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This paper describes the issues encountered in using conventionally acquired tire test data for dynamic total vehicle handling simulations and the need for improved methodology. It describes the new test procedure that was used to acquire all three forces and three moments in a transient mode for a matrix of loads, slip and camber angles. A study of the test data supports the premises that the overturning moment, Mx, should not be neglected in dynamic simulations, and that the effects of camber should not be treated as only an independent, linearly additive, camber thrust. Instead of the conventional application of a bi-cubic regression fit to a six region data division, a new algorithm is applied. The data is divided differently into five regions in the α - Fz plane, and a variable format regression equation is applied as appropriate. The resulting regression coefficients matrix is readily usable in dynamic simulations, and is shown to have a superior curve fit to the test data.

The development of numerical control, interactive computer graphics and finite element analysis has spawned an overabundance of new acronyms to describe the application of computers in the engineering and manufacturing environment. The purpose of this paper is to provide an overview of these technologies and describe how greater productivity improvement can be achieved via the synergistic benefits of integrating these diverse systems. Discussions will be based largely on the Ford Motor engineering and manufacturing environment which includes not only the internally developed Ford graphics systems, but systems provided by every major turn-key graphics vendor. Evaluation of the Initial Graphics Exchange Specification (IGES) and communication of computer graphics data to Ford suppliers will also be discussed.

The Ford Ranger will be a domestically built, small pickup truck engineered to many design objectives typical of a fullsize pickup, yet with four cylinder engine fuel efficiency. Ranger is a full-function on-and-off road pickup truck with a uniquely smooth ride and a capacity to carry up to a 725.7 kg. (1600 lb.) payload. The truck features a three passenger body-on-frame cab and a double wall pickup box with provision for 1.2m × 2.4m (4 ft. × 8 ft.) sheets of construction material. Featured in this comprehensive paper are the engineering highlights and innovations contributing to the accomplishment of these Small Truck objectives.

By applying some advanced features of the CAL3D occupant simulation model, a single model incorporating the vehicle structure and a simplified occupant was developed for studying the sensitivity of occupant response to parameter changes in perpendicular, vehicle-to-vehicle side impacts, not involving vehicle rotation. The results of the model show qualitative agreement with published experimental results, which indicate that occupant responses are related to the initial clearance of the occupant from the door, the stiffnesses of the front end of the impacting vehicle, and the side structure of the impacted vehicle.

A Headlight Evaluation Model has been developed which provides a broader and more comprehensive method for characterizing the performance of headlamps than is possible in traditional headlight seeing distance field tests. The Headlamp Evaluation Model accepts as input the candlepower patterns of the headlamp system being evaluated and provides a measure of driver visual performance based on a large number of simulated seeing distance tests and glare discomfort checks on a standardized test route. The output of the Model, termed the Figure of Merit, is the percentage of the distance traveled by the simulated driver on the standardized test route in which the seeing distance to pedestrians and pavement lines, and the discomfort glare levels experienced by opposing drivers, simultaneously meet certain acceptance criteria.

The design of an automotive instrument panel has become an increasingly complex job as product evolution in terms of customer safety, mechanical improvements, optional features and customer wants have altered the content of the automotive vehicle, and added substantially to the design requirements that must be observed in this area of the vehicle. To provide a perspective of the total job required to accommodate the changing and diverse standards and engineering requirements, this report will tell the story of the Ford Motor Company instrument panel design process. The report will cover all of the major considerations that affect the finished appearance of the design as well as the considerations required for customer convenience, and instrument panel serviceability.

This paper discusses the possible impact of the FM tape recorder and servo-hydraulic actuators on the testing of automotive structures. The use of tape recorders and automatic data reduction systems will permit more accurate definition of service conditions and properly “set-the-stage” for laboratory testing. Servo-hydraulic strokers should encourage better laboratory simulation because of their great flexibility. Test set-up time is reduced, fixtures can be simplified and load control is more precise. Simultaneous multiple inputs can be controlled as to amplitude and phase relationships.