Introduction: The design optimization of vehicle suspension system requires the best trade-off solutions involving the

vertical vehicle body accelerations, suspension working space and dynamic tire load, by finding optimal design variables. These design variables may include suspension spring stiffness, damping coefficient, geometry and inertial parameters. As per our requirements for design optimization, the main objective is to minimize the vertical vehicle body displacement. This is done by choosing the design variable to be the suspension damping coefficient as the main analysis is to be done w.r.t a MRF damper. After the damping coefficient is optimized, the next task is the geometric design of MRF damper which includes the determination of a no. of factors such as the gap size, dynamic range, shaft diameter, active pole length, maximum velocity, piston diameter, total length of damper etc. While some of the parameters are dependent on the characteristics of MR fluid being used, other factors are result of appropriate design of the damper for the desired control ability. After the designing, emphasis is to be paid on the manufacturing and thus a CAD model is created for stress and strain analysis as well as doing motion studies on the model. These studies are helpful in deciding the material for different components of the damper. Progress Made: 1.

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