Influence of Body Stiffness on Vehicle Dynamics Characteristics In
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Influence of Body Stiffness on Vehicle Dynamics Characteristics in Passenger Cars Master's thesis in Automotive Engineering OSKAR DANIELSSON ALEJANDRO GONZALEZ´ COCANA~ Department of Applied Mechanics Division of Vehicle Engineering and Autonomous Systems Vehicle Dynamics group CHALMERS UNIVERSITY OF TECHNOLOGY G¨oteborg, Sweden 2015 Master's thesis 2015:68 MASTER'S THESIS IN AUTOMOTIVE ENGINEERING Influence of Body Stiffness on Vehicle Dynamics Characteristics in Passenger Cars OSKAR DANIELSSON ALEJANDRO GONZALEZ´ COCANA~ Department of Applied Mechanics Division of Vehicle Engineering and Autonomous Systems Vehicle Dynamics group CHALMERS UNIVERSITY OF TECHNOLOGY G¨oteborg, Sweden 2015 Influence of Body Stiffness on Vehicle Dynamics Characteristics in Passenger Cars OSKAR DANIELSSON ALEJANDRO GONZALEZ´ COCANA~ c OSKAR DANIELSSON, ALEJANDRO GONZALEZ´ COCANA,~ 2015 Master's thesis 2015:68 ISSN 1652-8557 Department of Applied Mechanics Division of Vehicle Engineering and Autonomous Systems Vehicle Dynamics group Chalmers University of Technology SE-412 96 G¨oteborg Sweden Telephone: +46 (0)31-772 1000 Cover: Volvo S60 model reinforced with bars for the multibody dynamics simulation tool MSC Adams Chalmers Reproservice G¨oteborg, Sweden 2015 Influence of Body Stiffness on Vehicle Dynamics Characteristics in Passenger Cars Master's thesis in Automotive Engineering OSKAR DANIELSSON ALEJANDRO GONZALEZ´ COCANA~ Department of Applied Mechanics Division of Vehicle Engineering and Autonomous Systems Vehicle Dynamics group Chalmers University of Technology Abstract Automotive industry is a highly competitive market where details play a key role. Detecting, understanding and improving these details are needed steps in order to create sustainable cars capable of giving people a premium driving experience. Body stiffness is one of this important specifications of a passenger car which affects not only weight thus fuel consumption but also handling, steering and ride characteristics of the vehicle. By using a method developed to perform an extensive number of simulations and suitable for the analysis of the interesting points in the design space, it has been proved that not only torsional but lateral and local stiffness can play a role in giving the customer a premium feeling by affecting key metrics in the vehicle dynamics behavior of a passenger car. Furthermore it has been proved that the effect of the body in the vehicle dynamics of a car can be measured and targeted by using test maneuvers and metrics for handling and ride. Keywords: vehicle dynamics, body stiffness, handling, steering, ride, multibody dynamics i ii Preface Fast lead time play an important role during vehicle development. In order to increase vehicle perform and at the same time reduce lead time, testing is moving towards CAE simulations. Due to this movement an increased model accuracy is needed to be able to replace physical vehicle testing which usually takes place late in the design process with virtual testing. Previous work has shown that subjective physical measurements does not match the CAE results, therefore a deeper analysis of the influence of the body stiffness properties in the vehicle dynamics characteristic is needed. Acknowledgements We would like to thank Volvo Cars for the opportunity to perform a Masters Thesis connected to a real world application and for the possibility to use collected data to verify our results. We would also like to acknowledge the importance of all the support we have gotten throughout the project both at Volvo Vehicle Dynamics CAE department and at Chalmers VEAS Division. A special thanks to: Bengt Jacobson, Mathias Lidberg, Matthijs Klomp, Mohsen Bayani Khaknejad & Johan Hultqvist for the continuous supervision, feedback and useful discussions, Stavros Angelis for the support with IPG CarMaker, Kenneth Ekstr¨omfor his precise physical subjective vehicle analysis, Richard Dekker for his help with K&C analysis, Axel Jonson & Daniel Hedendahl for their help with Sympathy For Data and thanks to Asa˚ Eriksson and the Vehicle Dynamics CAE department at VCC for their help, support and nice work environment. iii iv Nomenclature CM CarMaker CAE Computer Aided Engineering VCC Volvo Car Corporation FEA Finite element analysis BIW Body in white CoG Center of gravity MNF Modal neutral file SPMM Suspension Parameter Measurement Machine K&C Kinematics and compliance HPG H¨alleredProving Ground TCL Tool Command Language TCP Transmission Control Protocol CSV Comma-separated values DOF Degrees Of Freedom LLT Lateral load transfer LLTD Lateral load transfer distribution FLLTD Front lateral load transfer distribution VFD Vertical force distribution FVFD Front vertical force distribution RBE2 Rigid Body Element US Understeer v vi Contents Abstract i Preface iii Acknowledgements iii Nomenclature v Contents vii 1 Introduction 1 1.1 Statement of the problem.........................................1 1.2 Research questions.............................................1 1.3 Literature review..............................................1 1.4 Scope and prerequisites..........................................2 1.5 Significance of the study..........................................2 1.6 Report layout................................................2 2 Theory 3 2.1 Body stiffness................................................3 2.1.1 Torsional stiffness............................................3 2.1.2 Bending stiffness.............................................4 2.1.3 Lateral stiffness..............................................5 2.1.4 Local stiffness..............................................6 2.2 Vehicle dynamics characteristic: handling, steering and ride......................6 2.2.1 Handling.................................................7 2.2.2 Steering..................................................7 2.2.3 Ride....................................................7 2.3 Lateral load transfer model........................................7 2.4 Steady state bicycle model........................................ 10 2.4.1 Lateral compliance............................................ 11 2.4.2 Torsional stiffness............................................ 11 2.4.2.1 Axle cornering stiffness........................................ 11 2.4.2.2 Roll steer................................................ 12 2.4.3 Understeer gradient........................................... 12 2.5 Design of experiment............................................ 14 2.6 Statistical analysis............................................. 15 2.6.1 Graphical visualization and correlation of large data sets...................... 15 2.6.1.1 Box-Whiskers............................................. 15 2.6.1.2 Student chart.............................................. 15 2.7 Flexible Bodies............................................... 15 2.8 Tire models................................................. 16 2.8.1 IPGTire (RealTime Tire)........................................ 16 2.8.2 Pacejka 5.2 (Magic Formula)...................................... 16 2.8.3 MF-Tire/MF-Swift 6.1 (RealTime Tire)................................ 17 2.8.4 TameTire................................................. 17 3 Method 18 3.1 Overview.................................................. 18 3.2 Component to subsystem relation..................................... 19 3.2.1 MSC Adams Model........................................... 19 3.2.1.1 Suspension............................................... 19 3.2.1.2 Body.................................................. 20 3.2.2 Parameterization of MSC Adams model................................ 20 3.2.2.1 Suspension............................................... 20 vii 3.2.2.2 Body stiffness............................................. 20 3.2.3 Validation of the model......................................... 21 3.2.4 Simulations................................................ 22 3.2.5 Design of experiment Adams...................................... 23 3.2.5.1 Post processing in modeFrontier................................... 23 3.2.6 FEM Model................................................ 24 3.2.7 Parameterization of FEM model.................................... 24 3.2.8 Validation of FEM model........................................ 25 3.2.9 Load Cases FEM............................................. 27 3.2.10 Design of experiment FEM....................................... 27 3.2.10.1 Post processing in modeFrontier................................... 29 3.3 Subsystem to vehicle relation....................................... 29 3.3.1 CarMaker Model............................................. 30 3.3.1.1 Global body stiffness model...................................... 30 3.3.1.2 Local stiffness model.......................................... 30 3.3.2 Parameterization of CarMaker model................................. 31 3.3.2.1 Suspension parametrization...................................... 31 3.3.2.2 Suspension components........................................ 32 3.3.2.3 Body stiffness parametrization.................................... 32 3.3.3 Validation of the model......................................... 34 3.3.4 Simulations and load cases....................................... 35 3.3.4.1 Brake in turn.............................................. 35 3.3.4.2 Constant radius............................................ 35 3.3.4.3 Constant radius with bump...................................... 35 3.3.4.4 Constant radius with angled bump.................................. 36