Design of fast magnetorheological damper using selective laser melting technology

Abstract eng:
This paper examines a potential of structured magnetic circuits for a construction of piston of magnetorheological (MR) damper with short response time, great force range and good mechanical properties. Using complex structures designed according to the magnetic FEM simulation can almost eliminate eddy-currents (and thus response time), reduce the weight of magnetic circuit with only a small drop in magnetic flux in the magnetic circuit. Due to the complexity of shapes of structured magnetic circuits, selective laser melting (SLM) technology is currently considered as the only possible technology. A shape optimization with respect to SLM limitations is therefore proposed. As a material for the magnetic circuit, nearly pure Fe was chosen. This material has very good magnetic properties but the drawback is a very good electric conductivity, which causes large generation of eddy currents during rapid changes of magnetic field. Suggested structured magnetic circuit is compared to a solid magnetic circuit by means of magnetic simulations. Simulations showed that the structured geometry of magnetic circuits can effectively reduce its weight (the weight of bobbin was reduced by up to 45 % and the weight of outer cylinder was reduced by up to 13 %) while time response is reduced more than 18 times and inductance drop is less than 20 %.

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