Faculty Publications
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Item Characterization and quarter car analysis with magnetorheological fluid damper using modified algebraic model (mAlg)(Elsevier Ltd, 2022) Kumbhar, S.; Puneet, N.P.; Kumar, H.Magnetorheological (MR) dampers have received the ever-increasing attention of many researchers considering their wide range of applications ranging from large seismic control of structures to prosthetics in the medical field. One such application is in semi-active vehicle suspension with MR damper. Modeling the dynamic behavior of MR damper is an intriguing challenge and many mathematical models are put forth to address this task. In this work, the MR damper is initially developed and characterized using in-house prepared MR fluid. This study aims at using a modified algebraic model (mAlg) for modeling the hysteretic behavior of the MR damper using experimental force data. Also, the study uses a Genetic algorithm toolbox to find optimal parameters for the mAlg model, and the accuracy of mAlg is visualized with various plots. The work also aims at analyzing the response of the quarter car model with MR damper to three kinds of road excitations using Simulink. © 2022Item Influence of temperature on magnetorheological fluid properties and damping performance(IOP Publishing Ltd, 2022) Kumar Kariganaur, A.; Kumar, H.; Arun, M.The magnetorheological (MR) system's performance depends on the MR fluid's temperature in operation. This study aims to evaluate the temperature effect of MR fluid on performance while the damper is working. Before synthesizing MR fluid, scanning electron microscopy, x-ray diffraction, and particle size analysis verifies for the synthesis of MR fluid in-house. Characterization of the MR fluid at different temperatures and magnetic fields was carried out. The Herschel-Bulkley model is used to analyse the nonlinearity in the fluid by incorporating the temperature effect. The range of critical parameters used to fabricate the MR damper is selected using the Technique for Order of Preference by Similarity to Ideal Solution performance score. The temperature of the MR fluid is measured using an embedded thermocouple while the damper is operating at different loading parameters. The results reveal that the fluid temperature rises significantly from atmospheric to 125.39 °C with decrease in damping force by 66.32% at higher loading parameters. The theoretical model predicts the increase in temperature similar to that of the experimental values with an average error of 10.24% in the on-state condition. Particle characterization after dynamic testing reveals particle morphology has not changed but the saturation magnetization of the particles reduced by 57% at higher temperatures (127 °C). It is observed through thermogravimetric analysis that, the life of the fluid is reduced by 0.25%, which is negligible after dynamic testing of the fluid for approximately 85000 cycles. Finally, to imitate the temperature effect on the particle, particles were heat-Treated at 200 °C, 400 °C, and 600 °C, and through scanning electron microscope image it is confirmed that deterioration of the particle starts after 200°C, if the fluid is operated for a prolonged amount of time. © 2022 IOP Publishing Ltd.Item Effect of temperature on sedimentation stability and flow characteristics of magnetorheological fluids with damper as the performance analyser(Elsevier B.V., 2022) Kumar Kariganaur, A.; Kumar, H.; Arun, M.dimentation stability and high yield stress of a magnetorheological fluid (MRFs) are essential parameters for better damping performance for any practical application. Preliminary investigations have been carried out on carbonyl iron particles to determine the morphology, particle size, crystal structure, and saturation magnetization for their feasibility of synthesizing magnetorheological fluids in-house. This study synthesizes various MRFs from various commonly used carrier oils and additives. The MRF samples were prepared for 25% volume fractions of carbonyl iron (CI) powder in either silicone oil (350cSt) or hydraulic oil (50cSt) and by using lithium and calcium-based additives or a combination of both the additives. The sedimentation stability and yield behaviour at different temperatures show a remarkable drop in sedimentation rate and yield stress for all the MR fluid samples. The characterization of the prepared MR fluids reveals that MRF-1, MRF-3, MRF-5 are more stable and have high yield stress values. MRF-1 is selected to further characterize its dynamic performance in magnetorheological damper fabricated based on geometric dimensions obtained from the response surface optimization technique. The results indicate a 164.45% and 135.48% increase in damping force at higher amplitude and higher frequencies at 0A and 1A currents. Further, similar tests have been carried out by synthesizing MRF-7 with silicone oil (50cSt) + lithium base grease as the additive. The sample's stability and yield stress with temperature are carried out, and performance analysis shows a remarkable change in damping force than MRF-1. The dynamic range obtained is practically viable in MRF-7 than MRF-1, with less variability. Finally, temperature characteristics captured from the thermocouple of the MR damper reveal that an average of 43.78% reduction in damping force when the temperature is increased by 19.5 °C with increased dynamic range. © 2022 Elsevier B.V.Item Real-time testing and thermal characterization of a cost-effective magneto-rheological (MR) damper for four-wheeler application(Springer Science and Business Media Deutschland GmbH, 2023) Jamadar, M.E.H.; Devikiran, P.; Desai, R.M.; Kumar, H.; Joladarashi, S.Recent studies show that the Magento-Rheological (MR) dampers can serve as a suitable replacement for passive dampers on ground vehicles. MR dampers are factory fitted in premium luxury vehicles. However, the high price of these MR dampers has restricted their use to premium vehicles only. The study presented in this article attempts to develop a MR damper, in collaboration with a shock absorber manufacturer, that can replace the existing passive dampers on a passenger van while being more affordable than the commercially available MR dampers. The developed MR damper is subjected to rigorous testing on the damper testing machine to evaluate its damping performance, reliability and thermal performance. The simulation results of the test vehicle model revealed a superior MR damper performance compared to the stock passive damper. The MR damper is later installed on the test vehicle to conduct real-time experiments. The real-time experiments showed that the developed MR damper improved the ride comfort of the test vehicle by 16.2% at 10 km/hr and by 17.6% at 20 km/hr compared to passive dampers while running over a speed bump. The road handling also improved by 14.32% at 10 km/hr and by 29.3% at 20 km/hr. At the end of the study, the cost evaluation performed on the developed MR damper revealed that it was more affordable than the commercially available MR dampers. © 2023, The Author(s), under exclusive licence to The Brazilian Society of Mechanical Sciences and Engineering.Item Determining the optimal composition of magnetorheological fluid for a short-stroke magnetorheological damper(Springer, 2023) Aralikatti, S.S.; Puneet, N.P.; Kumar, H.The current study investigates the effect of viscosity of base oil and weight fraction of carbonyl iron particles on maximum yield stress and effective damping range of a short-stroke magnetorheological damper (stroke length of 2 mm) designed for tool vibration mitigation. It is difficult to find the exact composition of magnetorheological fluid (MRF) based on the design equations, as unidentified practical parameters influence their behaviour hence, optimization by experimental techniques is necessary. Optimal composition of MRF are identified by genetic algorithm through central composite design of experiment. A validation study is conducted to cross verify the optimum values delivered by the algorithm. The damper is fitted onto lathe machine with the optimal fluid composition to evaluate its performance in controlling the tool vibration. The damper has been designed for the specific speed, feed and depth of cut however, the design procedure for developing a damper for higher/other cutting conditions can be achieved by the design scheme mentioned in this article. The vibration level of tool reduced by 28.66% and the amplitude of cutting force reduced by 68.18% indicating reduction of chatter vibration with the damper. An improved surface finish has been observed from 4.8 to 1.6 μm. © 2023, Indian Academy of Sciences.Item Experimental Investigation on Thermal Stability of Dual Particle Magnetorheological Fluid and Performance(Taylor and Francis Ltd., 2024) Kariganaur, A.K.; Kumar, H.; Mahalingam, A.Magnetorheological fluid and their properties are essential in Magnetorheological applications. The present study aims to obtain the thermally stable carrier fluid for Magnetorheological damper application through thermogravimetric analyses of three base fluids for higher stability fluid to synthesize Magnetorheological fluid. Scanning electron microscopic images of particles were also tested for their morphology. Magnetorheological fluid samples with 10%, 15%, and 20% by volume were prepared in-house with a 3% calcium base additive (base fluid). Sedimentation and thermal conductivity studies reveal that increasing particle concentration increases the settling time and thermal conductivity. The flow properties show an increase in yield stress with an increase in particle concentration and magnetic fields. The application part of the fluid consists of Magnetorheological damper fabrication and dynamic testing of 20% volume concentration particles at 10 mm amplitude, 2 Hertz frequency, and 0 Ampere and 0.5 Ampere currents, and the temperature of the system is captured with a K-type thermocouple. The results show an 8.2 °C rise at 0.5 Ampere with a 26.2% force decrease within 1000 cycles. The theoretical model based on the lumped parameter analysis predicts the temperature rise, similar to the experimental analysis with a 9.5% error. © 2023 Taylor & Francis Group, LLC.Item Study on operational temperature of magneto-rheological fluid and design dimensions of magneto-rheological damper for optimization(Institute of Physics, 2024) Kumar Kariganaur, A.; Kumar, H.; Arun, M.This study aims to restrict the upper limit for flow gap and effective length in magnetorheological (MR) damper for optimal performance. Initially, the sedimentation study of in-house MR fluid (25%) shows that an 8% reduction in the sedimentation ratio with the addition of additive and nonlinear Herschel-Bulkley (HB) model fit reflects a 32.5% decrease in average yield stress with increasing currents when the parallel plate gap is increased from 1 mm to 2 mm. Owing to this decrease in yield stress, further study is extended to fabricate two MR dampers with limit values (LV) of flow gap and effective length with a common magnetic outer cylinder. Testing results of MR dampers revealed a 72% reduction in damping force at 0.8 A current when the LV’s is increased from LV-1 to LV-2. Selecting LV-1 over LV-2 as the upper limit for any design optimization will give the MR damper optimal performance. At higher input parameters, amplitude has a 135% greater impact on damping force than frequency and current. It is also demonstrated that saturation magnetization depends on the applied magnetic field and input loading parameters. Finally, gravimetric analysis shows that the effectiveness of the MR fluid and magnetic particle starts to decline after 322 °C and 400 °C. © 2024 IOP Publishing Ltd.Item Design and fabrication of cost effective semi-active vehicular suspension system and testing on full scale quarter car suspension rig(Techno-Press, 2024) Puneet, N.P.; Saini, R.S.T.; Kumar, H.Smart materials, such as magnetorheological (MR) fluid, have received considerable research attention in recent years due to their unique capabilities. MR fluid, which possesses a magnetic field controllable viscosity, has been extensively studied for vehicular applications with the aim of synthesizing optimal MR fluids, designing optimal MR dampers, and developing control strategies. However, a comprehensive study that primarily focuses on developing a cost-effective semi-active suspension system for a commercial vehicle in a developing nation is still lacking. This study addresses this gap by synthesizing an in-house MR fluid and studying its rheological properties. Subsequently, a novel single-sensor-based controller is developed and closed-loop simulations are conducted on a quarter-car semi-active model. Finally, the overall semi-active quarter-car suspension system is experimentally tested using a suspension test rig. The performance of the proposed system in terms of ride comfort and road holding is evaluated and is compared with simple control strategies. The dynamic range of the developed semi-active MR damper is found to be around 2.3, indicating a significant MR effect. The results suggest an intermediate response using the proposed acceleration-driven controller (ADV) at lower frequencies and similar performance to that of the skyhook controller at higher frequencies. The cost-effective methodology proposed in this study is effective and can be adapted for other semi-active engineering applications. © © 2024 Techno-Press, Ltd.Item Optimization and experimental analysis of a cost-effective magneto-rheological (MR) fluid for application in semiactive suspension of a passenger van(SAGE Publications Ltd, 2024) Jamadar, M.E.H.; Devikiran, P.; Kumar, H.; Joladarashi, S.The study presented in this article attempts to determine the optimal composition of iron particles in the MR fluid for vehicular application based on the size of the particles, the simulation response of a test vehicle model, and the cost of the fluid. The MRF samples with two different-sized particles in varying compositions are prepared and characterized on a rheometer. The performance of each MRF sample in the semiactive suspension of a test vehicle is determined by simulating its full car model on a random road. The response of the vehicle model during simulation, the size of the particles, the volume fraction of the particles in the carrier fluid, and the fluid’s calculated cost are input for the Response surface optimization technique. The optimization results revealed that the MR fluid with large-sized particles in a 25% volume fraction would be suitable for the said application. Moreover, it was found that the rheological performance of the optimized MR fluid was better than the commercial MR fluid. The performance of the optimized fluid in a MR damper was experimentally evaluated against the stock passive damper of the test vehicle. The results of the experiment on the test vehicle showed that the MR damper improved the test vehicle’s ride comfort by 36.58% over a speed bump and 11.3% on an off-road test track. The road handling was also improved by 45% over a speed bump and 46% over the test track. © IMechE 2023.Item Synthesis, characterization and selection of optimal constituents of magnetorheological fluid for damper application(National Institute of Science Communication and Policy Research, 2025) Acharya, S.; Puneet, N.P.; Desai, R.M.; Sundaram, V.; Kumar, H.Magnetorheological (MR) dampers are a category of energy dissipating devices that employ magnetorheological fluids which undergoes drastic change in its behaviour under the presence of magnetic stimulus. The damping characteristics of an MR damper predominantly depends on the dimensions of damper and on the constituents of MR fluid (MRF). In this work, an optimal MRF composition suitable for a monotube MR damper has been selected from six prepared MRF based on optimization. Initially, MR damper piston dimensions have been obtained by means of optimization. The damper has been fabricated and filled with commercial MRF 132DG™ fluid (Lord Corporation) and its performance has been tested. The experimental results have been validated with computational results. In the next part of the study, MRF samples composed of three particle weight fractions of fine and coarse sized iron particles have been synthesized and the rheological properties have been measured and compared with those of commercial MR fluid. The force-displacement characteristics of damper employing synthesized MRF have been determined with and without application of current to damper coil. Finally, by means of Multi-Objective Genetic Algorithm, optimum iron particle size and weight fraction have been selected from the pareto front solutions. © 2025, National Institute of Science Communication and Policy Research. All rights reserved.