This paper describes an approach to simulate spindle coupled full vehicle durability tests for the purpose of completing virtual durability evaluations on components and full vehicles before a prototype is available. The reproduction of measured spindle loads was achieved on a virtual model of a passenger car coupled to a 4 Degree of Freedom (DOF) and 6 DOF spindle coupled test system. The tools and process improvements developed here will aid both test and analysis engineers in working closer together in solving their durability problems.
By using Remote Parameter Control® (RPC®) technology in the virtual world, analysts have a new method to understand the virtual model by reproducing field-measured or generic road predicted signals for a variety of road surfaces. With newly created test rig models and a user friendly RPC™ iteration process, virtual testing that accurately replicates laboratory tests are now a reality.
A comparison study was conducted to evaluate the difference between virtual testing using 4 DOF and 6 DOF spindle coupled full vehicle test rig models. The results show that a 4 DOF testing systems can only accurately reproduce Fx, Fz, Fy, and My wheel force transducer measurements. 6 DOF testing systems can accurately reproduce Fx, Fy, Fz, Mx, My, and Mz wheel force transducer measurements. This is due to the fact that a 6 DOF system can more accurately simulate the forces and moments the vehicle sees on the road.
A virtual to physical correlation study was conducted to compare physical and virtual ball joint forces, the trailing arm force, the assistant link force, suspension spring displacements, and the shock tower acceleration. After identifying and fixing problems related to the vehicle model, a satisfactory correlation result was achieved.