Optimal design and performance analysis of magnetorheological damper based on multiphysics coupling model

Magnetorheological (MR) fluid is a kind of intelligent magnetic material, and MR damper is widely used in various fields based on its rheological properties. Therefore, aiming at the problems of low optimization accuracy and efficiency in the optimization design process MR damper using single physical field analysis method, a multiobjective optimization design method for MR damper based on multiphysics coupling model was proposed. The magnetic circuit of the MR damper was calculated, and the mechanical model, electromagnetic field model, flow field model and stress field model of MR damper were established, respectively. A multiphysics coupling model of the MR damper was established in the COMSOL software. The multi-platform joint optimization model was setup, and a multi-objective optimization design method of DOE combined with the surrogate model was proposed. A test system was built up and the initial and optimal MR dampers were fabricated. The results show that the simulation and experimental error of the damping force and dynamic range of the optimal MR damper are only 4.9% and 8.8% at the applied current of 1.4 A, respectively. Also, the damping force and dynamic range of the optimal MR damper are increased by 21.9% and 11.9% compared with the initial MR damper, respectively, which verifies the accuracy of the multiphysics coupling model and effectiveness of optimal design.