Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561

www.springerlink.com/content/1738-494x(Print)/1976-3824(Online)
DOI 10.1007/s12206-018-0308-4

Design and analysis of a new magneto rheological damper for washing machine†
Abasin Ulasyar and Ismail Lazoglu*
Manufacturing and Automation Research Center, Koç University, Istanbul 34450, Turkey

(Manuscript Received September 8, 2017; Revised November 29, 2017; Accepted January 5, 2018)

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Abstract

In this article, a new magneto rheological (MR) sponge damper is proposed for suppression of vibrations in a washing machine. The
article presents design optimization of geometric parameters of MR sponge damper (MRSD) using the finite element analysis (FEA) and
first order derivative techniques for a washing machine. The article explains the hysteresis behavior and the relationship of damping force
with input current for the proposed MRSD. Moreover, the characteristics of the MRSD such as energy dissipation and equivalent damp-
ing coefficient are investigated experimentally in terms of input current and excitation amplitude. The passive dampers installed in wash-
ing machine are ineffective in reducing unwanted vibrations at resonant frequencies due to real time unbalanced mass. For this purpose, a
test setup is established in order to compare the performance of passive dampers with the proposed MRSDs in a washing machine. It is
noticed that MRSDs reduce average vibrations of 75.61 % in a low frequency band, whereas in a high frequency band, the MRSDs
lessen average vibrations of 30.57 % in a washing machine. In order to determine the performance of proposed design MRSD, a detailed
comparison of the performance parameters, such as total damping force, passive force, maximum average vibrations after suppression by
MR dampers, maximum current and power ratings is provided with the existing designs of MR damper for washing machine from the
literature.
Keywords: Finite element analysis; Hysteresis; Magnetic circuits; MR sponge damper; Washing machine
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tion algorithm (FFOA)-optimal control algorithm [15-19].

1. Introduction
On the other hand, the MR elastomers are solid field re-
A semi-active magneto rheological device contain MR fluid sponsive materials which consist of magnetic polarized parti-
which consists of micron sized magnetically polarized parti- cles, a rubber matrix and some additives such as silicon oil.
cles suspended in a non-magnetic carrier fluid. The character- The interaction of magnetic particles inside the MR elastomer
istics and apparent viscosity of MR fluid is dynamically plays a very crucial role in its overall functionality. A network
changed with the application of magnetic field. The induced of three dimensional crosslink is created among the magnetic
polarization of magnetic particles in MR fluid produces chain particles of MR elastomer. The strength of the crosslink net-
like structures of particles. These chain like structures in MR work in MR elastomer is a function of applied magnetic field
fluid generate a field dependent yield stress. MR fluid based intensity. A remarkable effect is observed in the modulus
devices are operated in three different modes such as flow property of MR elastomers as compared to its damping prop-
mode, shear mode, squeeze mode or a combination any of erty under the applied magnetic field intensity. The MR elas-
these three modes. The advantages of MR fluid and MR tomers have variable stiffness and are characterized according
damper are utilized in different applications such as a highway to its different modes of operation. In the field-active mode,
bridge structure, drawing press and shock test machine [1-7]. MR elastomer is used in designing different actuators [20].
Similarly, other useful applications of MR fluid and its de- The applications of shear mode MR elastomers are found in
vices are implemented in prosthesis knee, cable-stayed bridge base isolators, vibration isolators and vibration absorbers [21-
and seat suspension of wheeled tractor [8-14]. Smart struc- 23]. Moreover, the squeeze mode MR elastomers are used in
tures such as civil and mechanical structures are integrated compressive spring elements and engineering mounts [24, 25].
with MR dampers that can automatically suppress vibration by Besides that, the MR sponge devices is designed such that
using different intelligent control techniques such as nonlinear the MR fluid is kept inside the absorbent material. Fibre, felt,
H-infinity control, Neuro-fuzzy control and fruit fly optimiza- fabric, open-celled foam, sponge and polyurethane materials
*
Corresponding author. Tel.: +90 212 338 1587, Fax.: +90 212 338 1548 can be used as absorbent matrix materials. The absorbent ma-
E-mail address: ilazoglu@ku.edu.tr trix inside the MR sponge device is used to retain the MR
†
Recommended by Associate Editor Doo Ho Lee
fluid in its active regions. When electric current is applied to
© KSME & Springer 2018
1550 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561
the coil, these iron particles inside the sponge are exposed to
magnetic field where they align themselves according to the
direction of the magnetic field. The MR sponge devices oper-
ate in shear mode to generate yield stress and oppose the ap-
plied shear motion. The MR fluid inside the MR sponge de-
vices perform in post-yield region as compared to MR elas-
tomers whose particles chains within the polymeric medium
operate in pre-yield region. As compared to MR fluid based
devices, the MR sponge devices are less constrained due to
their simple open structure. The MR sponge devices can ac-
commodate multiple degree of freedoms. The low-off state
force and high dynamic range of MR sponge devices make
them highly robust for those applications having low to me-
dium range of forces. Moreover, the MR fluid in these type of
devices opposes the gravitational settling due to the wicking
property of the sponge matrix. The MR sponge is utilized in
rotary caliper brakes as well as in linear devices such as tubu-
lar dampers or flat and planar types of dampers [26].
The MR damper control valve is a magnetic circuit used for
generating magnetic flux density through which electrical
control of damping force is achieved. The magnetic circuit of
MR damper is designed using finite element method (FEM)
technique [27, 28]. In this paper, a 2D axis symmetric FEM
model of MR damper is built and analyzed. The desired value
of magnetic flux density and damping force is evaluated at
different values of electric current by performing design opti-
mization in FEM. The design and the field direction of mag-
netic circuit of MRSD is such that only small amount of MR
fluid shows the MR effect in the active regions as compared to
MR elastomer devices which require larger area to achieve the
desired MR effect by using the same geometry.
The spinning process in washing machines is a source of
undesired vibrations and noise [29]. During the spin cycle, the
unbalanced mass produces the disturbing centrifugal force that
excites the vibratory motion of the tub [30]. In the literature,
there are different methods applied for suppression of vibra-
tions in washing machine, which are categorized into two
main techniques. The first technique suggests balancing of the
tub for suppressing unwanted vibrations [31, 32]. This tech-
nique demonstrates a hydraulic dynamic balancer containing
salt water, which is used to balance the dynamics of the tub.
The fluid in the balancer shifts to unbalance side when the
speed of rotation becomes greater than the speed of drum [31].
Two balancing masses can also be used as a dynamic balancer
for suppressing the vibrations [32]. On one hand, this tech-
nique provides a great reduction of vibrations in the washing
machine, but on the other hand it requires a highly complex
mechanical structure as well as incurs huge cost and mainte-
nance.
The second technique utilizes the exploitation of controlled
damping in washing machine. It is observed that during the
spinning of the drum of washing machine, a low resonant
frequency range occurs between 200 to 400 RPM. This reso-
nance is experienced due to the unbalanced mass of the drum
of washing machine. Moreover, when the drum starts spinning
at high frequencies, the top and chassis panels contribute to
severe vibrations of washing machine. These vibrations are
due to the high resonant frequency range of washing machine
which occurs between 1000 RPM to 1400 RPM. However, the
washing machine usually uses fixed damping of passive
dampers for the suppression of vibrations. It is noticed that,
the passive dampers are ineffective in maximum suppression
of vibrations in the low resonant frequency region. Further-
more, the excitation force of the rotating drum is passed
through passive dampers to the panels of washing machine in
high resonant frequency region. This excitation force results
into vibrations of washing machine which further causes the
instability and walking of washing machine. Therefore, the
passive dampers are substituted with MR dampers in order to
improve the performance of washing machine at low and high
resonant frequencies.
The MR sponge damper is ideal for low force, cost effec-
tive, commercial and high productive applications. MR
sponge damper requires no sealing and a small amount of MR
fluid is used with minimum structural complexity as compared
to other designs of the MR damper for washing machine [33-
38]. A low cost MR sponge damper is also used in high per-
formance washing machines [39-43]. However, all these de-
signs provide a low value of total damping force and high
value of passive force. The MRSD proposed in this article has
high total damping force and low passive force for efficient
reduction of vibrations at low and high frequencies. Moreover,
it is shown experimentally in washing machine that at full
load suppression of average vibrations by the newly designed
MRSDs is better than the existing designs of MR damper. The
main contributions of this paper are as follows:
(1) A complete design optimization of the proposed MR
sponge damper is performed using FEA and a first order tech-
nique such as golden section algorithm. The relationship of
geometric parameters is investigated and validated experimen-
tally for the required values of magnetic flux density and
damping force at different values of electric current.
(2) An experimental test setup is built to compare the per-
formance of passive damper with the proposed MR sponge
damper in a washing machine. It is clearly demonstrated from
experimental tests that MRSD is very effective in suppressing
vibrations at resonant frequencies in low and high frequency
bands.
(3) The performance comparison of the proposed MR
sponge damper with the available MR dampers for washing
machine in the literature is provided.
2. Design optimization of MR sponge damper
A two dimensional (2D) model of washing machine is
shown in Fig. 1. The tub assembly of the washing machine is
suspended with two springs and two passive dampers. The tub
assembly inside the washing machine passes through different
resonant frequencies. These vibrations are caused due to the
unbalanced laundry inside the drum. The impact of passive
 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561
Table 1. Typical specifications of MRF-140CG [44].
Appearance Dark gray liquid
Viscosity, Pa-s @ (40 °C(140 °F)
0.280 ± 0.070
Calculated as slope 800-1200 sec -1
g æ lb ö
Density ç ÷ 3.54 - 3.74 (29.5 - 31.2)
cm3 è gal ø
Solid content by weight, % 85.44
Flash point, °C(°F) > 150(> 302)
Operating temperature, °C(°F) -40 to + 130 ( -40 to + 266 )
Fig. 1. Two dimensional model (2D) of washing machine.
dampers inside the washing machine is less effective at low
and high resonant frequencies, which cause undesirable noise
and failure of the machine. A three dimensional (3D) CAD
model of the proposed MRSD of washing machine is shown
in Fig. 2. It consists of ball joint, piston rod, cylinder, cover of
cylinder and bottom clamp. The piston of MRSD is a coil with
a sponge which is wrapped around the coil. The sponge is an
absorbent material filled with MR fluid 140-CG from Lord
Corporation and its physical properties are given in Table 1
[44]. The proposed MR sponge damper operates in a shear
mode, in which the cylinder acts as a stationary plate fixed to a
structure using a cover and bottom clamp and the piston acts a
movable plate with respect to the cylinder. The piston moves
inside a cylinder with a stroke of ±15 mm. It is highly recom-
mended to use low carbon steel for the design of the coil of
MR damper. Therefore, AISI-1020 steel is selected as a mate-
rial for the piston and cylinder. To avoid any leakage of mag-
netic flux, aluminum is used to manufacture the clamp, a
cover of the cylinder and shaft of the piston. Fig. 3 presents a
2D cross section view of the assembled MR damper showing
the design parameters such as coil length, flange length, core
radius, thickness of cylinder and sponge respectively. These
parameters play a very crucial role in the design and function-
ality of MR damper.
A finite element analysis is performed on 2D axis symmet-
ric model of MR damper. A mesh of magnetic circuit of MR
damper is created using 112725 domain elements and 2216
boundary elements. An electric current of 0.25 A is used dur-
ing the finite element analysis of magnetic circuit of MR
damper. A copper wire of diameter 0.33 mm is chosen for the
coil to withstand maximum current of 0.25 A. The desired
1551
Fig. 2. 3D model of proposed MR damper with its parts description.
Fig. 3. Design parameters in 2D cross section view of assembled MR
damper.
Fig. 4. Magnetic flux density distribution in 2D axis symmetric model
of MR damper.
damping force of MRSD is dependent upon the magnetic flux
density at the active areas of MRSD, material permeability of
steel and the MR fluid. A magnetic flux density distribution
across each section of MR damper is given in 2D axis sym-
metric FEM model of MR damper as shown in Fig. 4. In order
to evaluate the maximum desired magnetic flux density of
0.72 T for the MR damper at a single flange of the coil, it is
necessary to observe the effect of magnetic flux density by
varying all the design parameters. The cross-sectional area of
active region of MRSD is determined by the flange length Fl .
The magnetic flux density is inversely proportional to surface
area [36]. The high value of flange length results into large
volume of MR fluid at active regions of MRSD. However, the
mass of piston increases by increasing the flange length which
eventually decreases the natural frequency of MRSD. The
magnetic flux density at the active area is directly proportional
to the coil length Cl [36]. The small value of coil length
generates low MR effect across the MR sponge. However, the
thickness of cylinder Ct becomes too small, if the coil length
increases. This increase in coil length results into magnetic
loss due to the magnetic saturation in the cylinder. Moreover,
the increase in the coil length decreases the flange length
1552 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561
Fig. 5. Effect of magnetic flux density at a single flange for different
coil lengths at 0.25 A.
Fig. 6. Effect of magnetic flux density at a single flange for different
thicknesses of cylinder at 0.25 A.
which reduces the volume of MR fluid at active regions of
MRSD. Besides this, the optimum value of coil length is se-
lected according to the desired stroke length of the piston of
MRSD. For this purpose in Fig. 5, a parametric sweep is per-
formed using FEA for an optimal coil length that ranges from
20 to 50 mm. It is observed that the coil length is selected
between 20 to 30 mm according to the desired value of mag-
netic flux density and stroke length. The cylinder’s thickness
is also varied with a parametric sweep function using FEA
which ranges from 2 to 8 mm as shown in Fig. 6. It is ob-
served that the magnetic flux density at active region of
MRSD increases with the increase in thickness of cylinder [36,
38, 45]. However, further increase in the thickness of cylinder
results into saturation of magnetic flux density at the flanges
of MRSD. It is quite evident that after 4 mm there is no sig-
nificant effect on magnetic flux density by increasing the
thickness of the cylinder. Moreover, high value of thickness of
cylinder gives large value of passive force. The core radius
Cr is directly proportional to the magnetic flux density at the
active region of MRSD. The increase in core radius results
into high value of damping force. However, the high value of
core radius increases the passive force of MRSD [36]. More-
over, the high value of core radius increases the weight of the
piston of MRSD. The sponge thickness St affects the damp-
ing force and performance of MRSD. The sponge thickness is
inversely proportional to the magnetic flux density at active
region of MRSD [36, 38, 45]. The small value of sponge
thickness gives greater MR effect and damping force. How-
ever, this low value of sponge thickness results into high pas-
sive force of MRSD. On the other hand, the maximum yield
stress can also be achieved through the complete alignment of
carbonyl iron particles inside the MR sponge when it is sub-
Fig. 7. Behavior of yield stress with the reduction in the weight percent
of the particles in MRF-140 CG.
jected to the magnetic field intensity. The chain like structures
of the particles are oriented perpendicular to the surface of
cylinder of MRSD in order to achieve desirable damping force.
Besides this, the yield stress of MRSD is directly proportional
to the weight percent of particles of MR fluid. Moreover, the
number of particles in MR fluid has direct relationship with
the weight percent of particles of MR fluid. A test is per-
formed by using the apparatus “Anton Paar Rheometer MCR
302” in order to observe the behavior of yield stress with re-
spect to weight percent of particles of MRF-140 CG. The
MRF-140 CG contain 85.44 wt% (weight percent) of particles.
It is demonstrated, that the yield stress decreases by reducing
the weight percent of particles to 80 wt% of MRF-140 CG as
given by Fig. 7.
The design optimization procedure of MRSD can also be
performed by using several other techniques such as first order
derivative (FOD), second order derivate (SOD) and non-
derivative (NND). The SOD technique has a faster conver-
gence rate, however using this method, the solution of linear
equations proves to be expensive for the applications which
has large geometry. The NND techniques such as neural net-
works, genetic algorithms and simplex have low convergence
rate. This technique is applied on those function which are
random in nature. However, it is not suitable to apply NND
techniques on those functions whose design variables are in-
terdependent on each other. Therefore, the NND techniques
are not applied to systems which utilizes the MR fluid. The
convergence rate of FOD technique is less than the SOD.
However, the computational cost of FOD technique is inex-
pensive as compared to SOD technique. In this article, a FOD
technique such as golden section algorithm (GSA) is adopted
by using Fig. 10 for the optimization of geometry of MRSD.
The optimization of the design parameters of MRSD is ex-
plained in the following steps given below and their results are
presented in Fig. 8.
(1) Initialization of geometric design parameters Dp such
as; Fl , Cl , Cr , Ct and St .
(2) Calculate the values of L, Ro , Awire , l1 , Amrf , A1 , l10 , A10 ,
l9 , A9 , l7 , A7 , l6 , A6 , where Awire is the cross-sectional area of
the wire of coil and Amrf is the surface area of active regions
of MRSD.
(3) Maximize the objective function of magnetic flux den-
sity at active regions of MRSD as given by Eq. (1).
 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561 1553

Table 2. Final optimization results of parameters of MRSD.

Parameters GSA FEM Final value

Fl (mm) 5.975 6.013 6

Cl (mm) 25.014 25.109 25

Cr (mm) 19.891 20.052 20

Ct (mm) 4.954 5.027 5

Fig. 9. Overall flow diagram of MRSD design optimization, analysis,
St (mm) 1.583 1.608 1.6 vibration control mechanism and testing in washing machine.
Bmrf (T) 0.7157 0.7204 0.72

Fig. 10. 2D cross-sectional view of single coil MR damper showing

different geometric parameters and regions of magnetic circuit.
Fig. 8. Optimization of design parameters for the desired magnetic flux
density by using golden section algorithm.
machine is given in Fig. 9.
Bmrf ( D p ) =
3. Analytical modeling of MRSD
m 4 ( L - 2 Fl )( Ro - Cr - St - Ct ) I
.
æ lm A
Awire ç 2 St + 1 mrf mrf
2l m A 2l m A 2l m A lm A ö
+ 10 mrf mrf + 9 mrf mrf + 7 mrf mrf + 6 mrf mrf ÷
A magnetic circuit of MR damper is investigated analyti-
è mlcs A1 mlcs A10 mlcs A9 mlcs A7 mlcs A6 ø cally to find the effect of each geometric parameter on mag-
Subject to: Flmin £ Fl £ Flmax netic flux density. A cross-sectional schematic of single coil
Clmin £ Cl £ Clmax MRSD is shown in Fig. 10. The magnetic circuit is divided
Crmin £ Cr £ Crmax (1) into ten regions of reluctance R . A more exact solution can
Ctmin £ Ct £ Ctmax be achieved, if the number of regions is increased in the mag-
Stmin £ St £ Stmax netic circuit of MRSD. However, it will increase the computa-
tional load for solving the magnetic circuit. The total reluc-
where I is the electric current, m mrf and mlcs are the mate- tance R t of the magnetic circuit is given by Eq. (3);
rial permeability of MR fluid and low carbon steel, respectively.
(4) At ( i + 1) th iteration, the new values of design vari- n n
li
Rt = å Ri = å ; where n = 10
ables are calculated by using golden section algorithm as i =1 i =1 µi Ai
given Eq. (2). Z i is the line search parameter and K i is the R t = R1 + R 2 + R 3 + R 4 + R 5 + R 6 + R 7 + R 8 + R 9 + R10
direction vector, which is equal to the negative of gradient of
(3)
Bmrf ( D p ) at i = 0 iteration.
where li is the length of the i th region, µi is the material
D pi+1 = D pi + Z i K i . (2) permeability of the i th region and Ai is the cross-sectional
area at the middle point of the i th region. The lengths and the
(5) When the design parameters Dp of MRSD are con- areas of all ten regions of magnetic circuit are formulated by
verged to their optimal values, then the optimization is Eq. (4);
stopped. Otherwise, the step-(4) is repeated again till the con-
vergence is achieved for the optimal design parameters. l6 = L - Fl ; Ro = Cr + Cw + St + Ct ; Ri = Cr + Cw + St ;
A6 = p ( Ro2 - Ri2 )
It is clearly seen that the optimal values of design parame-
ters and desired magnetic flux density are very close to each St
l8 = l4 = St ; R8 = R4 = Cr + Cw +
other for both the FEM and GSA. In addition to this, the final 2
optimized geometry of MR damper is selected and manufac- A8 = A4 = 2p R8 Fl
tured as given in Table 2. A complete flow diagram of MRSD Ct 3
l7 = l5 = ; R7 = R5 = Ro - Ct ; A7 = A5 = 2p R7 Fl
design optimization and its implementation in the washing 2 4
1554 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561

t = t y ( H ) sgn (g& ) + hg& (8)

where yield stress t y is a function of applied magnetic field

intensity derived in Eq. (7). The relationship of induced yield
stress t y of MR fluid 140-CG from Lord Corporation with
applied magnetic field intensity H is approximated by Eq.
(9) [38];

Fig. 11. Magnetic circuit analogy of Kirchhoff's voltage law for the
single coil MR damper showing reluctances of different regions. t y = a3 H 3 + a2 H 2 + a1H + ao (9)

l1 = L - 2th ; A1 = p Cr2 where a3 , a2 , a1 and ao are the coefficients that are

C C 3 found by using the method of least square curve fitting. The
l9 = l3 = r + Cw ; R9 = R3 = w + Cr ; A9 = A3 = 2p R9 Fl surface area of active regions of MRSD is given by Eq. (10);
2 2 4
th
l10 = l2 = ; A10 = A2 = p ( Cr - tr2 ) .
2
(4) A = 2 ( 2p Fr Fl ) (10)
2

The analysis of the magnetic circuit is done by applying where Fr and Fl are the radius and length of active region
magnetic Kirchoff’s voltage law on Fig. 11. Where F is the respectively. The force F of MRSD is given by Eq. (11);
applied magnetomotive force, Ф is the magnetic flux flow-
ing through the total reluctance R t of the magnetic circuit, F =t A . (11)
N is the number of turns of the coil of MRSD and I is the
applied input current to MR damper. The resultant Kirchoff’s The performance of MRSD is compared with a conven-
voltage law for the magnetic circuit is given by Eq. (5); tional viscous damper by determining the equivalent damping
coefficient Ceq [36]. The energy dissipation W by MRSD
NI = Ф(R1 + R 2 + R 3 + R 4 + R 5 + R 6 + R 7 + R 8 + R 9 + R10 ) in one cycle is given in Eq. (12);
(5)
2p 2p 2p
we we we
2
where R 2 = R10 , R 3 = R 9 , R 4 = R 8 , R 5 = R 7 , m 2 = m10 , W= ò Fdx = ò & =
ceq xdx ò c ( w X cos ( w t ) )
eq e e dt
0 0 0
m3 = m9 , m 4 = m8 , m5 = m7 . Solving for Ф leads to Eq. (6); 2p
we
æ 1 - cos ( 2 wet ) ö
= ceq we2 X 2 ò çç
2
÷÷ dt = ceq we X p (12)
NI è 2 ø
Ф= . (6) 0
l1 2l10 2l9 2l4 2l7 l6
+ + + + +
m1 A1 m10 A10 m9 A9 m 4 A4 m7 A7 m6 A6
where we is the excitation frequency and x& is the relative
velocity of MRSD. By considering a simple harmonic excita-
The magnetic field intensities H 4 and H 8 on the surface tion of x ( t ) = X sin ( wet ) , where X is the peak amplitude
of sponge having MR fluid are the active regions of MRSD. In given to MRSD. The equivalent damping coefficient is de-
addition to this, m1 = m 2 = m3 = m5 = m6 = m7 = m9 = m10 = mlcs , rived in Eq. (13) by using Eq. (12).
where mlcs is the permeability of low carbon steel. Moreover,
m 4 = m8 = m mrf , where m mrf is the permeability of MR fluid. W
The permeability of MR fluid m mrf is considered negligible Ceq = . (13)
X 2p we
as compared to permeability of low carbon steel mlcs . Hence,
the magnetic flux Ф is related to H 4 and H 8 by Eq. (7); 4. Hysteresis modeling of MRSD

Ф The nonlinear hysteresis behavior of MR sponge damper is

B4 = B8 = investigated using different parametric models [46, 47]. In this
A4
study, a hysteretic model is used to explain the hysteresis be-
Ф NI NI
H 4 = H8 = = = . (7) havior of MRSD. This model offers better smoothness of hys-
m4 A4 2l4 2 St
teresis curves due to a tangent hyperbolic function which is
computationally very efficient [48]. The model shows the less
A bingham visco-plasticity model of MR fluid is used to value of the root mean square error as well as computationally
present the total shear stress t in terms of shear strain rate it shows better efficiency due to its simplicity and less number
g& , plastic viscosity h and yield stress t y as given by Eq. of identified parameters. This model consists of hysteresis
(8); component, a dashpot which shows the viscous damping and a
 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561
Fig. 12. Hysteretic model of MR damper.
Fig. 13. Experimental testing setup for MRSD.
spring represents stiffness as shown in Fig. 12. The damping
force of the model is given in Eqs. (14) and (15);
F = cx& + kx + a z + f o
z = tanh b x& + d sign ( x )
( )
where c represents viscous damping, k shows stiffness,
a denotes the scale factor and the tangent hyperbolic func-
tion which is used for modeling the hysteresis behavior of
MRSD is represented by z . The offset force of MR damper
is denoted by f o . In this study, the offset force is considered
negligible due to the absence of accumulator.
5. Experimental setup
A test setup for MR sponge damper is established as shown
in Fig. 13, which includes a linear actuator of Dunkermotoren,
STA-25 with its controller of Copley controls, Xenus XTL-
230-36-S, a laser displacement sensor of Keyence, IL-300, a
table type dynamometer of Kistler, Type 9257B with its mul-
tichannel charge amplifier of Kistler, Type 5019B and a com-
bined DC power supply of EZ for linear actuator and laser
displacement sensor. A coil inside the MRSD is energized by
another DC power supply of TTi CPX400D Dual 420 watt,
which results in a magnetic flux density depending upon the
value of input current. A linear actuator is coupled with
MRSD and excited at different ranges of amplitudes and fre-
quencies. A laser displacement sensor measures the displace-
ment of MR sponge damper during its excitation from linear
actuator. The force of the MRSD is measured by the table type
dynamometer in axial direction. The force of the MRSD
damper depends on the supplied current as oppose to passive
dampers which rely on its stroke velocity. The input current
rating of MR damper is 0-0.25 A with the peak force of 220 N
in both directions. In order to compare the performance of
1555
Fig. 14. Experimental test rig for performance comparison of passive
and MR sponge dampers.
MRSD with passive dampers in a washing machine, a test rig
is made as shown in Fig. 14. The washing machine model
BEKO, ECO WMB 81445 LW is used in this work has
suspended mass attached to the cabinet using two springs and
two dampers. The suspended mass consists of drum, water
and clothes in the tub and a pulley with motor. The drum of
the washing machine is rotated in clockwise and anticlockwise
directions at maximum spin speeds of 1400 RPM. The two
SUSPA passive dampers of model no. RD 32 FK are used
(14) inside this washing machine. Each passive damper has a
(15) maximum damping force of 100 N. The extended and
compressed lengths of the passive damper are 280 mm and
198 mm, respectively. The performance of passive and MR
sponge dampers are tested and analyzed by installing first both
passive dampers and then substituted it with two MR sponge
dampers in the washing machine. A single DC power supply
of TTi CPX400D Dual 420 watt is used for a continuous
supply of electric current to both MR sponge dampers. A laser
displacement sensor of Keyence, IL-300 is fixed to a beam
attached to a vibration isolation table. A reflection tap is glued
on the surface of weight attached to the tub assembly of the
washing machine for the laser displacement sensor. Moreover,
the measurement of angular velocity is realized using Allegro
A1324 hall-effect sensor. The sensitivity of the sensor is
5 mV/Gauss and its internal bandwidth is 17 kHz.
6. Results and discussion
A hysteretic model is used to study the hysteresis behavior
of the proposed MR sponge damper. The model is applied to
determine the hysteresis curves of force-velocity and force-
displacement. For this purpose, an optimization procedure is
defined in MATLAB/Simulink to minimize the root mean
square error (RMSE) between the experimental force Fexp
and hysteretic model force Fhm as shown in Fig. 15. In the
first stage of optimization, the experimental data of displace-
ment, velocity, force and input current are loaded. The test
data is collected at excitation amplitudes of 4 mm, 5 mm and 6
mm at different frequencies of 2 Hz and 3 Hz. Each set of
experimental data for displacement, velocity, force is collected
at fixed excitation amplitude and frequency. In addition to this,
1556 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561
Fig. 15. A flow diagram showing the optimization process for model-
ing the hysteresis behavior of MRSD.
Fig. 16. Hysteresis curves of force vs velocity for different values of
current at 6 mm and 3 Hz.
Fig. 17. Hysteresis curves of force vs displacement for different values
of current at 6 mm and 3 Hz.
at each excitation amplitude and frequency, the applied input
current is varied from 0 A to 0.25 A with an increment of 0.05
A. Initially, the predicted force of hysteretic model is evalu-
ated by initializing the parameters of hysteretic model. The
minimum of RMSE of objective function is determined by
using fminsearch in MATLAB/Simulink. The optimal values
of c, k, α, β and δ are obtained by finding the minimum of
objective function J. The behavior of hysteresis curves of the
force-velocity and force-displacement for the experimental
data and simulated hysteretic model at different values of elec-
tric current are given in Figs. 16 and 17. The relationship be-
tween the total damping force and the applied input current is
investigated using the analytical model of MRSD. For this
purpose, the analytical model of MRSD is implemented in
MATLAB/Simulink. The damping force is evaluated in terms
of shear stress and surface area of active regions of MRSD as
given by Eq. (11). The total shear stress of MRF-140 CG is
determined by using bingham visco-plasticity model of MR
fluid as given by Eq. (8). The yield stress is dependent upon
the magnetic field intensity at active regions of MRSD. More-
over, the magnetic field intensity at active regions of MRSD is
changed by varying the number of turns, electric current and
sponge thickness as shown in Eq. (7). Besides this, the effect
Fig. 18. Relationship of damping force of MR sponge damper with
different values of input currents.
of electric current on total damping force is also determined
experimentally by exciting MRSD with the linear actuator. A
linear actuator excites the MR sponge damper sinusoidally at
an amplitude of 8 mm and frequency of 10 Hz. In addition to
this, the input current to MR sponge damper is varied from 0-
0.25 A and the force is measured by the table type dynamome-
ter. The data of force from the dynamometer is acquired using
the national instruments (NI) USB 6259 Data Acquisition
(DAQ) card. Fig. 18 shows experimentally the behavior of
damping force of MRSD with respect to electric current along
with the forces which are determined by using the analytical
and FEM models of MRSD. The relationship of energy dissi-
pation W and equivalent damping coefficient ceq of MR
sponge damper with respect to input current and sinusoidal
signal amplitude of a constant frequency are investigated at
different testing conditions. From the linear actuator, a sinu-
soidal signal of different amplitudes of 4 mm, 5 mm, 6 mm
and 7 mm of fixed frequency of 3Hz is given to MRSD hav-
ing an input current of 0 A, 0.05 A, 0.1 A, 0.15 A and 0.2 A.
The input current to MR sponge damper is fixed at a constant
value during each excitation signal from linear actuator. The
dissipation of energy W by MRSD in one cycle is deter-
mined from the area enclosed by the hysteresis curve of force-
displacement. It is observed that at a particular frequency and
for different values of excitation amplitudes, the dissipation of
energy is increased versus input current as shown in Fig. 19.
Likewise, for different values of input current, the energy
dissipation increases versus excitation amplitudes at a same
constant frequency as given in Fig. 19. The greater energy
dissipation is due to high excitation amplitude which results
into large area of force-displacement hysteresis curve. In addi-
tion to this, the maximum energy dissipation is also observed
due to the high value of input current which results in greater
damping force.
On the other hand, for different excitation amplitudes at
fixed frequency, the equivalent damping coefficient increases
versus input current as shown in Fig. 20. The increasing trend
of equivalent damping coefficient is more obvious at low exci-
tation amplitudes. This is due to the fact that the velocity is
lowered at a particular frequency for small value of displace-
ment. However, for different values of input current the
 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561
Fig. 19. Effect of energy dissipation of MR damper for different exci-
tation amplitudes at fixed frequency of 3 Hz.
Fig. 20. Effect of equivalent damping coefficient of MR damper for
different excitation amplitudes at fixed frequency of 3 Hz.
Fig. 21. Vibration control mechanism of washing machine using MR
dampers and on/off controller.
equivalent damping coefficient dramatically decreases versus
excitation amplitude at a constant frequency as given in Fig.
20. The decreasing trend of equivalent damping coefficient is
clearly visible for high values of input current. This trend is
due to the inverse relation of equivalent damping coefficient
with excitation amplitude.
The block diagram in Fig. 21 shows a complete vibration
control mechanism for washing machine. The angular velocity
of washing machine is measured using hall-effect sensor. The
decision of the On/Off controller is based on the measured
RPM from the washing machine. The on/off controller with
PWM control is implemented with national instruments (NI)
USB 6259 DAQ card using Real Time windows target in
MATLAB/Simulink. The input sampling frequency of DAQ
card is 10 kHz. Moreover, the switching frequency of the
PWM input control voltage is 20 kHz. The PWM control
drives the power amplifier circuit which is built to supply
current to MR sponge dampers.
The washing machine is tested in spin plus drain mode with
different unbalanced masses of 14 kg, 16 kg, 18 kg and 20 kg.
The spin cycle ranges from 0 RPM to 1400 RPM. The
1557
Fig. 22. Performance comparison of passive and MR dampers at un-
balanced mass of 20 kg.
unbalanced mass inside the drum of washing machine is
composed of water and laundry. Initially, the weight of the
water is fixed at 12 kg in each unbalanced mass. However, for
each unbalanced mass the weight of the laundry is varied from
2 kg to 8 kg with an increment of 2 kg. The laundry sticks to
the surface of the drum after the spinning speed of about 80
RPM to 200 RPM. The measured displacement of a spin cycle
is recorded by laser displacement sensor for both passive and
MR sponge dampers. The duration of collected data for a spin
cycle is set to 400 seconds. The spin cycle is performed five
times for each unbalanced mass using passive dampers. The
average data for each unbalanced mass is determined and
investigated for further analysis. It is found that the higher
amplitude of vibrations is obtained at the unbalanced mass of
20 kg. Fig. 22 shows the amplitude of vibrations at the
unbalanced mass of 20 kg for both passive and MRSDs. The
dynamics of the drum show resonance in the low frequency
band which varies from 200 RPM to 400 RPM. The passive
dampers each of 100 N inside the washing machine are unable
to suppress the high amplitude of vibrations due to the
resonance. It is due to the reason that the passive dampers have
low damping and time delayed characterstics of damping. On
the other hand, an input current of 0.25 A is applied to each
MRSD by the power amplifier circuit. The MRSDs reduce
average vibrations of 75.61 % by applying 220 N in a low
frequency band as compared to passive dampers. This
maximum suppression of vibrations is achieved due to the fast
response time to switch from low to high damping ratios.
Furthermore, the MRSDs provide high value of yield stress in
the presence of MR fluid which results into high damping force
in the low frequency band as compared to the passive dampers.
When the washing machine operates in the high frequency
band which ranges from 400 RPM to 1400 RPM, the
vibrations start to become visible from the top and chassis
panels. It is due to this reason that the energy of the drum is
increased due to increase in the spin rate of washing machine
which is directly transferred to both panels. This energy of the
drum at the panels of washing machine result into undersirable
transmissibility of force. The passive dampers inside the
washing machine are ineffective to reduce these vibrations in
high frequency band. It is due to this reason that, the
suppression of these vibrations require very low damping force
1558 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561
Table 3. Comparison of the performance parameters of the proposed
MRSD with other MR dampers for the washing machine in literature.
Parameters MRSD [33, 34] [35] [40]
Tf ( N ) 220 150 80 150
Pf ( N ) 10.76 65 23.5 12.5
I (A) 0.25 3 0.4 2 2.5
P(W)
17.25 35 - 40
Disp ( mm ) 0.807 - - 3.07*
(
Acce m / s 2 ) 0.916 2.790* 1.25* 0.25*
* The data is calculated based on the provided results.
which the passive dampers are unable to offer. Furthermore,
there is no switching mehanism inside the passive dampers to
switch from high damping to low damping forces. However in
the high frequency band, the MRSDs are switched off by the
on/off controller. The MRSDs effectively suppress average
vibrations of 30.57 % in high band frequency by providing
minimum value of zero-field frition force of 10.76 N.
Moreover in the high frequency band, the maximum
suppression of vibrations is achieved due to the high
controllability range of MRSD. The high controllability range
of MRSD is determined using the ratio between maximum and
minimum forces which is about 22:1. Additionally, the
MRSD’s fast response time of about 30 ms helps in efficient
reduction of vibrations in the high frequency band.
The performance of the proposed MRSD with On/Off
controller is compared with the available designs of MR
damper for washing machine using different operating
conditions [33-43]. MR fluid dampers are designed for
washing machine in Refs. [34-38], whereas in Refs. [39, 40,
42, 43], MR sponge dampers are utilized for washing machine.
RD-1005-3 and RD-1097-01 MR dampers from Lord™ Cor-
poration are tested in washing machine in Refs. [37, 43]. An
online batch optimization technique is used as adaptive
control strategy in Ref. [43] for MR dampers in washing
machine, however, analysis of vibration is presented as
normalized vibration index. Moreover, the data of vibration in
washing machine is also not provided in Refs. [36, 38].
Therefore, the comparison of all the performance parameters
of the proposed MRSD is only shown experimentally with
Refs. [33-35, 40-42] as given in Table 3.
The total damping force T f of the single coil MRSD is
220 N, which is required to test the washing machine at full
load capacity of 20 kg. The total damping force of MRSD is
higher than all the existing designs of MR damper [33-43].
This force is very effective for vibration suppression at low
resonant frequency. It is analyzed that the passive force Pf
of the MRSD is 10.76 N. The passive force of MRSD is lower
than the available designs of MR dampers for washing
machine. However, the passive force of single coil MR
damper used in Refs. [41, 42] is 7 N. In addition to this, the
passive force of MR damper with three coil magnetic bobbin
is 8 N [36]. However, it is reported that the passive force
[41, 42] decreases, when the number of coils are increased but it would
effect the stroke length of MR damper [36]. It is observed that,
125
the low value of passive force is required at high resonant
10 frequency. Besides this, the maximum current I and power
P ratings of the proposed MRSD are less than Refs. [33-35,
40-42]. However, the input current and power consumption
are 2.5 A and 1.9 W respectively in Ref. [38]. Moreover, the
24.375
supplied current and power dissipation of three coil MR
- damper are 1.5 A and 16 W respectively in Ref. [36]. The low
value of power is due to small value of winding resistance of
0.933* the coil. It is further investigated that, in terms of acceleration
Acce the proposed MRSD gives average vibrations of 0.916
m/s2 at all RPM as compared to other designs of MR dampers
[34, 35, 42] as given in Table 3. Furthermore, in terms of
displacement Disp , the new MRSD gives average vibrations
of 0.807 mm at all RPMs. This value of displacement is less
than the design of MR damper for washing machine given in
Ref. [40].
7. Conclusion
This article provides a detail design and analysis of a new
MR sponge damper for reduction of vibrations due to unbal-
anced mass in a washing machine. It discusses the 3D CAD
model of MRSD. A 2D axis symmetric model of magnetic
circuit of MR damper is analyzed and evaluated for the opti-
mized geometry of MRSD using finite element analysis and
golden section algorithm. The final designed geometry of
MRSD is manufactured for the dynamic analysis. The article
gives detail explanation about the analytical modeling of MR
sponge damper. The modeling of the hysteresis behavior of
MR sponge damper is performed using the hysteretic model.
Furthermore, the hysteresis curves of force-velocity and force-
displacement of MR damper are determined. The relationship
of force versus input current is presented analytically and vali-
dated with FEM model and experimental results. In addition
to this, the effect of energy dissipation and equivalent damp-
ing coefficient in terms of input current and excitation ampli-
tudes are demonstrated analytically and experimentally. The
performance of MR dampers is compared with passive damp-
ers in terms of displacement of vibrations. It is investigated
experimentally that the proposed MR dampers provide effec-
tive reduction of vibrations in low and high frequency bands
for a washing machine. Furthermore, detail comparison of the
performance parameters of MRSD is demonstrated such as
total damping force, passive force and maximum average
vibrations after suppression by MR dampers.
Acknowledgment
The authors thank to the Scientific and Technological Re-
search Council of Turkey (TÜBITAK) and Arçelik A.Ş for
supporting this research.
 A. Ulasyar and I. Lazoglu / Journal of Mechanical Science and Technology 32 (4) (2018) 1549~1561 1559

Nomenclature------------------------------------------------------------------------ tion of smart passive damping system using MR damper to

highway bridge structure, Journal of Mechanical Science
R : Reluctance and Technology, 21 (6) (2007) 870-874.
Rt : Reluctance of i th region of magnetic circuit [2] Y. W. Yun, H. S. Bae and M. K. Park, A study of the control
li : Length of i th region of magnetic circuit of the blank holding force using an MR damper in a drawing
Ai : Area of i th region of magnetic circuit press, Journal of Mechanical Science and Technology, 24
µi : Material permeability of i th region of magnetic circuit (11) (2010) 2281-2288.
F : Magnetomotive force [3] T. H. Kim, J. S. Bae and C. W. Shul, Investigation on the
Ф : Magnetic flux density parameter determination and implementation of a dual-pulse
N : Number of turns shock test machine using a MR damper, Journal of Me-
I : Input electric current chanical Science and Technology, 30 (12) (2016) 5381-5387.
Hi : Magnetic field intensity of i th region of magnetic circuit [4] Y. W. Yun, S. M. Lee and M. K. Park, A study on the effi-
Bi : Magnetic flux density of i th region of magnetic circuit ciency improvement of a passive oil damper using an MR
Ro : Radius to the outer surface of cylinder accumulator, Journal of Mechanical Science and Technol-
Ri : Radius to the surface of the sponge ogy, 24 (11) (2010) 2297-2305.
Fl : Flange length [5] Y. J. Shin, W. H. You, H. M. Hur and J. H. Park, Semi-
Cl : Coil length active control to reduce carbody vibration of railway vehicle
Ct : Thickness of cylinder by using scaled roller rig, Journal of Mechanical Science
Cw : Coil width and Technology, 26 (11) (2012) 3423-3431.
Cr : Core radius [6] K. Kamalakkannan, A. Elayaperumal and S. Managlaramam,
Fr : Flange radius Input advanced control of semi active half car heave model,
St : Sponge thickness Journal of Mechanical Science and Technology, 27 (5)
tr : Radius of thread (2013) 1225-1231.
th : Length of thread [7] S. Aguib, A. Nour, T. Djedid, G. Bossis and N. Chikh,
L : Total length of cylinder Forced transverse vibration of composite sandwich beam
t : Shear stress with magnetorheological elastomer core, Journal of Me-
ty : Yield stress chanical Science and Technology, 30 (1) (2016) 15-24.
g& : Shear strain rate [8] H. Liu, M. Chen, B. Yu and Z. Fang, Configuration design
h : Plastic viscosity and accuracy analysis of a novel magnetorheological finish-
F : Damping force of MRSD ing machine tool for concave surfaces with small radius of
W : Energy dissipated by MRSD curvature, Journal of Mechanical Science and Technology,
Ceq : Equivalent damping coefficient 30 (7) (2016) 3301-3311.
we : Excitation frequency [9] A. Poznic, D. Miloradovic and A. Juhas, A new magnetor-
x& : Relative velocity heological brakes combined materials design approach,
X : Peak amplitude given by the linear actuator Journal of Mechanical Science and Technology, 31 (3)
c : Viscous damping (2017) 1119-1125.
k : Stiffness [10] J. U. Seo, Y. W. Yun and M. K. Park, Magneto-rheological
a : Scale factor accumulator for temperature compensation in hydropneu-
fo : Offset force of MR damper due to the accumulator matic suspension systems, Journal of Mechanical Science
b & d : Hysteresis modeling parameters used in tangent hy- and Technology, 25 (6) (2011) 1621.
perbolic function [11] H. Sayyaadi and S. H. Zareh, Intelligent control of an MR
Fexp : Experimental force prosthesis knee using of a hybrid self-organizing fuzzy
Fhm : Hysteretic model force controller and multidimensional wavelet NN, Journal of
J : Objective function of the root mean square error be- Mechanical Science and Technology, 31 (7) (2017) 3509-
tween experimental and hysteretic model forces 3518.
Tf : Total damping force [12] N. Mohammadi, M. J. Mahjoob, B. Kaffashi and S. Mala-
Pf : Passive force kooti, An experimental evaluation of pre-yield and post-
I : Current yield rheological models of magnetic field dependent smart
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Acce : Acceleration [13] S. W. Cho, J. H. Koo, J. S. Jo and I. W. Lee, Vibration
control of a cable-stayed bridge using electromagnetic induc-
tion based sensor integrated MR dampers, Journal of Me-
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1561
Abasin Ulasyar was born in Pakistan,
in 1986. He received the B.S. degree in
telecommunication engineering in 2011
from the FAST-NUCES, Islamabad,
Pakistan and the M.S. degree in elec-
trical engineering (Energy & Control) in
2013 from the University of
Engineering and Technology, Taxila,
Pakistan. He is currently a Ph.D. scholar in Department of
Electrical and Electrical Engineering, Koç University, Istanbul,
Turkey. Since 2014, he is working as Research Assistant at
Manufacturing and Automation Research Center, Koç Uni-
versity. His research interests include power electronics,
mechatronics and control of linear and nonlinear systems.
Ismail Lazoglu was born in Turkey. He
received the B.S. degree in mechanical
engineering in 1989 from Istanbul
Technical University, Istanbul, Turkey.
He received the M.S. and Ph.D. degrees
both in mechanical engineering from
Georgia Institute of Technology, Atlanta,
USA, in 1992 and 1997, respectively.
Since 2012, he is working as Professor of Mechanical Engi-
neering at Koç University, Istanbul, Turkey. He has more than
130 publications in the international journals, conferences and
books. His research interests include advanced manufacturing,
mechatronics and medical systems. He is the Fellow of the
International Academy for Production Engineering (CIRP).