Abstract
Time- and cost-efficient development processes in the automotive industry are often based on the application of modern IT-supported engineering tools. Continuously increasing product variants and functionalities call for design strategies and methods, which are capable to handle a quick data control and transfer supporting efficient geometry creation and evaluation. Computer aided three-dimensional design and calculation methods are widespread and well introduced in component development and digital mock-up processes, supporting the virtual development. The concept phase in automotive engineering is characterized by a wide range of variations, changes, alternating definitions, requirements and iterative actions, which are influenced by legislation boundaries, functional- and design requirements, crash and safety demands, comfort- and customer specifications and desired functionalities.
The present publication treats the development of an integrated 3D-CAD (computer aided design) model for the conceptual development of wheel suspensions for passenger cars. The CAD model is linked with an external data base, which includes all required geometry and simulation data of the suspension and also serves as a data base for different types of suspension. The 3D-CAD model itself includes four suspension configurations: A McPherson strut axle, a torsion beam axle, a double wishbone axle and a multi link lever axle. All configurations are parametric controlled and variable in their dimensioning. Beside the geometrical development and visualisation, integrated functionalities enable a kinematic analysis of each type of suspension, including the calculation of the swept volumes as a function of suspension travel and steering angle. In addition, the variable structure of the kinematic simulation model includes functionalities for the assessment and evaluation of the suspension movements and degrees of freedom. Diagrams of characteristic key numbers are generated to support improvements and optimisation cycles from the beginning of initial layout phases.
The applied methods and strategies, combining CAD design and CAE (computer aided engineering) simulation task, are able to support the concept phase in the automotive development process. The use of semi-automated functions leads to an increasing process quality and optimisation at the same time, while offering a user friendly application of the tool based on a shared database.
Keywords: vehicle suspension, concept phase, parametric design, kinematic simulation