Multi-Physics Numerical Modelling of a Magnetorheological Braking System

The global effort to reconsider transport in compliance with ecological challenges leads to a significant increase in the market share of Electric Vehicles (EVs), enlightening secondary sources of pollution. One of the most important is the particles emitted by the abrasion of braking pads. The innovative system addressed in this paper is among the most promising non-polluting solutions to ensure safety and comfort. It uses the capability of the Magneto-Rheological Fluid (MRF) to change its properties when subjected to a magnetic field, generating a braking torque between a stator and a rotor. This study focuses on characterizing the system's performance and endurance during an emergency braking situation by developing a numerical model that involves fluid and structural considerations. This model takes the form of a Finite-Element Model (FEM) that interpolates local forces determined from Computational Fluid Dynamics (CFD) and takes them as input. It enables analysis of the stresses induced by the variation of fluid behavior described by a Bingham theoretical model developed following experimental rheological results.