A Shear Stress Model for Magnetorheological Fluid with High Volume Fraction

Abstract

Shear stress prediction in high-concentration magnetorheological fluids (MRFs) faces limitations due to the oversimplified magnetic dipole interactions and neglect of multibody effects in classical single-chain models, particularly under conditions (30-40 vol.%) where stress prediction errors start escalating nonlinearly. To address this gap, based on the classic single-chain model, this study proposed a new revised calculation method that integrates three novel components: (1) a distance-weighted dipole interaction model incorporating material-specific correction factors, (2) dynamic chain reconstruction mechanisms accounting for magnetic aggregation under shear deformation, and (3) transverse field overlap parameters quantifying anisotropic field distributions. Validated against Lord Corp.’s MRF-132DG, the proposed approach reduces shear stress prediction root-mean-square error (RMSE) by 71.7% (from 27.40 kPa to 7.76 kPa). It rectifies the R-square metric from −0.9236 to 0.8457, outperforming existing models in high-concentration regimes. The work resolves the bottleneck of modeling chain-to-network transition behaviors through Monte Carlo simulations with energy barrier analysis, revealing how localized dipole rearrangement governs macroscopic rheological responses. The methodology’s adaptability to pre-saturation magnetization stages further enables systematic evaluation of multi-dipole interaction thresholds critical for high-performance MRF engineering applications.

Keywords

Magnetorheological fluid / Shear stress microscopic model / Magnetically-induced polarization force / Magnetic chain

Author Contributions

Conceptualization: L.M. and C.S.; Methodology: L.M. and Y.T.; Software: L.M. and Y.T. and C.C.; Validation: L.M. and Y.T. and Y.H.; Formal Analysis: L.M. and Y.T.; Writing—Original Draft Preparation: Y.T. and L.M.; Writing—Review & Editing: C.S. and L.M.; Visualization: L.M. and P.X.; Supervision: L.M.; Funding Acquisition: Y.H. and P.X.

Ethics Statement

Not applicable.

Informed Consent Statement

Informed consent was obtained from all subjects involved in the study.

Data Availability Statement

No data was used for the research described in the article.

Funding

This research was supported by Xinjiang Uygur Autonomous Region Key Research and Development Project (Grant No.2022B01036).

Declaration of Competing Interest

The authors declare that they have no known competing financial interests or personal relationships that could have appeared to influence the work reported in this paper.

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