Abstract. We present an improved experimental validation of our nonlinear quasi-steady electrorheological (ER) and magnetorheological damper analysis, using an idealized Bingham plastic shear flow mechanism, for the flow mode of damper operation with leakage effect. To validate the model, a double-acting ER valve or bypass damper was designed and fabricated. Both the hydraulic cylinder and the bypass duct have cylindrical geometry, and damping forces are developed in the annular bypass via Poiseuille flow. The ER fluid damper contains a controlled amount of leakage around the piston head. The leakage allows ER fluid to flow from one side of the piston head to the opposite side without passing through the ER bypass. For this flow mode damper, the damping coefficient, defined as the ratio of equivalent viscous damping of the Bingham plastic material, C_eq, to the Newtonian viscous damping, C, is a function of the non-dimensional plug thickness only. The damper was tested for varying conditions of applied electric field and frequency using a mechanical damper dynamometer. In this analysis, the leakage damping coefficient with incorporated leakage effects, predict the amount of energy dissipated for a complete cycle of the piston rod. Measured force verses displacement cycles for multiple frequencies and electric fields validate the ability of the non-dimensional groups and the leakage damping coefficient to predict the damping levels for an ER bypass damper with leakage. Based on the experimental validation of the model using these data, the Bingham plastic analysis is shown to be an effective tool for the analysis-based design of double-acting ER bypass dampers.

Print publication: Issue 3 (June 2003)
Received 22 January 1999, in final form 10 January 2003
Published 28 April 2003