**5. M.R. devices simulation**

### **5.1 Magnetorheological multi-coil brake**

This study describes a 3D magnetic simulation design of a magnetorheological multi-coil brake (M.R.B.). The design used in this study is an axial M.R.B. design with a configuration of more than one coil that is placed outside the casing. The placement of the device aims to simplify the brake maintenance process. **Figure 7** shows the multi-coil M.R. brake design in vertical and horizontal views. The simulation process is only carried out on a pair of coils that represent the entire coil and can distribute the magnetic flux to the entire electromagnetic part. The purpose of this simulation is to determine the results of the magnetic flux on the surface of the disc brake rotor. This simulation uses the FEMM modeling approach assisted by Ansoft Maxwell software.

**Figure 7.** *Multi-coil MR brake design; (a) vertical view; (b) horizontal view.*

The result is that the magnetic flux value of M.R.B. with a multi-coil configuration is higher than the magnetic flux value in conventional M.R.B. which only uses one coil with a larger size. Furthermore, the simulation results that have been obtained are used to determine the effect of different fluids on each variation. This study used several types of magnetorheological fluids (MRFs), MRF-122EG, MRF-132DG, and MRF-140CG, which were injected into each device design. Variations in the electric current input of 0.25 amperes, 0.50 amperes, 0.75 amperes, and 1.00 amperes are given in the simulation process. The results of magnetic flux distribution for MRF-132DG with the difference in current input can be seen in **Figure 8** below.

The resulting magnetic flux values were obtained from the FEMM simulation. The simulation is carried out by taking several variations of the electric current input and the difference in the fluid flow gap given to the device. The results show an increase in magnetic flux with each increase in electric current input and an increase with each narrower gap. As an example is the MRF-132DG design simulation for the MRF-132DG type, as shown in **Figure 9** below.

## **5.2 Fabrication and morphological characterization of anisotropic magnetorheological elastomer (M.R.E.)**

In this study, silicone R.T.V. based anisotropic magnetorheological elastomer with 70% weight fraction of iron particle were fabricated using a validated mold and capable of aligning the particle in several angles (0°, 45°, dan 90°). This study begins with the fabrication of anisotropic M.R.E. curing mold, which covers the stage of design, simulation, prototype fabrication, and validation. Anisotropic M.R.E. mold was designed using Autodesk Fusion 360. To determine the value of magnetic flux density and distribution throughout the print, it was examined using simulations on Ansoft Maxwell. The simulation results show that the best magnetic flux density value on the mold is 0.3 T to form a good particle alignment in the matrix. At the same time, the magnetic flux density value of 0.3 T can be achieved by providing an electric current input of 0.2, 0.1, and 1 ampere respectively for the mold angles of 0°, 45°, and 90° during the curing chamber. This curing process is carried out for three hours under a magnetic field and left for one day before the sample is taken.

Magnetostatic simulation has a vital role in this research. The simulation process is carried out using Ansoft Maxwell software. This simulation is useful in estimating the magnetic flux density value in the curing chamber and knowing the direction of the magnetic field vector formed. The mold design that has been made will be simulated with various current values so that it can be seen as the current value needed to

#### **Figure 8.**

*Comparison of magnetic flux distribution to variation of MRFs; (a) 0.5 amperes; (b) 0.75 amperes; (c) 1 ampere.*

*Finite Element Magnetic Method for Magnetorheological Based Actuators DOI: http://dx.doi.org/10.5772/intechopen.94223*

**Figure 9.** *FEMM simulation results for magnetic flux.*

generate a magnetic flux density value of 0.3 T in the curing chamber. The magnetic properties data from V.S.M. are used to create new materials in the simulation. Thus, the material formed in the simulation is the same as the material used as the mold material. After the material in the simulation is the same as the actual condition, it is expected that the results of the simulation will not differ much from the measurement using a gauss-meter.

The simulation was carried out by providing variations in the angle of formation of M.R.E. with 0°, 45°, and 90°. One of the simulation results using an angle of 45° is shown in **Figure 10** below.

**Figure 10** shows the distribution of the magnetic flux over a 45° curing space. The distribution of magnetic flux density in the curing chamber is marked in green color, which means that the value of the magnetic flux density in the area is medium. By changing the angle of the curing space by 45° relative to the direction of the magnetic field vector, anisotropic M.R.E. with a particle arrangement of 45° can be produced. After simulating several current values, the current required to produce 0.3 T in the curing chamber is 0.1 A. The graph in **Figure 11** shows the low magnetic flux density values on the left and right of the graph. This is because the measuring line of the magnetic flux density value touches the wall of the curing chamber, which is made of nonmagnetic aluminum.

### **5.3 Characterization torque of T-shaped magnetorheological brake**

In recent research, M.R.B. T-shaped usually used more than one wire coil electromagnetic to maximize magnetic flux reaching all Magnetorheological Fluids (MRFs) gap. This research was focused on the reduction of wire coil on Magnetorheological Brake (M.R.B.). Serpentine flux was used to maximize all MRFs gaps that only use a single coil. The research was begun by designing M.R.B. design, followed by magnetostatic simulation using Finite Element Method Magnetics, calculate braking torque based on simulation, prototyping M.R.B. to get real braking torque measurement, and the last was measure braking torque using a torque sensor with constant angular velocity. The result of magnetostatic simulation shows the magnetic flux that reaches all MRFs gap. The most excellent magnetic flux density was 0,45 T at 1 A current on the outer annular. This result was used to

**Figure 10.** *Simulation results of a 45°: Vector magnetic (a) distribution of magnetic flux and (b) vector.*

#### **Figure 11.**

*Magnetic flux density distribution values in a 45° curing chamber at a current of 0.1; 0.2; 0.3; 0.5; and 1 A.*

calculate shear stress based on Bingham Model that would generate braking torque. The braking torque generated on modeling torque and experiment was 1,51 Nm and 1,91 Nm at 1 A current with 20% difference, respectively. **Figure 12** shows an exploded design of M.R. brake.

*Finite Element Magnetic Method for Magnetorheological Based Actuators DOI: http://dx.doi.org/10.5772/intechopen.94223*

**Figure 12.** *Exploded design of M.R. brake.*

**Figure 13.**

*Simulation results for magnetostatics: (a) 0.1 A; (b) 0.5 A and (c) 1 A.*

**Figure 14.**

*Distribution of magnetic flux density along the MRF gap at variations of electric current 0.1–1 A.*

The use of an electric current greatly affects the magnetic flux density. The greater the electric current used, the greater the magnetic flux density produced. It can be illustrated in **Figure 13**. The results given show the change in the resulting magnetic flux density, which is marked in a darker color, accompanied by more flux lines produced. The change has a limit point due to the ability of the material [32] as well as the flux that attaches to a particular component.

**Figure 14** shows the distribution of magnetic flux density along the MRF gap with different variations of electric current. At current 1 A, the greatest magnetic flux density value exceeds 0.45 T, which is in the outer annular part. The higher the current applied, the lower the increase in magnetic flux density. This is because the direction of the magnetic flux is getting closer to the wall so that the resulting flux is limited. The ability of the copper wire to distribute magnetic flux also affects the result.

#### **5.4 Performance prediction of magnetorheological damper for seismic**

The new concept of a magnetorheological (M.R.) damping device used in the seismic building is discussed in this paper. The damper is aimed to deliver a comparable damping performance with the existing semi-active seismic damper design but with lower M.R. fluids volume requirement. This capability is achieved through the improvement in the M.R. valve performance using a meandering flow structure which was placed in the bypass line. **Figure 15** shows the sectional design of M.R. damper for seismic building and its valve.

This research is focused on the performance analysis of the M.R. valve pressure drop using an analytical approach. There are two main steps needed for the analytical approach, the magnetic field simulation, and the analytical pressure drop calculation. The simulation work of the M.R. valve magnetic circuit performance was carried out using finite element method magnetic (FEMM) software to calculate the distribution of magnetic flux density values. The simulated magnetic field density values would then be matched with the M.R. fluids characteristics data to predict the yield stress value of the fluids to be used in the pressure drop calculation. As a result, the M.R. valve is predicted to generate maximum off-state pressure drop of 5.35 MPa and a piston speed of 0.184 m/s. Meanwhile, at on-state condition (1.4 A), the valve is generating pressure drop up to 9.13 MPa at a piston speed of 0.184 m/s. The generated total pressure drop of the M.R. valve reaches 16.39 MPa. The MR fluids that are used in this design are only 1.5 x 10−4 m3 . From the generated total pressure drop, the peak of the damping force is obtained with 1.4 A, which is 32.19 kN. Meanwhile, the calculation result of the seismic force is 125.3 kN. Thus, it can be concluded that with the peak generated damping force, this seismic damper design will be capable of providing a damping performance which is appropriate to the seismic force with four parallel devices.

In this study, the FEMM simulation was used to obtain the magnetic flux density value in the valve section. The magnetic flux density value is used to calculate the predicted yield stress value, which is then used to predict the value of the pressure drop and the damping force. Yield stress is obtained through magnetic simulation using FEMM software which aims to obtain a magnetic flux density graph. Then the

**Figure 15.** *M.R. damper for seismic building design.*

*Finite Element Magnetic Method for Magnetorheological Based Actuators DOI: http://dx.doi.org/10.5772/intechopen.94223*

**Figure 16.** *Result of FEMM simulation.*

**Figure 17.** *Magnetic flux density result.*

resulting magnetic flux density value is included in the calculation to get the yield stress value. The simulation process used is a magnetic simulation of the working fluid with a viscosity of 0.112 Pa.s which is obtained from the MRF132-DG property data by Lord Corp [33]. **Figure 16** shows the results of 2D magnetic simulations with FEMM and magnetic flux density graphs obtained through the simulation process.

**Figure 17** above is obtained from a FEMM simulation based on a 2D design with an MRF132-DG working fluid and 900 coils. The wire used uses copper wire 28 A.W.G. with a diameter of 0.3211 mm with a resistance of 213 Ω/km. The graph shows the results of the magnetic flux density at the annular and radial channel against the variation of current input 0.5 A; 0.75 A; 1.0 A; 1.4 A.
