Faculty Publications
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Item Vertical dynamic analysis of a quarter car suspension system with MR damper(Springer Verlag service@springer.de, 2017) Hemanth, K.; Kumar, H.; Gangadharan, K.V.This paper presents ride comfort and road holding analysis of passive and semi-active suspension system using quarter car model. Semi-active suspension system with magnetorheological (MR) damper was modeled as non-parametric model-based magnetic flux density in the fluid flow gap. The skyhook control strategy was used to analyze semi-active control performance. The simulation of passive and semi-active suspension system was carried out under random road profile for different velocities. The result shows that semi-active suspension has significant improvement in terms of ride comfort and road holding of vehicle than passive suspension system. Experimental studies have been conducted to characterize MR damper and a good match is observed between results with simulation results obtained using non-parametric model. © 2016, The Brazilian Society of Mechanical Sciences and Engineering.Item Optimisation of monotube magnetorheological damper under shear mode(Springer Verlag service@springer.de, 2017) Gurubasavaraju, T.M.; Kumar, H.; Mahalingam, M.Magnetorheological dampers (MR) are one of the semi active devices, which has the capability of providing variable damping force for the variable input current. Induced force is directly dependent on the amount of magnetic flux density developed in effective fluid flow gap of the MR damper. In the present work, influence of material properties on the magnetic flux is investigated by considering magnetic and nonmagnetic material for the outer cylinder of shear mode type MR damper. Magnetostatic analysis is carried out to obtain magnetic flux density for the initial configuration of the MR damper. From the analysis, it is found that usage of magnetic material cylinder which is insulated with nonmagnetic material provided higher value of magnetic flux and damping force. The geometric optimisation of MR damper is carried out to obtain the maximum flux density in the fluid flow gap. The objective function of the optimisation includes the maximum magnetic flux density and minimising fluid flow gap. Design variables considered are fluid flow gap, number of turns in the electromagnetic coil, length of the flange and DC current input. The optimisation is performed through response surface method using finite element analysis software (ANSYS). The best optimal design parameters are obtained by choosing the appropriate value of objective function. The best configuration of the design parameters, which induce the maximum magnetic flux density, is identified. The force induced in the MR damper is estimated analytically and a comparative study of the optimised and non-optimised results was carried out. © 2017, The Brazilian Society of Mechanical Sciences and Engineering.Item Evaluation of optimal parameters of MR fluids for damper application using particle swarm and response surface optimisation(Springer Verlag service@springer.de, 2017) Gurubasavaraju, T.M.; Kumar, H.; Mahalingam, A.The controllable rheological properties of MR fluid exhibit viscoelastic properties within pre-yield, which are essential for the characterization of MR dampers for the isolation of vibration. In the present work, using particle swarm optimisation (PSO), it is identified that the proportion of MR fluid constituents, fluid gap and current are the parameters which influence majorly on the rheological properties and damping effect of MR damper. Initially, rheological properties of the prepared MR fluid samples are determined using rotational plate–plate type rheometer with the magnetorheological device cell attachment by keeping three levels of gap between the parallel plates. Three different proportions of MR fluid are prepared based on the volume fraction of carbonyl iron particle, i.e., 25, 30 and 35% in the silicone carrier fluid along with 1% of lithium-based grease as stabiliser. The objective function of this optimisation problem is to maximise the shear stress and damping force of the MR damper. The design of experiment (DOE) is employed to obtain the various combinations of parameters and their respective responses. The interaction of the regression model obtained from the DOE is used in PSO to evaluate the optimal parameters. The results indicated that the MR fluid with the particle concentration of 31% is the optimal proportion for MR damper application. © 2017, The Brazilian Society of Mechanical Sciences and Engineering.Item An approach for characterizing twin-tube shear-mode magnetorheological damper through coupled FE and CFD analysis(Springer Verlag service@springer.de, 2018) Gurubasavaraju, T.M.; Kumar, H.; Mahalingam, A.The most promising technology in the field of semi-active suspension systems is the use of magnetorheological property of MR fluid, whose material behavior can be controlled through external magnetic field. Devices developed based on this principle are adaptive and controllable as desired for a specific application. It is important to understand the damping characteristics of these devices before employing them, using experimental or computational approaches. In the present work, both experimental and computational methods have been adopted for characterizing a twin-tube MR damper with an intention to develop a computational approach as an alternative to experimental test in the preliminary design stage. Initially, experimental characterization of MR damper was carried out at 1.5 and 2 Hz frequencies for damper stroke length of ± 5 mm under different DC currents ranging from 0.1 to 0.4 A. Later, coupled finite-element and computational fluid dynamic analysis has been carried out to estimate the damping force under same conditions as used in the experiment. The results of computation are in good agreement with experimental ones. Furthermore, using this computational approach, the damping force at different frequencies of 1.5, 2, 3, and 4 Hz has been estimated and its time histories are also plotted. The influence of fluid flow gap on the damping force has been determined and results revealed that damping force behaves inversely with fluid flow gap. © 2018, The Brazilian Society of Mechanical Sciences and Engineering.Item Design and experimental characterization of a twin-tube MR damper for a passenger van(Springer Verlag service@springer.de, 2019) Desai, R.M.; Jamadar, M.E.H.; Kumar, H.; Joladarashi, S.; Raja Sekaran, S.C.The smart behavior of magneto-rheological (MR) fluid is used in the present work in designing, experimentally characterizing and analyzing a MR damper for automotive application using the twin-tube damper concept. A commercially available passive damper of a passenger van was tested to find the characteristic damping requirement of the vehicle. With this as reference, a twin-tube MR damper working in valve mode was designed and fabricated. The magnetic flux density induced in the fluid flow gap is maximized using Taguchi analysis and finite element method magnetics (FEMM) software. The FEMM results are validated by verifying with results obtained analytically using electromagnetic circuit theory. The MR damper filled with commercially available MR fluid was experimentally tested in damper testing machine. The results demonstrate that the force developed by the MR damper is indeed increasing with the value of the current supplied. At various frequencies of input oscillation, the energy dissipated by the MR damper in a single cycle increases significantly with current supplied. The novelty of this work is that a twin-tube MR damper working in valve mode was designed as a replacement for the passive damper used in a passenger van. The MR damper thus developed is capable of producing practical levels of damping force at actual operating frequencies and amplitudes of the passive damper in the passenger van. For further analysis, the behavior of the MR damper is modeled by using the Bouc–Wen model for hysteretic systems. A proportional–integral–derivative controller is used to track the desired damping force in time domain to demonstrate the application of the MR damper in a semi-active suspension system. © 2019, The Brazilian Society of Mechanical Sciences and Engineering.Item Determination of optimal magnetorheological fluid particle loading and size for shear mode monotube damper(Springer Verlag service@springer.de, 2019) Acharya, S.; Saini, R.S.S.; Kumar, H.Magnetorheological (MR) fluids belong to a class of controllable fluids, and the composition and concentration of its components govern its magnetorheological properties. In this study, an optimum particle loading (or mass fraction) and size of iron particles in MR fluid for use in a shear mode monotube MR damper were determined based on the damping force and off-state viscosity of synthesized MR fluid samples. Initially, the morphological and magnetic properties of carbonyl iron particles were characterized. Six MR fluid samples were prepared composed of combination of three different particle loadings and two sizes of iron particles. Magnetorheological tests were conducted on these samples to determine the flow curves at off-state and on-state magnetic field conditions. Herschel–Bulkley model was used for mathematical representation of flow curves at different magnetic fields and to determine their dynamic yield stress. Further, a shear mode monotube MR damper with accumulator was designed by using optimization technique for desired dynamic range and damping force. Magnetostatic analysis was performed to determine the magnetic field strength generated in the shear gap at different currents. The damping force was calculated for synthesized MR fluids based on their dynamic yield stress corresponding to the magnetic field strength in the shear gap. Analysis of variance was performed to analyse the significance of independent factors on the damping force and off-state viscosity of MRF. The optimal particle loading and size which yielded maximum damping force with minimum off-state viscosity were determined using a multi-objective genetic algorithm. © 2019, The Brazilian Society of Mechanical Sciences and Engineering.Item Design, characterization and control of MR damper for two-wheeler applications(Elsevier Ltd, 2022) Devikiran, P.; Shravya, P.; Puneet, N.P.; Kumar, H.The research on Automotive systems is always an ongoing process with varied advancements in different sectors. One such sector is suspension system and the recent trends in vehicular suspension has taken a turn towards semiactive suspension considering its salient features like cost effectiveness and low power consumption with variable damping force. This research work presents the design of radial flux Magneto Rheological damper (MRD) with magnetic field analyzed using the FEMM tool. The designed MR damper has fabricated and characterized for modelling the damper in order to simulate the quarter car model of two wheeler rear suspension. The entire simulation was carried out using MATLAB/SIMULINK. © 2022Item Experimental and Analytical Evaluation of an Acceleration-Based Semiactive Control Strategy for Automotive Suspension Systems with Magneto-Rheological Damper(SAE International, 2023) Jamadar, M.E.H.; Devikiran, P.; Kumar, H.; Joladarshi, S.Most of the control strategies presented to date are based on either the velocities or displacement of the vehicle body and the wheel which are derived by filtering and converting the data from the accelerometer. This increases the computational load and therefore directly affects the performance of the semiactive suspension system. This study presents a control strategy purely based on the acceleration for semiactive control of vehicle suspension with a magneto-rheological MR damper. The effectiveness of the acceleration-based skyhook (ASH) control strategy is compared with the existing velocity-based skyhook (VSH) control strategy based on the vibration response of a single-degree-of-freedom (SDOF) system. The effectiveness of ASH is evaluated experimentally, and the reaction time is evaluated analytically. The experimental results revealed that the ASH reduces the peak displacement and peak acceleration of the mass under the free vibration test and also improves the settling time as compared to VSH. The amplitude of the displacement and acceleration was also found to be reduced under the forced vibration test with maximum improvement observed during high-frequency excitation. The reaction time of ASH was also found to be considerably lower than VSH. Therefore, it was learned that the proposed ASH performed better under high-frequency excitation than under lower-frequency excitation. Moreover, the lower reaction time of the ASH could improve the overall performance of the semiactive suspension system. © 2023 SAE International.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.