NEW CORRELATION APPROACH FOR BODY DISTORTION OF A COMPLETE VEHICLE USING MBD AND TEST RESULTS

By using a fully trimmed vehicle body as flexible body (MNF model) in a complete vehicle Multibody Dynamics (MBD) analysis, the simulation setup gets considerably closer to the test conditions compared to only using a linear FEM approach. Since the MBD analysis includes the nonlinear behavior of the wheel suspension, the gravity and the rigid body modes of the vehicle, it brings the correlation between simulation and test to a new and more comprehensive level. As correlation criteria, the results of the so-called Multi Stethoscope (MSS) are used. The MSS captures the time history of distortion in all body openings and cross sections and enables a detailed stiffness evaluation of the body using the so-called Opening Distortion Fingerprint (ODF). The ODF gives the quasi-static response while the Operational Deflection Shape (ODS), which is another result of the MSS measurements, reflects the dynamic response. Apart from the different individual steps of this new correlation approach, the paper highlights the importance of considering Component Mode Synthesis (CMS) when embedding and evaluating a linear FE model of the fully trimmed body in the nonlinear MBD environment through an MNF. An example of CMS using the Craig-Bampton method shows the impact of the different parameters included in the CMS. Furthermore, a new graphical feature in combination with the ODS is presented which enhances correlation capability. Finally, an example shows how this new correlation approach can improve the simulation model of a newly developed robotaxi for Waymo.