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Improve Transient Response Correlation of SUV Using MSC.ADAMS & MSC.EASY5 Functional Mock-Up Interface for Hydraulic Power Steering System

Mahindra Research Valley-Baskar Anthonysamy, Visweswara Lenka, Balaramakrishna N, Abhijit Londhe
  • Technical Paper
  • 2020-01-0651
To be published on 2020-04-14 by SAE International in United States
This paper presents a comprehensive model of a hydraulic power steering system for predicting the transient responses under various steering inputs.The hydraulic system model, which integrates together all fluid line elements and hydraulic components, is formulated using the MSC Easy5 software. A full vehicle model is developed in ADAMS/Car. Functional Mock up Interface (FMI), a tool independent standard is used for co-simulation of ADAMS and Easy5 Dynamic models.This paper describes a co-simulation methodology developed using FMI interface for full vehicle Simulations using hydraulic power steering. A virtual simulation scheme is developed to obtain the system transient responses and the results are compared with those measured from the tests.In general, the simulation results agree with those obtained from the tests under the same steering inputs and operating conditions. The presented model can predict the dynamic steering characteristics of the full vehicle transient simulations with a good accuracy, which could otherwise only be done through testing on prototypes. These models can be used for tuning of performance and design of new power steering system.
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Study on Impact of SUV chassis stiffness on vehicle dynamics through CAE

Mahindra & Mahindra Ltd.-Visweswara Lenka, Baskar Anthonysamy, BALARAMAKRISHNA N, Abhijit Londhe
  • Technical Paper
  • 2020-01-1004
To be published on 2020-04-14 by SAE International in United States
Now a day’s automotive industry is a highly competitive market where continuous innovation in design and production of vehicles is required to gain market share and survive in the market. This resulted in the reduction of the life cycle of the design process and design tools. Identifying, understanding and refining these details is significant to develop sustainable cars. Body and Chassis stiffness are important specifications of a passenger car which affects handling, steering and ride characteristics of the vehicle. It has been proved that torsional, lateral and local chassis stiffness can play a role in giving the customer a premium feeling by affecting key metrics in the vehicle dynamics behaviour of a passenger car. In this paper, the effect of chassis stiffness on vehicle dynamics performance is studied using CAE. Different attributes of vehicle dynamics like vehicle handling, On-Center feel and vehicle ride are considered as performance characteristics. The chassis stiffness is varied by varying the material characteristics and evaluated the different performance attributes. It has been found the chassis stiffness influenced differently on On-center…
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Develop the Methodology to Predict the Engine Mount Loads from Road Load Data Using MSC ADAMS and FEMFAT Virtual Iteration

Mahindra Research Valley-Baskar Anthonysamy, Balaramakrishna N, Abhijit Londhe
  • Technical Paper
  • 2020-01-1401
To be published on 2020-04-14 by SAE International in United States
Design of powertrain mounting bracket is always a challenge in achieving good NVH characteristics and durability with less weight. For this activity engine mount load is necessary to optimize the weight to meet durability and NVH targets. This paper introduces a new method to calculate engine mount loads from chassis accelerations. The method starts by measuring chassis acceleration near engine mount location, then reproducing the same chassis acceleration in Multi Axis Shaker Table (MAST), and finally extracting the load in engine mount using testing (using load cell).The MAST test actuator displacement input is imported into ADAMS and engine mount loads are extracted. The extracted loads are correlated with physical test results. The correlation includes load time history and peak-to-peak load range. It is recommended to implement this method in early vehicle design phases.Implementing engine mount bracket weight optimization is desirable in early design stages. To avoid MAST testing and then MAST simulation based on road load data, FEMFAT virtual iteration and MSC.ADAMS integration helps us to integrate the road load data into MAST input data.…
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Systematic Work Flow for Fatigue Life Prediction of Automotive Components

Mahindra & Mahindra, Ltd.-Nitin Kumar Khanna, Baskar Anthonysamy, Krishna Shettipally, Manohar Kalal
Published 2019-10-11 by SAE International in United States
Fatigue life estimation of automotive components is a critical requirement for product design and development. Automotive companies are under tremendous pressure to launch new vehicles within short duration because of customer’s changing preferences. There is a necessity to have a comprehensive virtual simulation and robust validation process to evaluate durability of vehicle as per customer usage. Test track and field test are two of the most time-consuming activities, so there is a need of simulation process to substitute these requirements. This paper summarizes the overall process of Accelerated Durability Test with measured road loads. Based on category of vehicle, type road profiles and the customer usage pattern, the wheel forces, strains and acceleration are measured which is used to derive the equivalent duty cycles on proving ground. The wheel force transducers (WFT) are used to derive loads for fatigue life estimation. A full vehicle model is prepared in ADAMS CAR and validated through Physical testing. The loads on suspension hard points extracted from the validated MBD model. These loads at various hardpoint locations, are used…
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Develop the Methodology Using DOE Approach to Improve Steering Return Ability of a Vehicle through Virtual Simulation

Mahindra & Mahindra, Ltd.-Nitin Kumar Khanna, Baskar Anthonysamy, Naveen Medithi, Karthik Senthi
Published 2019-10-11 by SAE International in United States
In driving, Steering is the input motion to the vehicle. The driver uses steering input to change the direction of the vehicle. During Parking or U turn bends the Steering is locked and later released to follow the desired path. Steering return ability is defined as the ratio of difference between steering wheel position at lock condition and steering wheel angle after 3 seconds of release to the steering wheel angle at lock condition. Having proper steering return ability characteristics has an important effect on vehicle steering characteristics. In this study, a full vehicle ADAMS model is prepared, and virtual steering return ability have been simulated in ADAMS/CAR for a Pickup truck vehicle. Simulated responses in the steering wheel angle have been validated by comparison with measurements. A Design of Experiment study is setup and Iterations are carried out to find the effect of Hard points and friction parameters. The effect of different parameters in terms of their importance is plotted and discussed. The objective is to establish the methodology to predict correct steering return…
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Identification and Resolution of Vehicle Pull and Steering Wobble Using Virtual Simulation and Testing

Mahindra & Mahindra Ltd.-Baskar Anthonysamy, Vishal Barde, Naveen Medithi, Senthil S, Balaramakrishna N
Published 2018-10-05 by SAE International in United States
A vehicle drifts due to several reasons from its intended straight path even in the case of no steering input. Vehicle pull is a condition where the driver must apply a constant correction torque to the steering wheel to maintain a straight-line course of the vehicle. This paper presents an investigation study into the characteristics of a vehicle experiencing steering drift. The aim of the work is to study vehicle stability and the causes of vehicle drift/pull during straight line to minimize vehicle pull level and hence optimize safety measures.A wobble in the steering wheel feels like the steering wheel is shaking to the left and right. This may get worse, if speed increases.This paper focuses on modelling and evaluating effects of suspension parameters, differential friction, brake drag variation, Unbalanced mass in the wheel assembly and C.G. location of the vehicle under multibody dynamic simulation environment.Asymmetry of geometry and compliance between left and right side to be causing the drift. The sensitivities of the suspension parameters are presented for each driving condition. In case of…
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Multi-Objective Optimization to Improve SUV Ride Performances Using MSC.ADAMS and Mode Frontier

Mahindra Research Valley-Visweswara Rao Lenka, Baskar Anthonysamy, Abhijit Londhe, Harshad Hatekar
Published 2018-04-03 by SAE International in United States
Ride is an important attribute which must be accounted in the passenger segment vehicles. Excessive H point acceleration, Steering wheel acceleration, Pitch acceleration can reduce the comfort of the driver and the passengers during high frequency and low frequency rough road events. Excessive Understeer gradient, roll gradient, roll acceleration and Sprung mass lift could affect the Vehicle driver interaction during Steady state cornering, Braking and Step steer events. The concept architecture of the vehicle plays an important role in how comfort the vehicle will be.This paper discusses how to improve SUV ride performances by keeping handling performance attributes same or better than base vehicle. Multi Objective Optimization was carried out by keeping spring, bushing and damper characteristic as the design variables to avoid new system or component development time and cost.The first step in this process is DOE (Design of Experiments method) which allows to select critical or highly influence input variables and to understand the effect of input variables on output performances. The consequent Optimization leads to select the optimum from various conflicting solutions.
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Commercial Vehicle Two Cylinder Powertrain Mount Selection Based on Robust Optimization Using MSC/ADAMS and Mode Frontier

Mahindra Research Valley-Suyash Gawade, Baskar Anthonysamy, Perumal J
Published 2018-04-03 by SAE International in United States
Ride comfort, drivability and driving stability are important factors defining vehicle performance and customer satisfaction. The IC powertrain is the source for the vibration that adversely affects the vehicle performance. The IC powertrain is composed of reciprocating and rotating components which result in unbalanced forces, moments during operation and produce vibrations at the vehicle supporting members. The vibration reduction is possible by minimizing unbalanced forces and/or by providing anti-vibration mounts at the powertrain-vehicle interface.The power train is suspended on the vehicle frame via several flexible mounts, whose function is to isolate powertrain vibrations from the frame. Total six different modes of powertrain vibration namely - roll, yaw, pitch, vertical, lateral and longitudinal need to be isolated. Powertrain mount stiffness and location is critical in this regard. The corresponding six modal frequencies must meet certain acceptance criteria which are calculated based on factors like number of cylinders, idling rpm and wheel hop frequency. The modal kinetic energy distribution must ensure proper decoupling between the six modes.In this study, a commercial vehicle two-cylinder powertrain model mounted on…
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Tuning of Brake Force Distribution for Pickup Truck Vehicle LSPV Brake System During Cornering Maneuver

Mahindra & Mahindra Ltd.-Baskar Anthonysamy, Arun Kumar Prasad, Babasaheb Shinde
Published 2017-09-17 by SAE International in United States
Automotive industry has led to constant production innovation among manufactures. This has resulted in the reduction of the life cycle of the design philosophies and design tools. One of the performance factors that have continues to challenge automotive designer is to design and fine tune the braking performance with low cost and short life cycle.Improvement in braking performance and vehicle stability can be achieved through the use of braking systems whosebrake force distribution is variable. Braking force distribution has an important and serious role in thevehicle stopping distance and stability. In this paper a new approach will be presented to achieve the braking forcedistribution strategy for articulated vehicles. For this purpose, the virtual optimization process has beenimplemented. This strategy, defined as an innovative braking force distribution strategy, is based on the wheel slips.The simulation results illustrate proposed strategy can significantly improve the vehicle stability in curved braking fordifferent levels of vehicle deceleration.
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Prediction of Hub Load on Power Steering Pump Using Dynamic Simulation and Experimental Measurement

Mahindra & Mahindra, Ltd.-Vishal Barde, Baskar Anthonysamy, Ganeshan Reddy, Senthil S, Visweswara lenka, Gurdeep Singh Pahwa
Published 2017-03-28 by SAE International in United States
New trend in steering system such as EPS is coming up, but still hydraulic power steering system is more prevalent in today’s vehicles. Power steering pump is a vital component of hydraulic power steering system. Failure of steering pump can lead to loss of power assistance. Prediction of hub load on pump shaft is an important design input for pump manufacturer. Higher hub loads than the actual designed load of pump bearing may lead to seizure of pump. Pump manufacturer has safe limits for hub load. Simulations can assist for optimization of belt layout and placement of accessories to reduce the hub load. Lower hub load can have direct effect on improvement of pump durability. This paper deals with dynamic simulation of belt drive system in MSC.ADAMS as well as vehicle level measurement of hub load on power steering pump. Hub load is measured with two different belt layout as well as in different maneuver related to cranking and high speed conditions at which the worst load cases are seen.At cranking, the highest torque load…
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