Design, fabrication and testing of a magnetorheologic fluid braking system for machine tool application

Abstract

This technical article introduces a governable brake system that can be relevant for different machines, developed using magnetorheologic (MR) fluids. As an initial step, new MR fluids are developed considering different compositions of various constituents pursued by the formulation of a numerical model considering various elements such as magnetic field strength, magnetic particle size and MR fluid yield strength. Using a commercial software, COMSOL, a magnetically energized circuit is examined to obtain the details regarding the number of turns, current supply and strength of the magnetic field at predefined points, and a simulation study is carried out. Successively, the developed and optimized MR fluid is introduced between the gap of the fixed plate and rotating disk under the influence of the magnetic field over the fluid territory. A full-fledged test rig setup for the MR brake system is established, and an experimental study is carried out focusing on the shaft speed and braking torque developed during the braking process. The results are also plotted for various current input values. The current input value ranges from 0 to 2 amp, and the respective torque value is obtained. Likewise, the performance of the torque by the proposed MR brake system used simulated results in a derived theoretical model, and a comparative study is carried out with the experimented results.