Structure-Enhanced Stress Attenuation in Magnetically Tunable Microstructures: A Numerical Study of Engineered BCT Lattices

Magnetorheological fluids (MRFs) exhibit dynamic, field-responsive mechanical properties, as they form chain-like and networked microstructures under magnetic stimuli. This study numerically investigates the structural and mechanical behavior of three-dimensional (3D) microbead chain assemblies, focusing on cubic and hexagonal body-centered tetragonal (BCT) configurations formed under compressive and magnetic field-driven aggregation. A finite element-based model simulates magnetostatic and stress evolution in solidified structures composed of up to 20 particle chains. The analysis evaluates magnetic flux distribution, total magnetic force, and time-resolved stress profiles under vertical loading. Results show that increasing chain density significantly enhances magnetic coupling and reduces peak stress, especially in hexagonal lattices, where early stress equilibration and superior lateral load distribution are observed. The hexagonal BCT structure exhibits superior resilience, lower stress concentrations, and faster dissipation under dynamic loads. These findings offer insights into designing energy-absorbing MRF-based materials for impact mitigation, adaptive damping, and protective microfluidic structures.