Study On The Theory And Method Of Virtual Durability Test For Key Chassis Components Of Car

This paper described a method of virtual durability test for chassis components of vehicle during vehicle research and development period, based on the advanced testing technique and computer aided engineering (CAE). With this method structure of the component can be optimized, finite life design of the component can be realized, costs can be saved, time can be reduced, and so on.Firstly, the paper summaried the general procedure for the virtual durability tests and the theories of it, and then study on the theories of it was finished.Later, Focusing on the subframe of vehicle, this paper is using the advanced IGeL Wheel Force Transducer and Data Acquirement System that supported by SVW Technical Center to investigate the status of the typical road which lead to high vulnerability, and thus fixed on the real situation there reported by customers. In addition this thesis provided the road load spectrum of rear axis of vehicle on the typical road, EVP road and national automotive proving ground in Ding Yuan respectively. And then the test data was analyzed in frequency field, the statistical characters were analyzed, and components damage performance was obtained based on the test data. Road simulation test in laboratory was finished. Based on the former analysis, we got the drive signals for virtual prototype and for spindle force prediction in the further study, and key components of the chassis were also confirmed.Lastly, full vehicle virtual prototype for durability analysis was built, which was a rigid-flexible hybrid model, and was modified according to the test results. Then the fatigue life of the subframe and rearaxle was calculated with the help of the virtual prototype of the vehicle, and the fatigue life of the seam welds was also calculated. Additionally, the simulation results were compared with the test results, which were proved to be consistent.