Design & Development Process for Vehicle

Dynamics

Vehicle Dynamics : Design & Development

Process
Concept Development

Understand Customer
requirements
Target setting
Concept Generation
Concept Evaluation
Analytical Calculations
Initial ADAMS Analysis
Concept 3D models
System DFMEA
System Specification
finalisation

Detail Design

ADAMS Analysis
Durability analysis
DMU Packaging study
Critical Parts DFMEA
Tolerance Stack up
Detailed component
drawing
Manufacturing
feasibility
Prototype development
& build

Vehicle Tuning

K&C Measurement
Vehicle Tuning trails
Vehicle Objective
Measurement
Vehicle Subjective
Evaluation
K&C Tracking
Jury Evaluation
Engineering sign off

Concept Development

Understand Customer requirements

Target setting
Concept Generation
Concept Evaluation
Initial ADAMS Analysis
Concept 3D models
System DFMEA
System Specification finalisation

Target Setting

Analysis of QFD requirements from customer voice

Features / technologies to be used
Market / Future trends
Current / future legislative regulations
Generation of Target Books for full vehicle ride, handling and
steering.
A set of subjective ratings
Objective parameters at vehicle level
System level parameters
Targets are given as values, maxima, minima, or acceptable
ranges.

3D CAD data ( Pro E )

Front suspension
Lower Link , Upper link , coil springs , Anti roll bar , Front Strut ,
Suspension bushes , ARB linkages , Torsion bars , Stub Axle , Hub ,
bearings , Spacers , Ball Joints , Bump Stopper , Strut Top , Torsion Bar
attachments , Coil on Shock & it mounting , Spring Aids , Shock
Absorber , Wheel end assembly , Mounting / Attachment brackets ,
Rear Suspension
Leaf Springs , Coil Springs , Suspension Linkages , Shackles , U bolts ,
Guide Plates , Suspension bushes , Spring Seats on Axle , Dead Rear
Axle , Wheel end assembly , Hub , bearings , Shock Absorber ,
Mounting / Attachment brackets , Rear Anti Roll bar , ARB linkages ,
Steering System
Steering Column , Steering Rack , Ball Joints
Moving skeleton of front & rear suspension
Wheel envelop
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CAE Analysis

ADAMS ANALYSIS
ADAMS Kinematics & Compliance analysis of the concepts
ADAMS Full vehicle Ride & Handling report
Steering column UJ Phasing
Suspension & Steering Hardpoint attachment stiffness
Confirm the Targets set are achievable
Structural Analysis Report
Front & rear suspension All components
Front & rear wheel ends of final concept
Dead Axle
LHD / RHD steering system
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SYSTEM SPECIFICATIONS : Suspension

Suspension Hard Points

Wheel geometry specification
Wheel travels
Spring rates
Anti roll bar rate
Suspension bushes
Shock Absorber / Mcpherson strut damping rates
Strut top mount stiffness
Bump Stopper / Spring Aids stiffness
Suspension Ball joint specification (angle , size , etc)
Bearing sizes
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System Specifications
Steering
Hard points
Steering Geometry ,
Steering rack travels , ratio , lock Angles
TCD values
Steering pump requirement / specification
Steering Ball Joint specification (angle , size , etc) , etc
Wheels & tyres
Size
Load Rating
vertical stiffness
Cornering stiffness
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Detail Design

ADAMS Analysis
Durability analysis
DMU Packaging study
Critical Parts DFMEA
Tolerance Stack up
Detailed component drawing
Manufacturing feasibility
Prototype development & build

Vehicle Tuning Optimization

K&C Measurement
Vehicle Tuning trails
Vehicle Objective Measurement
Vehicle Subjective Evaluation
Engineering sign off

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K&C Measurement

Vertical test:
suspension vertical stiffness (wheel rate , ride rates) , camber change, toe change
, castor change, wheel centre locus (longitudinal & lateral) , tire contact point
locus , tire radial rate , track change, wheelbase change
Roll test (with & without ARB) :
suspension roll stiffness, roll centre height , roll steer , roll camber , castor
change , Track change , Axle steer , wheel loads , wheel rates
Lateral compliance test:
lateral wheel centre compliance, steer change, camber change, roll force centre
position ,lateral stiffness , track change
Longitudinal compliance test:
longitudinal wheel centre compliance, steer change, castor change, anti-dive
tangent.
Aligning torque compliance test:
steer change , camber change
Steering test:
steering ratio, camber change, Ackermann characteristics , steering friction ,
steering efficiency , kingpin inclination , castor , trail , kingpin offset & scrub
radius

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Vehicle Dynamics : Objective Evaluation

Steady state Circular test ( ISO 4138) :

To characterize vehicle balance ,grip and roll level (with and without ESP)
Step steer (ISO 7401):
To characterize the transient response of the vehicle to a sudden steering input including
time delays and overshoots throughout the lateral acceleration range.
Lateral Transient Frequency response test (ISO 8726):
hand wheel and road wheel input angle , within the linear regime.
lateral acceleration, yaw rate, roll rate and steering torque.
Sinusoidal Steering Input test (ISO 3875):
steering effort and response linearity in the on-centre region .
Self centering (IS13057):
To characterize the steering returnability
Ride comfort test
weighted RMS acceleration levels at the occupant contact points
Steering Tests:
To measure stationary and low speed steering efforts as per IS11948.
Steering column tilt mechanism adjustment force.
Temperature & Pressure mapping of the Power Assisted Steering system
Measurement of Turning Circle Diameter (TCD)
Straight line braking (ISO 21994) : Straight line braking performance

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Vehicle Dynamics : Subjective Evaluation

Ride Comfort :
Primary and secondary ride, harshness
Handling:
On and off centre , Limit of adherence ,
Steady State and Transient handling ,
Straight head stability ,
Lane change stability .
Steering Response :
Steering Feel ,
Steering Effort build-up
Braking :
Stopping Distance ,
Straight Line Braking Stability

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Learning
Often the difference between good vehicles and poor vehicles is
not in the
level of engineering and concept,
But in the detailing that goes into the components within
design and development.
Parameters often important determinants of the quality of the
vehicle
Hysterics, stiction, friction , Joint rigidity
This separates class leading vehicles from the competition.
We need to incorporate this into practice for projects under
development.

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