Magnetorheological composite dampers for railway wagon suspension: modelling validation and performance analysis

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    Konijeti Sri Manikanta,

  • DVA Ramasastry,

  • T Ravi Kumar,

  • SSS Lokesh,

  1. M. Tech Student, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India
  2. Associate Professor, Department of Mechanical Engineering & IRD, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India
  3. Professor, Department of Mechanical Engineering DMSSVH College of Engineering, Machilipatnam, Andhra Pradesh, India
  4. M. Tech Student, M. Tech Student, Department of Mechanical Engineering, Koneru Lakshmaiah Education Foundation, Vaddeswaram, Guntur, Andhra Pradesh, India

Abstract

Railway wagons encounter continuous vibrations due to track irregularities, resulting in reduced ride comfort and higher dynamic loads. Conventional suspension systems based on springs, hydraulic dampers, or air suspensions provide only limited vibration mitigation. This work investigates the application of magnetorheological (MR) fluid-based dampers, where a polymeric carrier oil (silicone oil) reinforced with carbonyl iron particles serves as a smart composite suspension medium. The MR fluid is synthesized and characterized for stability and rheological behavior, then integrated into damper assemblies for railway suspension systems. Different damper orientations in vertical and lateral directions are implemented, and their performance is evaluated across multiple suspension configurations. Mathematical models of passive and semi-active suspension systems are developed in MATLAB/Simulink, incorporating MR damper dynamics. System responses are evaluated in terms of vertical displacement, angular acceleration of the wagon body, and suspension travel. The results show that semi-active suspension systems with MR composite fluids significantly outperform passive systems, offering improved vibration control, enhanced ride comfort, and practical potential for modern railway applications. Further, the study also demonstrates how tailoring MR composite fluids and their integration into semi-active dampers using various placing configurations and control approaches can significantly enhance railway ride comfort, thereby bridging smart material development with advanced transportation applications. The results demonstrate the benefits of integrating material innovations with contemporary control strategies and underscore the robust potential of MR-based systems to address persistent problems in rail dynamics. Overall, the study highlights that MR dampers can provide next-generation railway suspension technologies with a reliable, flexible, and energy-efficient solution.

Keywords: Polymer-based magnetorheological composite fluid, Carbonyl iron–silicone oil suspension, Smart damping materials, Semi-active suspension systems, Railway wagon ride comfort, Primary and secondary suspension.

How to cite this article:
Konijeti Sri Manikanta, DVA Ramasastry, T Ravi Kumar, SSS Lokesh. Magnetorheological composite dampers for railway wagon suspension: modelling validation and performance analysis. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
Konijeti Sri Manikanta, DVA Ramasastry, T Ravi Kumar, SSS Lokesh. Magnetorheological composite dampers for railway wagon suspension: modelling validation and performance analysis. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=239318


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Ahead of Print Subscription Original Research
Volume 14
02
Received 29/09/2025
Accepted 30/12/2025
Published 28/03/2026
Publication Time 180 Days
60

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