In modern automotive manufacturing, ensuring the integrity of suspension joints under real-world driving conditions is a critical aspect of vehicle safety and performance. These joints endure substantial transverse loads and large vibrations due to irregular road surfaces, dynamic manoeuvres, and varying environmental factors. As a result, bolt loosening becomes a significant concern, compromising joint integrity and overall vehicle reliability. This paper delves into the challenges associated with maintaining joint integrity, specifically focusing on pre-load determination, torque application, and production-related issues.
The pre-load generated during torquing is the primary factor that ensures a suspension joint remains securely fastened under dynamic road conditions. This pre-load is derived using road load data acquisition (RLDA) inputs, which capture the forces acting on the joint during actual driving scenarios. RLDA inputs provide critical insights into the forces experienced by a joint, enabling engineers to calculate the optimal pre-load required to withstand real-world stressors. The torque applied during assembly is directly dependent on these calculated pre-load values, ensuring the joint remains secure during the vehicle's lifecycle.
During production ramp-up, several concerns arise that impact the torque application process. Friction at the bolt and nut interface plays a significant role in achieving the desired pre-load. Variations in friction surfaces, such as presence of lubrication, debris, or surface roughness, can lead to major issues
These torque-related concerns have cascading effects on production efficiency and workplace safety. Additionally, the increased strain on assembly tools due to high torque demands reduces tool life and increases maintenance costs.
Automotive suspension joints are subjected to significant challenges during production ramp-up due to the interplay of friction, torque, and pre-load parameters. Addressing these concerns is essential to ensure joint integrity, improve production efficiency, and create a safe workplace environment. By adopting advanced monitoring systems, enhancing friction control, and optimizing tool design, manufacturers can mitigate the risks associated with bolt loosening, breakage, and high torque issues, securing the reliability and safety of suspension joints in real-world driving conditions.