Browse Topic: Crossmembers
In automotive product development, design and development of the chassis plays an important role since all the internal and external loads pass through the vehicle chassis. Durability, NVH, Dynamics as well as overall vehicle performance is dependent on the chassis structure. Even though passenger vehicle chassis has a ladder frame or a monocoque construction, small commercial vehicle chassis is a hybrid chassis with the cabin welded to the ladder frame. As mileage is critical for sale of SCVs, making a light-weight chassis is also important. This creates a trade-off between the performance and weight which needs to be optimized. In this study, a parametric beam model of the ladder frame & the cabin of the vehicle is created in COMSOL Multiphysics. The structure has been parameterized into the long member & crossmember geometry & sections. The model calculates the first 12 natural frequencies, global stiffness, and weight. It has been validated and further used for optimization study
To stave off competition in the light-truck segment, Ford has improved upon its perennial best-seller by giving it a stiffer fully boxed frame, a unique rear suspension design, a more powerful 5.4L V8, and a variety of interior refinements. A pickup truck that combines toughness, capability, and dependability with a level of refinement not seen before in the segment was the goal of Chief Program Engineer Frank Davis while working on the redesigned 2004 Ford F-150. Davis and his engineering team accomplished all aspects of that goal largely through a new chassis design. Improvements in ride, handling, and quietness are due in part to a solid fully boxed frame with hydroformed front rails. Hydroforming was used for the sections of the front rails that bear the loads of the front suspension, which is “probably the most critical portion of the frame” for providing a consistent riding experience, said Jim Baumbick, Manager of Truck Vehicle Integration for Ford
Highlights of the GMT360 family are a new inline six-cylinder engine, chassis, and electrical system. “Virtually every system-powertrain, frame, electronics, suspension, and more-includes new technologies specifically targeted at the priorities of SUV customers,” said Ted Robertson, Chief Engineer, GM Midsize Trucks, speaking about GM's new midsize SUVs-the Oldsmobile Bravada, GMC Envoy, and Chevrolet TrailBlazer. “We designed these trucks to achieve outstanding performance across the wide spectrum of expectations a world-class SUV must meet, without compromises.” Innovations and new technologies on GM's GMT360 family of SUVs include an inline six-cylinder engine producing a V8- like 201 kW (270 hp) from 4.2 L. The chassis employs the industry's first fully hydroformed frame rails in conjunction with independent front and multilink rear suspensions. The electrical system uses distributed computing to enable many segment-leading features such as next-generation OnStar. In addition, rain
This paper describes the design cycle of the permanent mold A356-T6 cast aluminum front and rear suspension crossmembers of the Fifth Generation Corvette. The cycle starts with the definition of requirements followed by concept development and mainstream selection. A design/analysis loop is undertaken to optimize the design before the construction of prototypes. The prototype crossmembers are then tested in the laboratory and in product assurance vehicles. The empirical data is fed back into the design loop to ensure that the final production release of the crossmembers meets the Corvette's performance objectives. The program business case, engineering specifications, and manufacturing processes all contribute requirements that must be satisfied by the design of these components. The most challenging design requirement was to design crossmembers with the least possible mass and the highest possible stiffness
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