Properties of magneto-rheological fluids based on amorphous micro-particles

To improve the magneto-rheological (MR) properties of magneto-rheological fluids, self-made amorphous alloy particles, the composition of which was Fe76Cr2Mo2Sn2P10B2C2Si4, were used as the disperse phase to replace traditional carbonyl iron (CI) particles to prepare amorphous based magneto-rheological fluid (AMRF). Soft magnetic properties and densities of the amorphous particles and the CI particles were tested and compared. The results indicate the amorphous particles present a lower density but larger magnetization intensity and larger permeability at lower field levels. Properties of the AMRF with 20% particles in volume fraction were tested and compared with the CI based MR fluid (CMRF). The AMRF presents a saturation yield stress of 41 kPa at ~227 kA/m and a sedimentation ratio of 80%. The results indicate the magneto-rheological fluid based on amorphous micro-particles has better MR properties and sedimentation stability than that based on CI particles at lower field levels (0-200 kA/m).

Novel magneto-rheological fluid damper for passive force/torque feedback

The damper is capable of providing a continuously variable dampering force/torque in response to a magnetic field. It consists of an upside cap and an underside cap with a rotor located between them, the magneto-rheological （MR） fluid is filled into the gaps between the rotor and the caps. When the viscosity of the MR fluid increases under the influence of the magnetic field, the movement of the rotor will be resisted. The output torque is made up of the torque caused by the magnetic field, the torque caused by the plastic viscosity of the MR fluid, and the torque caused by the coulomb friction. The viscous torque can be calculated by a simple method and the frictional torque can be obtained by experiments. The torque dependent on the magnetic field is obtained by electromagnetic finite dement analysis. Experiments are done on the damper prototype and the validity of the design is verified.

An approach for simulating the air brake system of long freight trains based on fluid dynamics

Air brake systems are critical equipment for railway trains, which affects the running safety of the trains significantly. To study air braking characteristics of long freight trains, an approach for simulating air brake systems based on fuid dynamics theory was proposed. The structures and working mechanisms of locomotive and wagon air brakes are introduced, and mathematical models of the pipes, brake valves, reservoirs or chambers, cylinders, etc., are presented.Besides, the dynamic motions of parts in the main valve are considered. The simulation model of the whole air brake system is then formulated, and the solving method based on the finite-difference method is used. New efficient pipe boundary conditions without iterations are developed for brake pipes and branch pipes, which can achieve higher computational efficiency. The proposed approach for simulating the air brake system is validated by comparing with published measured data. Simulation results of different train formations indicate that models that consider the dynamic behavior of brake pipes are recommended for predicting the characteristics of long trains under service braking conditions.

Reciprocating friction characteristics of magneto-rheological fluid for aluminum under magnetic field

Reciprocating friction characteristics of magneto-rheological （MR） fluid for aluminum under a magnetic field at different loads and oscillation frequencies were studied when MR fluids were worked in reciprocating motions such as in dampers for automobiles, and surface polishing and other finishing. Thus, experiments were carried out to evaluate the reciprocating friction characteristic of MR fluid for aluminum. The obtained data from the tests are sorted in groups depending on various loads and oscillation frequencies, to analyze the relationship between test condition and travel cycle. Surfaces of specimens were compared by measuring the surface roughness and observing the surface images. The performance of reciprocating friction characteristics of MR fluid for aluminum is evaluated through analyzing the experiment results.

Analysis and Design of Cylindrical Magnetorheological Fluid Brake

Magnetorheological (MR) fluids consist of stable suspensions of magnetic particles in a carrying fluid such as water or silicone oils. The magnetorheological response of MR fluids results from the polarization induced in suspended particles by application of an external magnetic field. The interaction between the induced dipoles causes the particles to form columnar structure, parallel to the applied field. These chain-like structures restrict the motion of fluids, thereby increasing the viscosity and yield stress of the MR fluids. These mechanical characteristics allow for the construction of magnetically controlled device such as the MR fluids rotary brakes. However, there has been little information published about the design of MR fluid brakes. In this paper the design of the cylindrical MR fluid brake is investigated theoretically. Bingham model is used to characterize the constitutive behaviors of the MR fluids subject to an external magnetic field. The operational principle of the cylindrical MR fluid brake is presented. The theoretical method is developed to analyze the transmission properties of the torque of the cylindrical MR fluid brake. An engineering expression for the torque is derived to provide the theoretical foundations in the design of the cylindrical MR fluid brake. Based on this equation the volume and thickness of the annular MR fluids within the brake is expressed as functions of the desired ratio of torques with saturated magnetic field and without external field, the controlled mechanical power and the MR fluid material properties. The parameters of the thickness and width of the fluid in the brake can be calculated from the obtained equations when the required mechanical power level, the desired torque ratio are specified.

A disc-type magneto-rheologic fluid damper

A disc-type magneto-rheological fluid damper operating in shear mode is proposed in this paper,which is based on the special characteristics of the magneto-rheological (MR) fluid with rapid, reversible and dramatic change in its rheological properties by the application of an external magnetic field. The magneticfield of the disc-type MR fluid damper is analysed by the finite element method ; the controllability of the disctype MR fluid damper on the dynamic behaviour of a rotor system ; and the effectiveness of the disc-type MR fluid damper in controlling the vibration of a rotor system, are studied in a flexible rotor system with an over-hung disc. It is shown that the magnetic flux density of the disc-type MR fluid damper in the working areas can significantly change with the applied current in the coil ; and that the dynamic behavior of the disc-type MR fluid damper can be varied by the application of an external magnetic field produced by a low voltage electromagnetic coil. The disc-type MR fluid damper can significantly change the dynamic characteristics of a rotor system, provided that the location of the disk-type MR fluid damper is carefully chosen. The disc-type MR fluid damper is a new actuator with good dynamic characteristics for rotating machinery.

Analysis and Design of Circular Plate MR Fluids Brake

A magnetorheological (MR) fluids brake is a device to achieve brake by shear force of MR fluids. A MR rotary brake has the property that its braking torque changes quickly in response to an external magnetic field. In this study, the design method of the circular plate MR fluids brake is investigated theoretically. The equation of the torque transmitted by the MR fluids in the brake is derived to provide the theoretical foundation in the design of the brake. Based on this equation, after mathematically manipulated, the calculations of the volume, thickness and width of the MR fluids within the circular plate MR fluids brake are yield.

进口防旋板对汽轮机交错齿迷宫密封泄漏特性和动力学特性影响研究

为提高汽轮机高压缸和中压缸之间过桥汽封的气流激振动力学性能、抑制汽轮机轴系振动失稳,针对交错齿迷宫密封,开展了进口防旋板结构方案设计和动力学性能评估研究。首先,建立了具有“虚拟旁路边界”的交错齿迷宫密封动力学计算模型,实现了对动密封进口压力场和高预旋速度场的精准模拟;然后,采用基于多频椭圆轨迹涡动模型的非定常计算流体动力学(CFD)摄动数值方法,对比分析了进口预旋(预旋比为0、0.3、0.5)对无防旋板结构的迷宫密封的动力特性系数的影响规律;最后,详细评估了不同进口防旋板结构方案的止旋抑振性能,比较分析了防旋板倾角和数量对迷宫密封的泄漏量、动力特性系数和周向旋流比分布的影响规律。研究结果表明:迷宫密封泄漏量对防旋板倾角和数量变化不敏感(泄漏量变化小于0.5%);进口预旋会导致迷宫密封交叉刚度和有效阻尼穿越频率增大、有效阻尼减小,易诱发轴系失稳;进口防旋板能够显著减小迷宫密封的交叉刚度(约为53%)和有效阻尼穿越频率(约为24 Hz)、增大有效阻尼,使密封泄漏量略有增加(约为4.5%);相较于直防旋板,45°倾角斜防旋板使密封交叉刚度进一步降低约14%,有效阻尼穿越频率变化较小;当防旋板数由36增加到72时,密封交叉刚度降低约24%,有效阻尼穿越频率减小约5 Hz;而当防旋板数由72增加到144时,密封的转子动力特性对防旋板数变化不敏感;综合考虑加工成本和止旋抑振性能,具有72个直防旋板的迷宫密封进口防旋板结构方案最优。研究结果可为交错齿迷宫密封防旋板设计提供参考。

多盘连续可变工作间隙磁流变制动器仿真与验证

为提高磁流变制动器制动能效,提出一种多盘连续可变磁流变液工作间隙结构的磁流变制动器。在ANSYS workbench环境下完成不同电流、间隙状态下的三维静态磁场仿真,对磁场沿工作间隙分布状况进行分析,通过试验台架对制动器性能进行测试。结果表明,磁流变液工作区域磁矢量分布相对均匀,无明显积聚现象,磁路设计合理。理论与实验结果变化趋势基本吻合,但在电流较大时,两者之间误差呈逐渐增大趋势。制动力矩在0~2.5 A电流变化区间增速较快,而在2.5~4.0 A区间明显放缓,最大力矩达到146.4 N·m,较间隙未改变状态增加25.80%。设计的制动器TVR值达到48.81 kN·m/m^(3),较传统磁流变制动器结构更紧凑,力矩调节范围更广,设计思路及实验结论对磁流变制动器结构的进一步研究具有借鉴意义。

内外液流通道筒式磁流变制动器制动性能分析

针对传统磁流变制动器磁场利用率不高的问题,提出了一种具有内外液通道的筒式磁流变制动器;通过在缸筒和旋转套筒中增设非磁性器件,使得磁力线蜿蜒通过内外轴向液流通道的6段有效阻尼间隙,从而使该制动器在外形尺寸不变的前提下能产生较好的转矩性能;阐述了内外液流通道筒式磁流变制动器的结构和工作原理,并对有效阻尼间隙在磁场作用下的磁路进行分析;同时推导建立了制动转矩和温度场数学模型;基于COMSOL软件对磁流变制动器电磁场和温度场进行了仿真分析。由电磁场仿真可知,在外加电流为2.0 A、转速400 r/min时,制动转矩可达101.96 N·m,转矩动态可调范围由1.00增加至29.69;由温度场仿真可知,在多次紧急制动下最高温度为42.88℃,符合磁流变液正常工作范围。

一种新型剪切阀式旋转MR制动器的开发与评估

基于磁流变(Magnetorheological,MR)液的流变特性,MR制动器具有的高转矩-体积比(Torque-to-Volume Ratio,TVR)和低功耗优点使其成为一种应用前景广泛的被动力输出装置。为了提高旋转型MR制动器在单位空间内的输出制动转矩,基于凸轮结构提出了一种在剪切阀模式下工作的旋转型MR制动器。首先,介绍了这种新型MR制动器的总体结构,并基于Bingham塑性模型和凸轮模型对MR制动器的输出制动转矩进行了理论推导。然后,利用ANSYS软件和多目标优化设计方法,对制动器的结构进行有限元分析,得到最优的几何参数。在自主搭建的实验平台上对制动器进行了性能测试实验,结果表明,该制动器具有较高的TVR、较低的初始制动转矩和良好的动态特性。该制动器在较小的体积下能够实现最大42.4 kN/m^(2)的TVR,可以很好地满足力触觉交互、康复训练、可穿戴设备等需要小体积和大输出转矩的应用场景。

基于NSGA-Ⅱ的内外液流通道筒式磁流变制动器优化设计

【目的】针对传统磁流变制动器磁场利用率不高的问题,设计了一种具有内外流道的筒式磁流变制动器。【方法】通过将隔磁环和隔磁盘集成在导磁材料旋转套筒和定子磁缸内,使得磁力线蜿蜒穿过内外液流通道的6段有效阻尼间隙,从而在制动器外形尺寸不变的前提下提高了转矩性能。阐述了内外液流通道筒式磁流变制动器的结构和工作原理,同时建立了制动转矩的数学模型。在电磁场和转矩分析的基础上,通过理论计算和DOE实验正交法预测模型精度,并利用NSGA-Ⅱ算法对内外液流通道筒式磁流变制动器进行多目标优化。【结果】结果表明,当加载电流为2.0 A时,制动器的转矩最大值由36.38 N·m提高到47.35 N·m,相比优化前提升了30.15%;转矩动态可调范围系数由18.28提高到21.31,相比优化前提升了16.58%。【结论】优化后的制动器满足无人配送小车的制动性能需求。

设计参数对鼓式磁流变液制动器传动性能的影响

针对传统圆筒式磁流变液制动器制动转矩小的缺点,提出了一种鼓形间隙磁流变液制动的方法。鼓式磁流变液制动器的磁流变液工作体积比圆筒式的更大,从而制动性能显著提升。通过有限元法对装置进行磁场分析,得到了两种间隙形状和鼓形张角对磁场的影响以及不同电流下磁感应强度与轴向距离的关系;建立了鼓式磁流变液制动器转矩与磁感应强度、半径、角速度等参数的关系。结果表明,鼓形的张角对磁流变液的工作体积影响显著;制动器转矩随电流增大而增大,在3 A时输出转矩为10.56 N·m,比圆筒式磁流变液制动器提高了23.6%。

Optimum Position of Electromagnetic Brake on Slab Caster

Three-dimensional mathematical models were developed for studying the molten steel flow and the trajectories of inclusions and bubbles in continuous casting mold with electromagnetic brake.The results show that the effect of the electromagnetic brake on the molten steel flow and the movement of inclusions and bubbles depends on the position of electromagnetic brake.While EMBR Ruler is installed at the exit of the submerged entry nozzle,the velocity of the main jet of molten steel from the nozzle can be decreased effectively,the velocity of the molten steel streams near the free surface and the narrow face is reduced obviously;Meantime more inclusions and bubbles could float up to the slag layer.

Numerical optimisation and experimental validation of divided rail freight brake disc crown

In this study, numerical optimisation and experimental validation of a divided rail freight brake disc crown made of grey cast iron EN-GJL-250 is presented.The analysed brake disc is used in rail freight wagons and possesses a load capacity of 22.5 tons per axle. Two of the divided rail freight brake discs are mounted on each axle.With the aid of numerical analysis, the thermal dissipation properties of the brake disc were optimised and ventilation losses were reduced, and the numerical results were compared with experimental results. A one-way fluid–structure interaction analysis was performed. A computational fluid dynamic model of a divided rail freight brake disc, used to predict air flow properties and heat convection, was incorporated into a finite element model of the disc and used to evaluate the temperature of the disc. A numerical parametrical optimisation of cooling ribs of the brake disc was also performed, and novel optimised cooling ribs were developed. A transient thermal numerical analysis of the brake disc was validated using temperature measurements obtained during a braking test on a test bench. The ventilation losses of the brake disc were measured on a test bench specifically designed for the task, and the losses were compared to the simulation results. The experimentally obtained ventilation losses and temperature measurements compared favourably with the simulation results, confirming that this type of simulation process may be confidently applied in the future. Through systematic optimisation of the divided rail freight brake disc, ventilation losses were reduced by 37% and the mass was reduced by 21%, resulting in better thermal performance that will bring with it substantial energy savings.

Squeeze-Strengthening Effect of Silicone Oil-based Magnetorheological Fluid

In order to study the squeeze-strengthening effect of silicone oil-based magnetorheological fluid （MRF）, theoretical basis of disc squeezing brake was presented and a squeezing braking characteristics test-bed for MRF was designed. Moreover, relevant experiments were carded out and the relationship between squeezing pressure and braking torque was proposed. Experiments results showed that the yield stress of MRF improved linearly with the increasing of external squeezing pressure and the braking torque increased three times when external squeezing pressure achieved 2 MPa.

THE THEORETICAL MODEL FOR PREDICTING CIRCULATION VELOCITY OF HYDRAULIC BRAKE

By rational hypothesis of fluid flow pattern, applied the law of conservation of energy and integrated the laboratory test results, finished the prediction by the theoretical model of cir-culation velocity of hydraulic brake which is important parameter. Thus provide the theoritical basis for hydraulic brake of bblt conveyor whose research has just been started.

Aerodynamic Brake for Formula Cars

In the last years, in formula racing cars championships, the aerodynamic had reached an ever more important stance as a performance parameter. In the last four seasons, Red Bull Racing Technical Officer had designed their Formula 1 car with the specific aim to generate the optimal downforce, in relation to the car instantaneous setup. However, this extreme research of higher downforce brings some negative effects when a car is within the wake of another car;indeed, it is well known that under these condition the aerodynamic is disturbed, and it makes difficult to overtake the leading car. To partially remedy this problem, Formula 1 regulations introduced the Drag Reduction System (DRS) in 2011, which was an adjustable flap located on the rear wing;if it is flattened, allowing to reduce the downforce, increasing significantly the velocity and, therefore, the chances to overtake the leading car. Vice versa, when the flap is closed, it ensures a higher grip, which is very useful especially in medium-slow speed turns. Keeping the focus on the rear wing, but by shifting attention from the increased top speed to increase the grip in the middle and slow speed curves, we decided to study a similar device to the DRS, but with the opposite effect. The aim is to design an aerodynamic brake integrated with the rear wing. In particular, the project idea was to sculpt, on the upper surface of the wing (pressure side), a series of 'C' shaped cavity, normally covered by adequate sliding panels. These cavities, when they are discovered, at the beginning of the braking phase, produce a turbulence and additional increase downforce, lightening the load on the braking system and allowing the pilot to substantially reduce slippage and to delay the braking. Since it seems that the regulations adopted by the FIA Formula 1 Championship do not allow such a device, it has been decided to apply the concept on a Formula 4 vehicle. This paper describes the design and analyzes the effects of these details on a standard wing cavity, using a commercial CFD software.

速度400 km/h高速列车风阻制动装置布置的数值研究

基于三维定常可压的黏性流场N-S及k-ε双方程模型,以CR400AF平台动车组流线型外观为参考,装配新型“蝶形”风阻制动装置,模拟计算高速列车风阻制动装置不同布置状态时的气动特性,给出单排及多排制动风翼板布置的确定方法及最优方案。研究表明:在高速列车头车司机室流线型尾端连接处后2~5 m范围内设置安装首排制动风翼板,可有效为高速列车高速制动阶段提供较为可靠稳定的制动力,同时对首排制动风翼板工作时流固耦合及振动特性进行评估和说明;研究提出以列车制动需求为目标,纵向制动风翼板最优布置范围逐渐缩减的方式,通过计算流体动力学的方法确定制动风翼板设置位置及布置排数选择的研究方法,给出3节编组高速列车2排及3排制动风翼板最优布置方案。

磁流变液与形状记忆合金复合制动性能研究

针对现有磁流变液制动器使用存在发热严重的缺点,设计一种磁流变液与形状记忆合金复合制动装置,利用装置在制动过程中产生的热量,使形状记忆合金弹簧产生附加的摩擦转矩,提高了装置的制动转矩。阐述该复合制动装置结构和工作原理,进行磁场有限元分析、形状记忆合金弹簧挤压力分析以及复合制动转矩分析。结果表明:磁流变液传递的转矩随电流的增大而增大,形状记忆合金弹簧的摩擦转矩随温度的增加而提高;当线圈电流为3 A、温度达到100℃时,复合制动转矩比单一的磁流变制动转矩提升约31.4%。