New technologies in driving dynamics performance simulation

Abstract

Today's vehicle dynamics engineers are facing many different challenges at the same time, such as achieving full vehicle response target requirements for ride and handling, simulating accurate road loads prediction, developing and integrating chassis subsystems (such as steering, brake, damper) and even the more complex active safety systems, keeping a good balancing compromised solution with other vehicle performances such as road noise, passive safety and NVH. In order to answer to such complex panorama, vehicle dynamics engineers are using CAE for the development of a vehicle with usage of 1D modelling and 3D MBS and FEA. The concurrent use of all these technologies represents a standard in the automotive industry, depending on the frequency range and on the vehicle development stage. However, the current simulation process is not efficient because there is very limited integration between the different approaches. In addition local geometrical and material nonlinearities are not accurately modelled in classical MBS software. This paper introduces an integrated methodology for vehicle dynamics simulation with particular application to MBS nonlinear FEA environment. The integration of MBS capabilities in one single nonlinear FEA environment enables an accurate modelling of nonlinearity in vehicles. The advantages of using the "Motion in FEA" simulation capabilities are demonstrated with relevant vehicle dynamics examples. The "Motion in FEA" approach is very accurate since it can describe all the non-linear effects present in the vehicle. As they are not limited to low frequencies or connection modes, results are more accurate. With respect to the engineering process efficiency the "Motion in FEA" model also allows eliminating unnecessary iterations between local separate mechanical models, improving productivity during the complete vehicle development process. © Springer-Verlag 2013.