Optimal design of a shear magnetorheological damper for turning vibration suppression

The intelligent material, so-called magnetorheological (MR) fluid, is utilized to control turning vibration. According to the structure of a common lathe CA6140, a shear MR damper is conceived by designing its structure and magnetic circuit. The vibration suppression effect of the damper is proved with dynamic analysis and simulation. Further, the magnetic circuit of the damper is optimized with the ANSYS parametric design language (APDL). In the optimization course, the area of the magnetic circuit and the damping force are considered. After optimization, the damper's structure and its efficiency of electrical energy consumption are improved. Additionally, a comparative study on damping forces acquired from the initial and optimal design is conducted. A prototype of the developed MR damper is fabricated and magnetic tests are performed to measure the magnetic flux intensities and the residual magnetism in four damping gaps. Then, the testing results are compared with the simulated results. Finally, the suppressing vibration experimental system is set up and cylindrical turning experiments are performed to investigate the working performance of the MR damper. (paper)