Design optimization and experiment of a disc-type MR device considering the centrifugal effect and plug flow region

Abstract Magnetorheological (MR) technology has received tremendous attention, which is playing more and more roles in modern industry. In order to give full play to advantages of the MR devices, a good design is of great importance for a high-performance MR device. This work introduces the centrifugal effect (CE) and plug flow region (PFR) into disc-type MR devices’ design for obtaining a higher design accuracy. And, a novel structure with trapezoidal cross section coil is proposed for the design of disc-type MR devices to improve the magnetic field distribution. With this structure, a disc-type MR damper is designed and optimized with consideration of the CE and PFR. The optimal result is analyzed to demonstrate the influence of the CE and PFR. And, the advantages of the proposed structure are displayed by a contrast simulation. Finally, a prototype is manufactured and tested to verify the designed MR damper. The results show that the proposed structure can achieve a better magnetic field distribution for improving the material utilization. And, when considering the CE and PFR, the relative error between the calculated torque and the tested value is steady though the velocity changes. It is smaller than the half of the relative error between the torque of traditional calculation and the tested value. These reveal a more accurate design can be achieved for disc-type MR devices by considering the CE and PFR