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.
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.
This study presents the design and fabrication of a flow-mode bifold magnetorheological (MR) damper for shock and vibration mitigation for high piston velocity (15 mph or 6.75 m/s) as well as an evaluation of its performance at low speed. Based on a Bingham-plastic (BP) model, as well as a BP model coupled with a low speed hysteresis model, two theoretical MR damper models for flow-mode MR dampers are constructed. Using the design strategy associated with the Bingham-model based damper model, two MR damper designs for achieving the performance requirement with a limited space are considered: first, the conventional MR damper that has an MR valve inside the piston head and second, the bifold MR damper that has MR valves at each end of the damper. After numerically comparing the damping performances of the two MR damper designs, the bifold MR damper has been chosen because its dynamic range is better at high speed. The bifold MR damper was tested at a relatively low piston velocity using an MTS testing machine under sinusoidal loading. Experimental data compare well with the results predicted by the theoretical models.
This paper presents an effective design strategy for a magnetorheological (MR) damper using a nonlinear flow model. The MR valve inside a flow mode MR damper is approximated by a rectangular duct and its governing equation of motion is derived based on a nonlinear flow model to describe a laminar or turbulent flow behavior. Useful nondimensional variables such as, Bingham number, Reynolds number, and dynamic (controllable) range are theoretically constructed on the basis of the nonlinear model, so as to assess damping performance of the MR damper over a wide operating range of shear rates. First, the overall damping characteristics of the MR damper are evaluated through computer simulation and, second, the effects of important design parameters on damping performance of the MR damper are investigated. Finally, the effective design procedure to meet a certain performance requirement is proposed. A high force-high velocity damper is fabricated and tested, and the resulting model and design procedure are experimentally validated.
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