Magnetohydrodynamics Simulation Analysis and Optimization of a Three-Coil Magnetorheological Damper Based on a Multiphysics Coupling Model

A magnetorheological (MR) damper is an intelligent semi-active control device characterized by its output damping force and adjustable coefficient that vary in response to changes in the internal magnetic field. This study proposes a multiphysics coupling model that takes into account the electromotive force within the magnetorheological fluid, which is related to both the magnetic field intensity and shear stress. The Bingham–Papanastasiou constitutive model was employed to accurately represent the dynamic performance during the simulation of magnetorheological dampers, thereby overcoming its discontinuity. The investigation delves into the unique responses elicited by single-coil and three-coil configurations under identical excitation conditions. Through theoretical and magnetohydrodynamic analyses, the nonlinear rheological behavior of the MR fluid is elucidated. The study also scrutinizes the effects of various internal structural parameters on the mechanical characteristics of the MR damper using the results of simulations. An assessment of parameter sensitivity on the damper’s output was carried out, and the response surface methodology was subsequently utilized to derive a surrogate model expression. Ultimately, an optimized design was obtained, achieving a balance between output damping force and adjustable coefficient. This method lays the groundwork for the mathematical modeling and simulation analysis of multi-coil magnetorheological dampers.