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A methodology for an efficient failure prediction of automotive steel wheels during fatigue experimental tests is proposed. The strategy joins the CDTire simulative package effectiveness to a specific wheel finite element model in order to deeply monitor the stress distribution among the component to predict damage. The numerical model acts as a Software-in-the-loop and it is calibrated with experimental data. The developed tool, called VirtualWheel, can be applied for the optimisation of design reducing prototyping and experimental test costs in the development phase. In the first section, the failure criterion is selected. In the second one, the conversion of hardware test-rig into virtual model is described in detail by focusing on critical aspects of finite element modelling. In conclusion, failure prediction is compared with experimental test results.

In some situations, designers need quick and powerful instruments to provide information for philosophical choices in powertrain layout. The increase of computational capabilities favors the implementation of complex equations and the possibility of making powerful software for supporting technical decisions. The paper presents a numerical model of a shaft that provides information about shaft dynamic and structural behavior. The model can be used for simulating gearbox shaft, drive shaft or axle shaft. By means of a MATLAB/Simulink® model, a finite element (FE) procedure is implemented: the shaft is depicted as its inertial and stiffness features and it is also possible to evaluate stresses, strains and boundary condition forces. In addition, MATLAB/Simulink® powerful allows evaluating shaft behavior during working or test conditions, such as the abuse maneuver, and not only in an abstract situation used by analysts for structural and dynamic calculations.

Rattling noise is one of the most significant noises pertinent to manual gearboxes. The paper deals with modeling and numerical analysis of commercial powertrains. Multi-body modeling is adopted to investigate gear rattle phenomenon in several engine operating conditions. The linear and nonlinear models include: crankshaft with pistons and flywheel, friction clutch, primary and secondary shafts with their corresponding gears pinion, differential crown wheel, axle shaft, tires and vehicle body. In order to analyze the gear rattle, the numerical analysis is made with respect to teeth relative displacement, teeth contact force and index β.

The aim of this paper is to study in deep the peculiar test-rigs and experimental procedures adopted to the fulfilment of the principal requirements of automotive steel wheels, in particular regarding fatigue damaging. In the discussion, the standard requirements, the OEM specifications and the dimensional and geometric tolerances are approached. As result of an increasingly necessity to improve the performance of the components, innovative virtual test benches are presented. Differently from their traditional precursors, virtual test-rigs give an extended view of the physical behaviour of the component as the possibility to monitor stress-strain distribution in deep. In the first section, the state of the art and the specifications are listed. Secondly, the adopted hardware test-rigs as the experimental tests are described in detail. In the third one, proposed virtual test-rig is discussed.