MAGNETORHEOLOGICAL FLUIDS

-K.Sai Malleswar

CONTENTS
1. What is Magneto rheological fluid?
2. Aim
3. Objective and Work plan
4. Material Behavior and Properties
5. Common MR fluid surfactants
6. How a MR fluid works?
7. Modes of operation
8. Applications
i. Mechanical Engineering
ii. Military and Defense
iii. Optics
iv. Automotive and Aerospace
9. Recent advances
10. Limitations
11. Bibliography

WHAT IS MAGNETO RHEOLOGICAL FLUID ?

A magnetorheological fluid is a fascinating smart fluid with the ability to

switch back and forth from a liquid to a near-solid under the influence of
a Magnetic field. It is usually used for applications in braking. The term
"magnetorheological fluid" comes from a combination of magneto,
meaning magnetic, and rheo, the prefix for the study of deformation of
matter under applied stress. Magnetorheological fluids are not currently
in wide use but are considered a futuristic type of material.

A magnetorheological fluid (MR fluid) is a type of smart fluid in a

carrier fluid, usually a type of oil. When subjected to a magnetic field,
the fluid greatly increases its apparent viscosity, to the point of
becoming a viscoelastic solid. Importantly, the yield stress of the fluid
when in its active ("on") state can be controlled very accurately by
varying the magnetic field intensity. The upshot of which is that the
fluid's ability to transmit force can be controlled with an electromagnet,
which gives rise to its many possible control-based applications.

AIM:
Magnetorheological effect is one of the direct
influences on the mechanical properties of a fluid. It
represents a reversible increase, due to an external
magnetic field of effective viscosity.
MR fluids and devices have the potential to
revolutionize the design of hydraulic systems, actuators,
valves, active shock and vibration dampers, and other

components used in mechanical systems. The key to

success in all of these implementations is the ability of
MR fluid to rapidly change its rheological properties upon
exposure to an applied magnetic field .MR fluids find a
variety of applications in almost all the vibration control
systems. It is now widely used in automobile suspensions,
seat suspensions, clutches, robotics, design of buildings
and bridges, home appliances like washing machines etc.
At present, there is a compelling need to develop
new and improved MR fluids, to lower their production
cost through improved manufacturing processes, and to
develop MR fluid-based application devices that will
demonstrate the engineering feasibility of the MR fluids
concept and will highlight the implementation challenges.
For this purpose, the present project is undertaken.

Objective:
>>Ultra precision polishing of Si3N4 ceramics using magnetorheological
fluids and diamond abrasives:

Silicon nitride (Si3N4) ceramics have features such as low density, high
strength, wear resistance, etc.. Moreover, Si3N4 has been given much
attention as a new structural material because it has excellent fracture
strength, fracture toughness, and thermal shock resistance compared
with other fine ceramics.
Aerospace applications of silicon nitride:

Gas turbine manufacturing

Silicon nitride bearings are used in main engines of NASAs space
Shuttle.
Thruster in rocket engine

Si3N4 ceramics are sensitive to defects resulting from the grinding and
polishing processes due to their inherent brittleness. Failure begins in
regions of surface irregularities, such as scratches,pits and microcracks.
So, it is important to fabricate Si3N4 ceramics with a superior quality
and finish with minimum defects in order to obtain reliability in
performance.
In order to achieve this, magnetorheological fluids can be used along
with diamond abrasives. The MR polishing method can provide
excellent surface roughness compared with the existing lapping
methods.

WORK PLAN:
To prepare the required fluids for MR polishing, carbonyl iron (CI)
powder, which is sensitive to magnetic fields, is to be used. The fluids
consist of approximately 50 wt% magnetic particles (CI powders, 2 m),
abrasive diamond particles (0.1-2000 m), and DI water. A dispersion
stabilizer (glycerin) is to be added to the aforementioned materials as it
enhances the cohesion of the magnetic fluids and facilitates proper
mixing of the polishing slurry and magnetic particles. However,
excessive use of a stabilizer may deteriorate the finishing quality for
certain materials.

The MR fluid is supplied to the gap between a workpiece and a moving

wall to polish the workpiece. When a proper magnetic field is applied to
the MR fluid, the viscosity and stiffness of the fluid increase by more
than several tens of times within milliseconds. Thus, the MR fluid can
rotate continuously as long as it adheres to the wheel surface resulting
from the applied magnetic field . For polishing purposes, a suitable
abrasive slurry (a mixture of DI water and abrasive particles, which are
generally of non-magnetic materials) is incorporated into the fluid,
which is supplied to the narrow gap between the wheel and the
workpiece. The experiments can be performed by changing therotating
speed of the polishing wheel and the strength of the applied magnetic
fields.

Imposed magnetic field and shear direction

in MR polishing

Material behavior
To understand and predict the behavior of the MR fluid it
is necessary to model the fluid mathematically, a task
slightly complicated by the varying material properties
(such as yield stress). As mentioned above, smart fluids
are such that they have a low viscosity in the absence of
an applied magnetic field, but become quasi-solid with
the application of such a field. In the case of MR fluids
(and ER), the fluid actually assumes properties
comparable to a solid when in the activated ("on") state,
up until a point of yield (the shear stress above which
shearing occurs). This yield stress (commonly referred to
as apparent yield stress) is dependent on the magnetic
field applied to the fluid, but will reach a maximum point
after which increases in magnetic flux density have no
further effect, as the fluid is then magnetically saturated.
The behavior of a MR fluid can thus be considered similar

to a Bingham plastic, a material model which has been

well-investigated.
However, a MR fluid does not exactly follow the
characteristics of a Bingham plastic. For example, below
the yield stress (in the activated or "on" state), the fluid
behaves as a viscoelastic material, with a complex
modulus,that is also known to be dependent on the
magnetic field intensity. MR fluids are also known to be
subject to shear thinning, whereby the viscosity above
yield decreases with increased shear rate. Furthermore,
the behavior of MR fluids when in the "off" state is also
non-Newtonian and temperature dependent, however it
deviates little enough for the fluid to be ultimately
considered as a Bingham plastic for a simple analysis.
Thus our model of MR fluid behavior becomes:

Where = shear stress; y = yield stress; H = Magnetic

field intensity = Newtonian viscosity;
gradient in the z-direction.

Shear strength

is the velocity

Low shear strength has been the primary reason for

limited range of applications. In the absence of external
pressure the maximum shear strength is about 100 kPa. If
the fluid is compressed in the magnetic field direction and
the compressive stress is 2 MPa, the shear strength is
raised to 1100 kPa.. If the standard magnetic particles are
replaced with elongated magnetic particles, the shear
strength is also improved.

Particle sedimentation
Ferroparticles settle out of the suspension over time due
to the inherent density difference between the particles
and their carrier fluid. The rate and degree to which this
occurs is one of the primary attributes considered in
industry when implementing or designing an MR device.
Surfactants are typically used to offset this effect, but at
a cost of the fluid's magnetic saturation, and thus the
maximum yield stress exhibited in its activated state.

Common MR fluid surfactants

MR fluids often contain surfactants including, but not
limited to:
oleic acid
tetramethylammonium hydroxide
citric acid
soy lecithin
These surfactants serve to decrease the rate of
ferroparticle settling, of which a high rate is an
unfavorable characteristic of MR fluids. The ideal MR fluid
would never settle, but developing this ideal fluid is as
highly improbable as developing a perpetual motion
machine according to our current understanding of the
laws of physics. Surfactant-aided prolonged settling is
typically achieved in one of two ways: by addition of
surfactants, and by addition of spherical ferromagnetic
nanoparticles. Addition of the nanoparticles results in the
larger particles staying suspended longer since to the

non-settling nanoparticles interfere with the settling of

the larger micrometre-scale particles due to Brownian
motion. Addition of a surfactant allows micelles. to form
around the ferroparticles. A surfactant has a polar head
and non-polar tail (or vice versa), one of which adsorbs to
a nanoparticle, while the non-polar tail (or polar head)
sticks out into the carrier medium, forming an inverse or
regular micelle, respectively, around the particle. This
increases the effective particle diameter. Steric repulsion
then prevents heavy agglomeration of the particles in
their settled state, which makes fluid remixing (particle
redispersion) occur far faster and with less effort. For
example, magnetorheological fluids will remix within one
cycle with a surfactant additive, but are nearly impossible
to remix without them.
While surfactants are useful in prolonging the settling
rate in MR fluids, they also prove detrimental to the fluid's
magnetic
properties
(specifically,
the
magnetic
saturation), which is commonly a parameter which users
wish to maximize in order to increase the maximum
apparent yield stress. Whether the anti-settling additive is
nanosphere-based or surfactant-based, their addition
decreases the packing density of the ferroparticles while
in its activated state, thus decreasing the fluids onstate/activated viscosity, resulting in a "softer" activated
fluid with a lower maximum apparent yield stress. While
the on-state viscosity (the "hardness" of the activated
fluid) is also a primary concern for many MR fluid
applications, it is a primary fluid property for the majority
of their commercial and industrial applications and
therefore a compromise must be met when considering
on-state viscosity, maximum apparent yields stress, and
settling rate of an MR fluid.

How it works?
The magnetic particles, which are typically micrometer or
nanometer scale spheres or ellipsoids, are suspended
within the carrier oil are distributed randomly and in
suspension under normal circumstances, as below.

When a magnetic field is applied, however, the

microscopic particles (usually in the 0.110 m range)
align themselves along the lines of magnetic flux, see
below. When the fluid is contained between two poles
(typically of separation 0.52 mm in the majority of
devices), the resulting chains of particles restrict the
movement of the fluid, perpendicular to the direction of
flux, effectively increasing its viscosity. Importantly,
mechanical properties of the fluid in its on state are
anisotropic. Thus in designing a magnetorheological (or
MR) device, it is crucial to ensure that the lines of flux are
perpendicular to the direction of the motion to be
restricted.

Modes of operation and applications

An MR fluid is used in one of three main modes of
operation, these being flow mode, shear mode and
squeeze-flow mode. These modes involve, respectively,
fluid flowing as a result of pressure gradient between two
stationary plates; fluid between two plates moving
relative to one another; and fluid between two plates
moving in the direction perpendicular to their planes. In
all cases the magnetic field is perpendicular to the planes
of the plates, so as to restrict fluid in the direction parallel
to the plates.

Flow mode

Shear Mode

Squeeze-Flow Mode

The applications of these various modes are numerous.

Flow mode can be used in dampers and shock absorbers,
by using the movement to be controlled to force the fluid
through channels, across which a magnetic field is
applied. Shear mode is particularly useful in clutches and
brakes - in places where rotational motion must be
controlled. Squeeze-flow mode, on the other hand, is
most suitable for applications controlling small,
millimeter-order movements but involving large forces.
This particular flow mode has seen the least investigation
so far. Overall, between these three modes of operation,
MR fluids can be applied successfully to a wide range of
applications
The method of operation of a magnetorheological fluid is simple. A
magnetorheological fluid is made up of micrometer-sized ferroparticles,
particles like iron that respond to a magnetic field, suspended in an oilbased medium. When outside the influence of a magnetic field, the
particles float freely, causing the material to behave like any colloidal
mixture, such as milk. When a magnetic field is turned on, however, the
ferroparticles align in vertical chains along the field's flux lines,
restricting the fluid flow and increasing the viscosity up to around that
of a weak plastic.

Because the strength of the magnetorheological fluid comes from

aligned ferroparticles that only make up a minority of the overall
mixture, there are definite limits to how strong it can be, but the
significant difference between the "off" and "on" modes makes it
appealing for use in a variety of applications where conventional brakes
are ineffective. Typically, the magnetorheological fluid is kept between
two small plates, only a few millimeters apart, which maximizes the
mixture's braking properties. The system must be arranged such that the
magnetic flux lines are perpendicular to the direction of motion to be
stopped.

Applications

The application set for MR fluids is vast, and it expands

with each advance in the dynamics of the fluid.
>>Mechanical Engineering
Magnetorheological dampers of various applications have
been and continue to be developed. These dampers are
mainly used in heavy industry with applications such as
heavy motor damping, operator seat/cab damping in
construction vehicles, and more.
As of 2006, materials scientists and mechanical engineers
are collaborating to develop stand-alone seismic dampers
which, when positioned anywhere within a building, will
operate within the building's resonance frequency,
absorbing detrimental shock waves and oscillations within
the structure, giving these dampers the ability to make
any building earthquake-proof, or at least earthquakeresistant.
>>Military and Defense
The U.S. Army Research Office is currently funding
research into using MR fluid to enhance body armor. In
2003, researchers stated they were five to ten years
away from making the fluid bullet resistant.[8] In
addition, Humvees, certain helicopters, and various other
all-terrain vehicles employ dynamic MR shock absorbers
and/or dampers.
>>Optics
Magnetorheological Finishing, a magnetorheological fluidbased optical polishing method, has proven to be highly
precise. It was used in the construction of the Hubble
Space Telescope's corrective lens.

>>Automotive and Aerospace

If the shock absorbers of a vehicle's suspension are filled
with MR fluid instead of plain oil, and the whole device
surrounded with an electromagnet, the viscosity of the
fluid (and hence the amount of damping provided by the
shock absorber) can be varied depending on driver
preference or the weight being carried by the vehicle - or
it may be dynamically varied in order to provide stability
control. This is in effect a magnetorheological damper.
The MagneRide magnetic ride control (a kind of active
suspension) is one such system which permits the
damping factor to be adjusted once every millisecond in
response to conditions. GM is the origin company of this
technology as applied to automobiles. As of 2007, BMW
manufactures cars using their own proprietary version of
this device, while Audi and Ferrari offer the MagneRide on
various models. All Corvettes made since 2005 have also
employed a dynamic MR suspension system.

>>Vehicle Suspension Dampers

The MR damper has a built-in MR valve across which the
MR fluid is forced. The piston of the MR damper acts as an
electromagnet with the required number of coils to
produce the appropriate magnetic field. Also the MR
damper has a run-through shaft to avoid an accumulator.

>>MR Transmission Clutches

They are used in automotive power train to transmit torque from the
engine to the transmission and the vehicle. The MR sponge clutch may
be used to provide launch control of an automobile thereby achieving
smooth vehicle launch. The MRF clutch thus may replace the existing
torque converters and therefore help increase the fuel economy.

General Motors and other automotive companies are

seeking to develop a magnetorheological fluid based
clutch system for push-button four wheel drive systems.
This clutch system would use electromagnets to solidify
the fluid which would lock the driveshaft into the drive
train.
Magnetorheological dampers
commercial helicopter cockpit
the event of a crash, are
decreases the shock delivered

for use in military and

seats, as safety devices in
under development. This
to each passenger's spinal

column thereby decreasing the rate of permanent injury

during a crash.
Porsche has introduced magnetorheological engine
mounts in the 2010 Porsche GT3 and GT2. At high engine
revolutions, the magnetorheological engine mounts get
stiffer to provide a more precise gearbox shifter feel by
reducing the relative motion between the power train and
chassis/body.

Recent Advances
Recent studies which explore the effect of varying the
aspect ratio of the ferromagnetic particles have shown
several improvements over conventional MR fluids.
Nanowire-based fluids show no sedimentation after
qualitative observation over a period of three months.
This observation has been attributed to a lower closepacking density due to decreased symmetry of the wires
compared to spheres, as well as the structurally
supportive nature of a nanowire lattice held together by
remnant magnetization. Further, they show a different
range of loading of particles (typically measured in either
volume or weight fraction) than conventional sphere- or
ellipsoid-based fluids. Conventional commercial fluids
exhibit a typical loading of 30 to 90 wt%, while nanowirebased fluids show a percolation threshold of ~0.5 wt%
(depending on the aspect ratio). They also show a
maximum loading of ~35 wt%, since high aspect ratio
particles exhibit a larger per particle excluded volume as
well as inter-particle tangling as they attempt to rotate
end-over-end, resulting in a limit imposed by high offstate apparent viscosity of the fluids.

This new range of loadings suggest a new set of

applications are possible which may have not been
possible with conventional sphere-based fluids.
Newer
studies
have
focused
on
dimorphic
magnetorheological fluids, which are conventional
sphere-based fluids in which a fraction of the spheres,
typically 2 to 8 wt%, are replaced with nanowires. These
fluids exhibit a much lower sedimentation rate than
conventional fluids, yet exhibit a similar range of loading
as conventional commercial fluids, making them also
useful in existing high-force applications such as
damping. Moreover, they also exhibit an improvement in
apparent yield stress of 10% across those amounts of
particle substitution.

Limitations
Although smart fluids are rightly seen as having many
potential applications, they are limited in commercial
feasibility for the following reasons:
High density, due to presence of iron, makes them heavy. However,
operating volumes are small, so while this is a problem, it is not
insurmountable.
High-quality fluids are expensive.
Fluids are subject to thickening after prolonged use and need
replacing.
Settling of ferro-particles can be a problem for some applications.
Commercial applications do exist, as mentioned, but will
continue to be few until these problems (particularly cost)
are overcome.

BIBLIOGRAPHY
1.
2.
3.
4.
5.

www.wikipedia.com
www.google.com
"Mechanical properties of magnetorheological fluids under
squeeze-shear mode" by Wang, Hong-yun; Zheng.
"Physical Properties of Elongated Magnetic Particles" by Fernando
Vereda, Juan de Vicente.
Influence of particle shape on the properties of magneto
rhelogical fluids. By R.c.bell and E.D.Miller.