Geometric parameter optimization of magneto-rheological damper using design of experiment technique

Background: Magneto-rheological (MR) damper is one of the most promising semi-active devices. The MR dampers offer a reliability of a passive system yet maintain the versatility and adaptability of the fully active control devices. Methods: In this paper, an optimization process is developed to optimize the geometrical parameters of an MR damper using finite element method (FEM) coupled with Taguchi approach which is rarely available in the literature. The damping force of the MR damper is selected as an objective function. To achieve this objective, 18 FEM models, based on Taguchi orthogonal array, are developed on ANSYS platform. Results: These results have been analyzed by using the design of experiment (DoE) methodology and an optimized solution is then arrived. The optimal solution is validated experimentally as well as through FEM for 95% confidence level. These results are found to be in good agreement with each other. Conclusions: This paper establishes that numerical technique results, e.g., FEM, can be used over the real experimental results for the geometric parameter optimization of an MR damper. The proposed methodology will save time and resources for designing an optimized MR damper for automotive and other applications. © 2015 Mangal and Kumar.