This paper presents the results of a study about the influence of the suspension manufacturing and assembly induced dimensional variation on the vehicle dynamic behavior for a compound crank rear suspension. A selection of representative vehicle dynamics metrics has been considered for this assessment and each individual dimensional variation has been categorized with respect to its overall effects on the selected metrics. By doing this, it is possible to identify the critical points where the dynamic behavior of the vehicle is more sensitive to the resulting dimensional variation, therefore creating a new criteria to define the appropriate tolerance control for the manufacturing and assembly of the related parts.
The analysis procedure is based on a DOE (Design of Experiments) with the position tolerance of the attachment points between the suspension and the body structure defined as variables, as well as the wheel carrier surface tolerance with respect to position and angle (toe and camber).
The results were obtained by means of a K&C (Kinematic and Compliance) and a constant radius maneuver simulation for the vehicle using a multibody CAE (Computer Aided Engineering) model, where the metrics of interest have been calculated. Finally, these results have been used to rank the influence of each individual tolerance variable on the observed aspects of the vehicle dynamics.