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Magnetoactive elastomers (MAEs) have gained significant attention in recent years due to their wide range of engineering applications. This paper investigates the important interplay between the particle microstructure and the sample shape of MAEs. A simple analytical expression is derived based on geometrical arguments to describe the particle distribution inside MAEs. In particular, smeared microstructures are considered instead of a discrete particle distribution. As a consequence of considering structured particle arrangements, the elastic free energy is anisotropic. It is formulated with the help of the rule of mixtures. We show that the enhancement of elastic moduli arises not only from the induced dipole–dipole interactions in the presence of an external magnetic field but also considerably from the change in the particle microstructure.

Magnetoactive elastomers (MAEs) claim a vital place in the class of field-controllable materials due to their tunable stiffness and the ability to change their macroscopic shape in the presence of an external magnetic field. In the present work, three principal geometries of shear deformation were investigated with respect to the applied magnetic field. The physical model that considers dipole-dipole interactions between magnetized particles was used to study the stress-strain behavior of ellipsoidal MAEs. The magneto-rheological effect for different shapes of the MAE sample ranging from disc-like (highly oblate) to rod-like (highly prolate) samples was investigated along and transverse to the field direction. The rotation of the MAE during the shear deformation leads to a non-symmetric Cauchy stress tensor due to a field-induced magnetic torque. We show that the external magnetic field induces a mechanical anisotropy along the field direction by determining the distinct magneto-mechanical behavior of MAEs with respect to the orientation of the magnetic field to shear deformation.

Commercially important extrusion film casting (EFC) processes for manufacturing plastic films or sheets are hampered by several instabilities that severely limits their productivity. In this research we focussed on one important instability: the draw resonance that occurs during the EFC process mainly under extensional flow conditions. Draw resonance is the sustained periodic oscillations in the film dimensions, notably film width and thickness, when the process operates beyond a critical draw ratio (CDR). In this research our goal was to reduce this draw resonance instability by incorporating well dispersed nanoclay fillers in a base polymeric resin (such as a linear low density polyethylene – LLDPE) to determine how these nanocomposite (NC) formulations can prevent or reduce the draw resonance defect. EFC experiments were conducted on the base resin and on the NC formulations under non-isothermal conditions to determine the onset of the draw resonance experimentally. Conventional linear stability analysis was performed to determine the onset of the draw resonance defect numerically. Numerical predictions for the onset of draw resonance were in qualitative agreement with our experimental data. Our results showed that incorporating appropriate nanoclay concentrations in a base polymeric resin indeed enhanced the EFC process stability for those polymer formulations and thus can have important economic implications for processors.