Multi-Objective Pareto Optimization of Hydraulic Shock Absorbers Using a Multi-Domain Modeling Framework

This study introduces a comprehensive modeling framework for the evaluation of automotive hydraulic shock absorbers, developed on the basis of an interdisciplinary coupled model that integrates the shock absorber and the servo-hydraulic test-rig subsystems. The coupled formulation captures the key dynamic interactions within the damper assembly and establishes a virtual experimental environment for multi-criteria design exploration and optimization. Three interdependent performance objectives are addressed concurrently: (i) ensuring damping-force conformity within specified tolerance limits to maintain vehicle stability and safety, (ii) minimizing vibration amplitudes, quantified by piston-rod acceleration as an NVH (Noise, Vibration, and Harshness) performance indicator, and (iii) evaluating the fatigue life of the shim-stack valve system based on alternating stress analysis and experimentally determined Wöhler material characteristics, to ensure long-term operational durability. A Pareto-frontier-based multi-objective optimization strategy is applied to identify and interpret the trade-offs and synergies among these competing criteria. The resulting set of non-dominated solutions provides engineering insight into optimal configuration selection under conflicting design constraints, thereby supporting early-stage, risk-informed decision-making in the development of advanced suspension systems.