Thanks for the nice words Bryan. As mentioned, I try to take a very scientific approach to a discipline seen as more art than science. I've tried all the typical approaches, including "re-stackor" and as an engineer was frustrated when the actual results didn't match the tool/theory. My current process is very time consuming and involves measuring the bike very accurately (within .005") using a portable CMM arm to determine the kinematics, and scales to determine the mass properties (both by component and in total). I then build a CAD model that mimics these.
Once I have a CAD model I import it into ANSYS, a very sophisticated simulation software. In ANSYS I assign initial damping curves to shock/fork (generated in re-stackor), spring rates to same (including the effects of fork air pressure and shock gas pressure and bottoming systems), preloads, friction tables for any moving part, chain torque table, tire data, and of course an articulated "rider" with proper kinematics and mass properties.
There's a whole process for determining the proper dynamic front/back spring rates (with no damping). After that I'll apply the damping and do more simulations while tweaking the damping curve. Finally, I'll put the entire COUPLED system (most math models do not couple front and rear) through some simulated track conditions where the rear tire is actually driving the system (traction coefficients added) through the chain.
There's literally hundreds of outputs calculated by ANSYS during a simulation of this type. From forces, to velocities, accelerations, elongations (travel), attitude, etc. The trick is identifying the ones that affect the two biggies, comfort and control. Damping changes are just one variable I can alter. Note, I'm currently using Re-Stackor to generate valve stacks required for desired damping curves. Since I can create ANY (ie, physically impossible to achieve) damping curve I want in ANSYS, Re-Stackor keeps me within the limits of current damping control technology, almost! My next level process step is to model the actual valving using CFD to validate damping curves.
Here's a slow motion clip showing shock velocities in one condition (low amplitude, high speed, high frequency).
https://www.instagram.com/p/BtFvLrIgX7I/
Retired Mechanical Engineer, published technical writer, mscperformance.com, Bisimotoengineering.com,