Finite element analysis of multi-level leaf spring systems combined with an MRE-based isolator

A car suspension system reduces vibrations on uneven roads and enhances wheel stability. An advanced solution for improving suspension systems involves the use of smart materials such as magnetorheological elastomers (MREs). When exposed to an external magnetic field, these MREs can change their elastic moduli, making them highly valuable in applications that require adaptive or controllable properties. This paper presents a novel multilevel leaf spring (MLS) system that combines a multilevel steel leaf spring with an MRE-based isolator. The system was analyzed using the finite element method to assess the ability of the vehicle to withstand external forces on different road surfaces. The findings indicate that adjusting the module levels to match forced conditions significantly reduces vibration compared to multilevel leaf spring systems. Amplitude response analysis indicated that the innovative MLS system led to a substantial reduction in vibration amplitude. The natural frequency of the system can also be tuned from 40 to 63 Hz by varying the current applied to the MRE-based isolator. The proposed tuning algorithm effectively prevents resonance across the frequency range of 1–1000 Hz. The leaf spring system aims to enhance the vehicle’s performance, particularly on rough and complex terrain.