This　article　presents　the　design　and　multi-physics　coupling　analysis　of　a　shear-valve-mode　magnetorheological　fluid　damper　with　different　piston　configurations.　The　finite　element　model　is　built　to　study　the　effects　of　the　shape　of　the　piston　slot　and　magnetism-insulators　at　both　ends　of　the　piston　yoke　on　the　performance　of　the　magnetorheological　damper.　Particle　swarm　optimization　and　finite　element　simulation　are　combined　to　optimize　the　structural　parameters　of　the　magnetorheological　damper.　The　influences　of　different　piston　configurations　on　the　magnetic　flux　density　in　the　working　gap,　the　shear　stress,　the　viscous　stress,　and　the　dynamic　range　are　investigated.　The　simulation　results　reveal　that　the　magnetorheological　damper,　in　which　the　corners　of　the　piston　slot　are　chamfered　and　the　edges　of　the　magnetism-insulators　are　filleted,　exhibits　a　better　damping　performance.　Furthermore,　magnetorheological　dampers　with　and　without　magnetism-insulators　are　fabricated.　The　influences　of　control　current,　displacement,　and　velocity　on　the　mechanical　performance　of　the　magnetorheological　dampers　are　experimentally　investigated,　and　the　experiment　results　are　in　accordance　with　the　theoretical　derivation　and　finite　element　simulation　results.