A full-sized rotor magneto-rheological damper structure is designed based on a kind of inlay coil shear valve structure， and an optimization method of the magnetic circuit structure parameters is proposed by correlating structural parameters with magnetic circuit parameters. Based on the improved Bingham model， the parameterized damper characteristic mathematical model of full-sized rotor magneto-rheological damper is established. By performance test and test verification on samples， impacts of structure parameter， motion parameter and current parameter on magneto-rheological damper performance are studied. By comparing the damping performance curve of the stimulation model with the test curve， we find that the stimulated computation model is complained with the test model， and the performance of samples is stable， which proves that the simulation method has great practical value.