Sub-frame Crack Rig Testing and Simulation Analysis Based on Full-vehicle Rough Road Spectrum

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Sub-frame Crack Rig Testing and Simulation Analysis Based on Full-vehicle Rough Road Spectrum

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[1]PAN Gongyu,XU Rui,YANG Xiaofeng.Sub-frame Crack Rig Testing and Simulation Analysis Based on Full-vehicle Rough Road Spectrum[J].Journal of Zhengzhou University (Engineering Science),2024,45(01):29-33.[doi:10.13705/j.issn.1671-6833.2023.04.008]

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Journal of Zhengzhou University (Engineering Science)[ISSN 1671-6833/CN 41-1339/T] Volume: 45 Number of periods: 2024 01 Page number: 29-33 Column: Public date: 2024-01-19

Title:: Sub-frame Crack Rig Testing and Simulation Analysis Based on Full-vehicle Rough Road Spectrum

Author(s):: PAN Gongyu; XU Rui; YANG Xiaofeng; 1. School of Automobile and Traffic Engineering,Jiangsu University, Zhenjiang 212013,China; 2. Evergrande New Energy Automotive R&D Institute Global Headquarters, Shanghai 201620, China

Keywords:: rig test; durability; virtual iteration; fatigue simulation; correlation

CLC:: -

DOI:: 10.13705/j.issn.1671-6833.2023.04.008

Abstract:: The study was conducted to examine the durability issue occurred in front stabilizer bar bracket connected to sub-frame in full vehicle testing. Firstly, stabilizer bar system was plastered with strain gauges and calibrated, and drop link force and stabilizer bar twist displacement acquired on proving ground, sub-frame with stabilizer bar system physical test rig was designed and built, and rig tests in accordance with durability specifications were conducted. The test results showed that built physical test rig could greatly reappear crack location in full vehicle testing, the fatigue life of the physical bench had a deviation of 2. 5% compared to full vehicle testing. Based on this, a stabilizer bar and sub-frame multi-body virtual model was built with the same constraint boundary and the same loading method of the physical test rig. Then CAE fatigue simulation was used through quasi-static finite element fatigue life analysis method to reappear related area risk. The simulation results showed that phase and amplitude had a good coincidence in time domain, the PSD spectrum also had a good accuracy in frequency domain, the relative damage was almost closed to 1 with the comparison between the simulation and test in droplink force and stabilizer bar relative displacement. The deviation between the simulated fatigue life at the relevant risk position and the test life of the full vehicle was 6. 25%. A higher accuracy risk position load was obtained, and the reappearance of durability risk position was achieved. Finally, based on simulation fatigue load, the optimization risk structure was evaluated. Optimized proposal eventually passed the test rig and full vehicle testing successfully.

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