In order to meet the damper performance requirements of heavy vehicles, a stepped-bypass magnetorheological damper is proposed. The mathematical model of damping force is deduced, and its mechanical properties are numerically simulated. Then the damper is manufactured, and the mechanical properties of the stepped bypass magnetorheological damper are experimentally studied. The simulation are consistent with the experimental results. The damper is optimized by orthogonal optimization design test. Finally, it is concluded that the maximum output damping force of the stepped bypass magnetorheological damper is about 4500 N, and the adjustable coefficient K is about 5.4. After optimization, the damping force of the stepped bypass magnetorheological damper is increased by at least 5.3%, and the adjustable coefficient K is at least 1.37 times that before optimization, which is 13% wider than that before optimization.
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