows the symmetrical geometry model of the four-
stage MR damper. In order to simplify the FEM simulation,
Coil1 Coil2 Coil3 Coil4
R (m)
Z(m)
I
1
I
2
I
4
I
3
Figure 10: Symmetrical model of multistage damper.
0.0 0.5 1.0 1.5 2.0 2.5
26
28
30
32
34
36
38
40
42
44
46
T
e
m
p
e
r
a
t
u
r
e

(
C
)
Time (s)
Coil2
Coil1 + 2 + 3 + 4
(a) = 0.5 A
0.0 0.5 1.0 1.5 2.0 2.5
27
30
33
51
36
39
42
45
48
T
e
m
p
e
r
a
t
u
r
e

(
C
)
Time (s)
Coil2
Coil1 + 2 + 3 + 4
(b) = 1.5 A
Figure 11: Temperature at the piston head ( = 18.5 mm, = 95 mm).
the input currents are fxedwithout any control strategies. Te
model of the four-stage MR damper is established to analyze
the process of electromagnetic feld, fow feld, and thermal
feld on the basis of sequential coupling method, the results
of which are to be shown in the following sections. In this
simulation, the motion of the piston head is specifed by a
sine wave function of 0.4 Hz and displacement of 300 mm.
Te constants (, , and ) were specifed as 0.3, 0.002, and
0.0169, respectively.
5.2.1. Results of Termal Analysis. Figure 11 shows a sine-wave
rise of the temperature within two cycles except some discon-
tinuity points. Te case when all the coils are applied with
current shows a relative high temperature compared with the
other cases. Meanwhile, temperature at the piston head ( =
18.5 mm, = 95 mm) increases as the input current rises
from0.5 to 1.5 A, the maximumof which reaches 37 and 39
C
respectively, except for the discontinuity points. However, the
majority of the temperature rise is causedby the frictioninthe
MR damper rather than from the electromagnetic coils.
As we can see from Figure 12(a), the fuid region (cross-
section = 115 mm) involved with temperature-rising
extends as the piston moves forward and Figure 12(b) shows
that the temperature in the case of coil2 rises higher than the
case of coil4 when they are applied with the same current.
Due to the instantaneous friction between the cylinder and
the mainpiston, the temperature appears to be anexponential
rising in the working gap. Figure 13 shows the coupled results
of fuid fowand temperature in two cycles with varying input
current and the temperature increases rapidly in the frst
0.125 s and slows down in the next cycle ( = 1.25 s).
5.2.2. Results of FlowField Analysis. Due to MRefect, behav-
iors of the MR fuid being active in the annular gap act like a
rigid body below the dynamic yield stress.
So, the fuid fow slows down above the magnetic poles
when the MR fuid is forced to pass through the working gap
and the velocity drops above the magnetic pole become
larger whenmore electromagnetic coils are appliedwithinput
current (Figures 14(a) and 14(b)). However, MR fuid in the
nonactive area has a relative higher velocity because of less
external magnetic feld. As (16) shows that the piston () is a
sinusoidal input displacement, the velocity inthe working gap
changes sinusoidally. When only coil4 is applied with current
(1.5 A), the maximum velocities in the gap reach 16.25 m/s,
5.0 m/s, and 13.25 m/s as the time increases from 0.625 s to
1.125 s by step 0.25 s (Figure 14(a)).
Obviously, the pressure drop caused by MR efect incre-
ases when four electromagnetic coils are applied with input
currents. Te total pressure dropdevelopedinfour-stage axial
fow is apparently equal to the sum of that produced in each
section, given by
=
1
+
2
+
3
+
4
. (22)
0.50 0.25 0.00 0.25 0.50
26
28
30
32
34
36
38
T
e
m
p
e
r
a
t
u
r
e

a
l
o
n
g

t
h
e

g
a
p

(
C
)
z-coordinate (m)
t = 0s
t = 0.125 s
t = 0.25 s
(a) Temperature versus time
Coil4
Coil2
Coil1 + 2 + 3 + 4
40
T
e
m
p
e
r
a
t
u
r
e

(
C
)
0.50 0.25 0.00 0.25 0.50
26
28
30
32
34
36
38
z-coordinate (m)
(b) Temperature versus coils
Figure 12: Temperature in the MR fuid cross-section ( = 115 mm) (a) coil4 with 1.5 A and (b) = 0.25 s, = 1.5 A.
So, the damping force triggered by piston rod movement
is given by
=
, (23)
where
is the efective area of the piston head. Due to the

single-rod damper, the efective area
is diferent as the
piston moves back and forth in one cycle and it can be given
by
=
{
{
{
{
{
0.25(
)
2
(0 s, 0.3175 s)
(0.9625 s, 1.25 s)
0.25
2
(0.3175 s, 0.9625 s) ,
(24)
where
is the cross area of the piston head and
is the
cross area of the piston rod.
From Figures 15 and 16, we conclude that the pressure
drop is mainly produced in the annular gap and its peak
value is dominated by the input current. Te maximum
damping force reaches 17000 Nat 0.625 s whenall the coils are
applied with input current (1.5 A). Inaddition, the rheological
behavior of MRfuid is easily controlled by the input currents.
Figure 17 shows the radial fow feld at = 115 mm ( =
1.125 s). As we can see, the peak velocity decreases from
4.8 m/s to 3.2 m/s when the number of coils applied with
current increases to four and the second peak velocity is
accelerated by the MRfuid that comes fromthe lef chamber.
5.3. Finding Objective. Te constitutive model of MR fuid
is ofen represented as the Bingham plastic due to its sim-
plicity. Based on the constitutive model, the coupling phys-
ical parameters involving fuid features (such as yield stress,
apparent viscosity, and fow index), structure parameters
(annular gap width and active length), and the velocity of
piston rod can be theoretically constructed. Among those,
the yield stress is also a function of input current except for
temperature.
Te main performance parameters of novel MR damper
are its maximumdamper force, dynamic range, and inductive
time needed for magnetic coil. For comprehensive conside-
ration, a newmeasurement index involving the total damping
force, dynamic range, and induction time needed for mag-
netic coil was presented as follows:
Objective
max
max
,
Subject to 0 < <
,
1
< 15%,
0 < (, ) <
max
, 0 < <
max
,
,
(25)
where , , and are the scale factors;
, and
are
the target damper force, dynamic range, and time constant;
is the constraints of geometric dimensions;
max
is the
maximum induction magnetic feld intensity in the gap;
is the number of the wire winding turns; and
1
is the ratio of
lost power.
Te objective in (25) is a crucial parameter to evaluate the
performance of the novel multistage damper. Te way of
magnet input coils connected in parallel responds faster than
that connected in series [26]. Te average inductive time for
the respective magnetic coil is about 16.5 ms and could be
lowered to 10 ms by adding a correctioncircuit [27]. However,
the dynamic range changes as the piston moves sinusoidally
(Figure 18) and it rises promptly to about 10 when the
Coulomb force dominates the fuid fow. Furthermore, from
Figure 19, we can see that the multistage damper behaves
unstably when single coil is working and it works better when
more electromagnetic coils are applied with input currents.
Besides, the electromagnetic coils, being independent of
current input, enable to apply diferent values of current at
Surface: temperature (
C)
Contour: velocity magnitude (m/s)
20
0
20
0
0
20
x
y
z
24.886
24.866
23.59
22.315
21.04
19.765
18.49
17.215
15.939
14.664
13.389
12.114
10.839
9.5637
8.2885
7.0134
5.7382
4.463
3.1879
1.9127
0.6376
0.6376
27.392
27.3
27.2
27.1
27
26.9
26.827
10
3
10
3
(a) = 0 A, = 0 s
x
y
z
23.034
23.034
21.853
20.672
19.491
18.309
17.128
15.947
14.766
13.584
12.403
11.222
10.041
8.8593
7.6781
6.4968
5.3156
4.1343
2.9531
1.7719
0.5906
0.5906
40.214
40
38
36
34
32
30
28
26.421
C)
20
0
20
0
0
20
10
3
10
3
(b) = 0.5 A, = 0.125 s
x
y
z
17.552
17.552
16.652
15.751
14.851
13.951
13.051
12.151
11.251
10.351
9.4509
8.5508
7.6507
6.7506
5.8506
4.9505
4.0504
3.1503
2.2502
1.3501
0.45
0.45
47.175
45
40
35
30
25
24.511
C)
20
0
20
0
0
20
10
3
10
3
(c) = 1.0 A, = 0.5 s
x
y
z
25.127
25.127
23.838
22.55
21.261
19.973
18.684
17.396
16.107
14.818
13.53
12.241
10.953
9.6642
8.3757
7.0871
5.7985
4.51
3.2214
1.9328
0.6443
0.6443
54.213
50
45
40
35
30
25.359
20
0
20
0
0
20
10
3
10
3
C)
(d) I = 1.5 A, t = 2.5 s
Figure 13: Temperature feld coupled with fow feld in two cycles (coil2).
the same time. Tus, the pressure drop caused by MRefect in
the long damping channel will be diferent between adjacent
active regions. Figure 20 shows six diferent kinds of current
inputs; here are some introductions of corresponding phe-
nomenon.
Case 1 (
1
=
2
=
3
=
4
= 0.5 A). Te produced pressure
drop looks like saddle-shaped in the long damping channel
with the lowest occurs in the inlet and outlet of working
channel.
Case 2 (
1
=
4
= 0.7 A,
2
=
3
= 0.3 A). It is also saddle-
shaped, but the lowest pressure drop occurs in the middle of
the channel.
Case 3 (
1
=
4
= 0.3 A,
2
=
3
= 0.7 A). It behaves like a
downward parabola.
Case 4 (
1
= 0.3 A,
2
= 0.4 A,
3
= 0.6 A,
4
= 0.7 A).
Increasing current along the working channel produces step-
wise pressure drop with the highest one in the fourth active
region.
Case 5 (
1
= 2 A,
2
=
3
=
4
= 0 A). Te pressure drop
along the working gap decreases progressively.
Case 6 (
2
= 2 A,
1
=
3
=
4
= 0 A). Tere is a peak value in
the second active region.
All the above cases afect the fuid fow through the long
damping channel during the whole process which will be
validated by experiments in the future work.
Te total pressure drop
in Figure 21 shows that

Case 5 and Case 6 only reach 900 kPa and 1800 kPa,
respectively, which is much less than other cases. However,
0.4 0.2 0.0 0.2 0.4
0.0
2.5
5.0
7.5
10.0
12.5
15.0
17.5
V
e
l
o
c
i
t
y

(
m
/
s
)
z-coordinate (m)
Coil4 (t = 0.625 s)
Coil4 (t = 0.875s)
Coil4 (t = 1.125 s)
(a) Velocity versus time
0.30 0.25 0.20 0.15 0.10
11.2
11.6
12.0
12.4
12.8
13.2
V
e
l
o
c
i
t
y

(
m
/
s
)
z-coordinate (m)
Coil2 (t = 1.125 s)
Coil1 + 2 + 3 + 4 (t = 1.125 s)
(b) Velocity versus coils
Figure 14: Velocity in the working gap (a) coil4 with 1.5 A and (b) velocity in the active region ( = 1.125 s).
0.4 0.2 0.0 0.2 0.4
0.0
Right chamber
P
r
e
s
s
u
r
e

(
P
a
)
z-coordinate (m)
Coil4
Coil2
Coil1 + 2 + 3 + 4
Working gap
Lef chamber
15.0 M
12.0 M
9.0 M
6.0 M
3.0 M
Figure 15: Pressure drop in the chamber ( = 1.125 s, = 1.5 A).
the corresponding power consumption accounts for a much
larger percentage. Inorder toreduce the energy consumption,
it is recommended to apply more electromagnetic coils with
relative low current and reasonable control strategy enabling
the impact force to bufer in a more smooth and steady way.
6. Summary
A novel type of MR damper which has four coils and can be
applied with current separately was proposed in this work.
Considering the complex condition it works for, the multi-
physics of the novel MR damper was theoretically analyzed
300 200 100 0 100 200 300
0.0
Coil4
Coil2
Coil1 + 2 + 3 + 4
D
a
m
p
i
n
g

f
o
r
c
e

(
N
)
Displacement (mm)
12.0 k
6.0 k
6.0 k
12.0 k
18.0 k
Figure 16: Damping force in one cycle ( = 1.5 A).
and carried out by sofware COMSOL, including electromag-
netic, thermal dynamic, and fow mechanism.
For electromagnetic analysis, the equivalent magnetic
circuit model is investigated along with the relation between
the magnetic induction density in the working gap and the
input currents of the electromagnetic coils. Te magnetic
induction densities of the fve active regions, being functions
of input currents only, were obtained by FEM analysis as
shown in (11). Applied with the same current in one coil (e.g.,
coil2 or coil3), it was found that the distribution of magnetic
feld is being symmetrical. Te magnetic induction density
in the working gap would be enhanced by applying currents
with opposite direction in the adjacent coils. Otherwise, the
damping force shows little increase no matter howmuch cur-
rents are applied.
Z = 0.115 (m)
0.03 0.04 0.05 0 0.01 0.02
0.16
0.165
0.01 0.03 0.02
0.125
0.13
0.135
0.14
0.145
0.15
0.155
0.1
0.105
0.11
0.115
0.12
0.095
Streamline: velocity feld (spatial)
Arrow: velocity feld (spatial)
R (m)
Z(m)
(a) Fluid fow distribution
0.000 0.005 0.010 0.015 0.020
0
1
2
3
4
5
V
e
l
o
c
i
t
y

(
m
/
s
)
r-coordinate(m)
Coil4
Coil2
Coil1 + 2 + 3 + 4
(b) Cross-section fuid fow
Figure 17: Radial velocity ( = 115 mm, = 1.125 s).
0.00 0.25 0.50 0.75 1.00 1.25
0
2
4
6
8
10
D
y
n
a
m
i
c

r
a
n
g
e
Time (s)
Coil4
Coil2
Coil1 + 2 + 3 + 4
Figure 18: Dynamic range ( = 1.25 s).
For thermal analysis, the heat is transferred in both the
solid and the fuid domains and generated from self-induc-
tance of the electromagnetic coil with fast-changing current
and friction of the relative motion between the piston and
the cylinder. However, the majority of the temperature rise
is caused by the friction inside the MR damper rather than
self-induction from electromagnetic coils and the maximum
temperature occurs in the piston head around the coils. Te
temperature appears to be an exponential rising in the
working gap at the beginning but slows down when the max-
imum temperature reaches about 45
C due to low thermal

conductivity of MR fuid.
0.00 0.25 0.50 0.75 1.00 1.25
0.3
0.4
0.5
0.6
0.7
O
b
j
e
c
t
i
v
e
Time (s)
Coil4
Coil2
Coil1 + 2 + 3 + 4
Figure 19: Objective ( = 0.5, = 0.3, = 0.2).
For fow feld analysis, the reciprocating motion of the
piston has been implemented by using CFD analysis with
deformed mesh. In addition, fow feld (fow velocity, pres-
sure, dynamic viscosity, etc.) at any position inside MR dam-
per has been obtained. A modifed Bingham plastic model
as shown in (21) was proposed to model the fow of non-
Newtonian fuid. Te results show that the pressure drop
between lef and right chamber rises dramatically when mag-
netic feld is applied.
Besides, a new measurement index involving the total
damping force, dynamic range, and induction time needed
for magnetic coil was proposed to evaluate the performance
I
1
= I
2
= I
3
= I
4
= 0.5 A
I
1
= 2A
1 2 3 4 5
0
150
300
450
600
750
(
k
P
a
)
Active region
I
1
= 0.7 A, I
2
= 0.3 A, I
3
= 0.3 A, I
4
= 0.7 A
(a)
I
2
= 2A
1 2 3 4 5
0
150
300
450
600
750
(
k
P
a
)
Active region
I
1
= 0.3 A, I
2
= 0.7 A, I
3
= 0.7 A, I
4
= 0.3 A
I
1
= 0.3 A, I
2
= 0.4 A, I
3
= 0.6 A, I
4
= 0.7 A
(b)
Figure 20: Pressure drop in the damping channel.
Figure 21: Comparison of pressure drop and power consumption.
of multistage MR damper and the results show that it per-
forms better when working coils increase. For reducing the
energy consumption, it is recommended to apply more elec-
tromagnetic coils with relative low current and reasonable
control strategy to enable the impact force to bufer in a more
stable way which will be done in the future work.
Conflict of Interests
Te authors declare that there is no confict of interests
regarding the publication of this paper.
Acknowledgments
Tis work was supported by the Natural Science Foundation
of China (NSFC) Grant funded by the Chinese Government
(no. 51175265 and no. 51305207).
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Research Article

Magnetic Circuit Design and Multiphysics Analysis of

relationship is shown in Figure 3.

is the thickness of outer cylinder;

are the active lengths in the annular gap;

)/2) 6.5 (mm)

is the input current.

means the inductive magnetic feld density in the

) is the vector sum of the cases

is the summation of the internal energies of

are the oil viscosities when the temper-

is introduced into the dynamic model

is the efective area of the piston head. Due to the

is the cross area of the piston head and

in Figure 21 shows that

C due to low thermal

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