Excerpt from the Proceedings of the COMSOL Users Conference 2006 Milano
Nonlinear Magnetic Analysis of Multi-plate
Magnetorheological Brakes and Clutches
M. Benetti*1, E. Dragoni1
1
DISMI, University of Modena and Reggio Emilia, Italy
*Corresponding author: Via Amendola, 2, 42100 Reggio Emilia, Italy, benetti.matteo@unimore.it
Abstract: This paper deals with the nonlinear
magnetic analysis of a 100 Nm, multi-disc,
magnetorheological fluid rotary brake or clutch,
carried out with COMSOL Multiphysics
software. Along with the results of the analysis,
the paper presents merits and limitations found
in the use of the software and introduces current
efforts to include in future simulations the
thermal and the mechanical responses of the
device.
Keywords: smart materials, magnetorheological
fluids, nonlinear magnetic analysis.
. the system, performed by means of COMSOL
1. Introduction
Magnetorheological fluids are suspension of
micron sized magnetizable iron particles in a
carrying fluid, with the addiction of stabilizing
substances to avoid particles sedimentation and
wear. MR fluids can change in some
milliseconds their viscosity when exposed to a
magnetic field, turning into a Bingham solid with
a well defined shear stress.
The maximum shear stress they can develop is a
function of the field applied and for some fluids
it is in the order of 100 kPa. Typical applications
for these materials are controlled energy
dissipation devices, such as brakes, dampers,
shock absorber and clutches. In designing MRF
devices the most important aspect is the intensity
and the distribution of the magnetic field over
the working fluid volume. The magnetic field
depends on materials, geometry, position of the
wiring and number of turns in the coil.
1
Unfortunately, ferromagnetic materials and MR
fluids show a highly nonlinear behaviour,
presenting hysteresis and saturation, thus the
calculation of the field distribution and intensity
is usually complex. Obtaining a better magnetic
flux distribution in the fluid means the device
needs less electric power or less fluid to properly
work: this is a key aspect in designing MR
devices. In this paper, the mechanical design of a
100 Nm magnetorheological multi-plate brake is
presented. The design capitalizes on the detailed
analysis of the magnetic field distribution over
software.
2. Brake (Clutch) design
When magnetized, MR fluids behave like
Bingham solids with a total shear stress given
by:
τ = τ 0 ( H ) + η ⋅ γ& (1)
where τ0 is the yield stress (function of the
applied magnetic field, H), η is the dynamic
viscosity and γ& is the shear rate. For a disc
brake (or clutch) the maximum resistant or
transmissible torque is thus function of both τ0
and γ& . The static yield stress τ0 is a function of
the magnetic field only, while γ& depends both
on the rotational speed and the fluid gap
dimension. For a brake, the minimum resistant
torque is obtained for γ& = 0. As for small
deformations (in the order of 10-3) magnetized
fluid behaves like a viscoelastic solid, to
calculate the torque on a disc face equations for
torsional shear stresses in elastic solids will be
considered (scheme of Fig. 1):
 Excerpt from the Proceedings of the COMSOL Users Conference 2006 Milano

Figure 2. Section view of the MR Brake

Figure 1. Single disc brake (or clutch) scheme
Let’s now carry out the design for a 100 Nm
τ (r ) = C ⋅ r (2)
brake. As working fluid, the 140CG hydrocarbon
oil based MR fluid from LORD Corporation has
been chosen, presenting the highest yield stress
in which r is the radius and C is a constant. among commercially available MR fluids. As
The expression for the maximum torque is: shown in Figure 3, the maximum shear stress is
60 kPa at 200 kA/m.
τ ( R0 ) = τ 0 (3)
From Equations 1 and 2 then we obtain:

r
τ (r ) = τ 0 ⋅ (4)
R0
The contribution to the total torque from a
elementary element is:

dT = τ (r ) ⋅ 2π ⋅ r 2 dr (5)

By integrating Eq. 5 from Ri to R0 we obtain the

final value of the torque: Figure 3. Magnetic field vs. yield stress in MR140CG
fluid

Tstatic = πτ 0
(R 4
0 − Ri4 )
(6)
Choosing a maximum diameter for the discs of
100 mm (2R0), with a Ri of 10 mm (shaft radius),
2 R0 using Equation 6 we obtain a torque of 23.5
In Figure 2 the axial section of a brake featuring Nm/disc. Five discs are then needed for a 100
N = 6 plates is shown. It is seen that each disc Nm torque, if the maximum shear stress for the
has two working surfaces. The final design fluid is considered. Employing 6 discs only 17
equation is then: Nm per disc are needed to achieve the 100 Nm.

Tstatic , N = N πτ 0
(R 4
0 − Ri4 )
(7)
That means the shear stress in the fluid must be
only 43.5 KPa.
R0
3. Magnetic Analysis

As shown in Figure 2, the brake is composed by

6 rotating discs (mounted on the shaft) and 5
stator discs. The discs are 1 mm thick, and the
MR fluid gap between them is 0.5 mm. Discs
and case are made of AISI 1010 steel, with good
magnetic properties, while the shaft, disc spacers

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 Excerpt from the Proceedings of the COMSOL Users Conference 2006 Milano

and bearing are made of non magnetic materials

(stainless steel and aluminium). The total
diameter of the brake is 200 mm including the
wiring. The problem is obviously axisymmetric.
In Figure 4 the COMSOL model is shown.

Figure 6. B-H curve for MR140CG fluid

4. Results
To work properly, the magnetic field lines
should be perpendicular to the direction of
motion of the fluid, and the field intensity must
be as high as possible in the working fluid gaps.
On the other hand, the desired torque (or force
for linear devices) should be obtained with low
currents (i.e. low electrical power). In Figure 7
the magnetic field streamlines are shown. The
Figure 4. COMSOL axysimmetric model streamlines are almost perfectly perpendicular to
the disc faces.
Magnetic materials and MR fluids exhibit a non
linear relationship between the applied magnetic
field H and the magnetic flux B (Figures 5 and
6). The analysis is stationary and non linear.
Moreover, as the braking torque is function of
the magnetic field, and thus of the current, a
parametric analysis has been carried out for
current densities Jφ of 0.5, 1, 1.5, 2, 2.5, 3, 5 and
10 A/mm2.

Figure 7. Magnetic field streamlines in the brake

Figure 5. B-H curve for AISI 1010 steel

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 Excerpt from the Proceedings of the COMSOL Users Conference 2006 Milano

Figure 10. Magnetic flux density on each disc for Jφ =

2.5 A/mm2

Employing the relationship between τ and B for

the MR140CG fluid (Figure 11) it’s now
possible to calculate the exact torque
Figure 8. Magnetic flux density contour map (Jφ = 2.5
A/mm2)
contribution for every disc (Table 1) and then the
total resistant torque. To do that, the results
In Figure 8 the magnetic flux density contour obtained with COMSOL have been exported in
map is shown for a current density Jφ = 2.5 MATLAB. Then vectors listing the magnetic
A/mm2. It is evident that the magnetic flux flux density value B versus the radial coordinates
density value is practically constant on every of every discs have been interpolated with a
disc and fluid gap. The graph of Figure 9 shows cubic polynomial and then substituted in the τ(B)
a comparison of the flux density along a disc function for the MR fluid, to obtain a τ(r)
face (radial direction) for different currents. The function. Integrating τ(r) as shown in Equation
graph of Figure 10 shows the field B for Jφ = 2.5 5, the exact torque has been calculated for a Jφ
A/mm2 on each disc. The field value is constant of 2.5 A/mm2.
over the discs, with a maximum difference of 0.1
T. The values are, as expected, symmetrical (i.e. DISC TORQUE (Nm) DISC TORQUE
the first disc shows the same value than the last (Nm)
one and so on). 1 8,439 7 8,492
2 8,356 8 8,385
3 8,452 9 8,459
4 8,437 10 8,537
5 8,556 11 8,369
6 8,358 12 8,396
Table 1. Torque contribution for each disc at 2.5
A/mm2 current density

Figure 9. Magnetic flux density on the first disc for

different current densities

Figure 11. B vs. yield stress interpolated curve for

MR140CG fluid

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 Excerpt from the Proceedings of the COMSOL Users Conference 2006 Milano

shows as an example the design of a rotary

According to Table 1, the total torque is 84.4 Nm brake, but the same equations and models apply
at 2.5 A/mm2 and the torque contribution is to a multi plate clutch as well.
practically the same for each disc. To obtain 100
Nm a current density Jφ = 5 A/mm2 is needed. 6. References
Being the coil section area about 400 mm2, it’s
possible to calculate the number of wires N and 1. D. Lampe, A. Thess, C. Dotzauer, MRF
their cross section to obtain the Jφ value entered Clutch Design Considerations and Performances,
in COMSOL simulations. It’s then easy to find Dresden University of Technology, Dresden
out the total coil resistance, inductance, the 2. D. Carlson, D.M. Catanzarite, K.A.St. Clair,
electrical power needed to obtain the desired Commercial Magneto-Rheological Fluid
braking torque and the electric time constant of Devices, LORD Corporation
the brake for control simulations. 3. COMSOL Multiphysics USERS’ Manual
4. W.I. Kordonsky, Magnetorheological Effect as
5. Remarks on COMSOL usage a Base of New Devices and Technologies,
Journal of Magnetism and Magnetic Meterials,
Advantages in using COMSOL Multiphisics are 122 (1993), 395-398 (1993)
the flexibility in model and material definition
and the possibility to easily interface the program
with MATLAB and Simulink to customize the
results postprocessing. Moreover, model creation
and definition are far more simple than in other
FEM software. Especially the Simulink interface
will allow to directly design a control system for
the MR brake (or clutch), without studying and
implementing a new Simulink model for the
controlled device. However, sometimes, the
convergence for nonlinear (magnetic, in this
case) analysis is difficult: the reason seems to be
in the B(H) function for ferromagnetic materials.
For 2D problems, COMSOL needs a B-µr law
rather than a H-B one: unfortunately, the µr(B)
curve is not monotonic (it usually grows to a
maximum and then decreases), while the H-B
curve always grows monotonically. That can be
the reason why sometimes the convergence is
difficult, at least for certain current density
values. Moreover, in the case of electromagnetic
problems an improvement could be the
definition, instead of a current density J, of a
current i, wire diameter and number of coil turns
N. Future work will include a control system for
the brake and a complete thermal analysis.

6. Conclusions and Future Work

A nonlinear magnetic analysis of a multi plate

magnetorheological brake (clutch) has been
performed with COMSOL Multiphisics. With a
simple 6 disc structure it is possible to obtain a
resistant (or transmissible) torque greater than
100 Nm with low currents and power. The paper