Experimental and simulation-based optimization of semi-active suspensions using magnetorheological dampers

Abstract

The dynamic behavior of heavy vehicles is significantly influenced by suspension design, which governs both ride comfort and road-holding characteristics. Conventional passive suspension systems exhibit inherent limitations in isolating the vehicle from road-induced vibrations, especially under high-speed operating conditions. To address this issue, the present study developed a comprehensive bond-graph-based dynamic model of a semi-active suspension system integrated with a magnetorheological damper. The model is experimentally validated using a quarter-car test rig, capturing the nonlinear hysteretic response of the magnetorheological damper through a modified Bouc–Wen formulation. Simulation results are compared with the measured data to confirm model accuracy across varying excitation frequencies and input currents. Subsequently, the response surface methodology is applied to determine the optimal configuration of suspension parameters, namely spring stiffness, damper current, tire stiffness, and tire pressure, to achieve enhanced ride comfort and road-holding. An optimized ride comfort value of 0.679545 m/s 2 and an optimized road holding value of 21.81 mm were obtained with a corresponding desirability value of 0.785. The proposed methodology effectively integrates analytical modeling, experimental validation, and optimization to evaluate and enhance the performance of heavy vehicle suspension systems.