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Optimal Design of a T-Shaped Drum-Type Brake for Motorcycle Utilizing Magnetorheological Fluid

This research focuses on developing a new configuration and optimal design of magnetorheological (MR)-fluid-based brake (MR brake in short) for a middle-sized motorcycle that can replace conventional drum-type brake. A novel configuration featuring a T-shaped drum and a hybrid concept of magnetic circuit (using both axial and radial magnetic flux) to generate braking force is proposed for the MR brake. An optimal design of the MR brake considering the required braking torque, the temperature due to zero-field friction of MR fluid, the mass of the brake system, and all significant geometric dimensions is performed. After a brief introduction of the configuration of the proposed MR brake, the braking torque is derived based on Herschel–Bulkley rheological model of the MR fluid. The optimal design of the MR brake is then analyzed taking into account available space, mass, braking torque, and steady heat generated by zero-field friction torque of the MR brake. An optimization procedure based on the finite element analysis (FEA) integrated with an optimization tool is used to obtain optimal geometric dimensions of the MR brake. From the results, discussions on the performance improvement of the optimized MR brake are described.