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Technical Paper

Aerodynamic Development of the 2019 Chevrolet Corvette C7 ZR1

2019-04-02
2019-01-0665
This paper presents an overview of the aerodynamic development of the 2019 Chevrolet Corvette C7 ZR1. Extensive wind tunnel testing and computational fluid dynamics simulations were completed to engineer the ZR1’s aerodynamics to improve lift-to-drag efficiency and track capability over previous Corvette offerings. The ZR1 architecture changes posed many aerodynamic challenges including increased vehicle cooling, strict packaging demands, wider front track width, and aggressive exterior styling. Through motorsports-inspired aerodynamic development, the ZR1 was engineered to overcome these challenges through the creation of new devices such as a raised rear wing and front underwing. The resulting Standard ZR1 achieved a top speed of 212 mph making it the fastest Corvette ever [1]. Optionally, the ZR1 with the ZTK Performance Package provides the highest downforce of any Corvette, generating approximately 950 pounds at the ZTK’s top speed [1].
Journal Article

FWD Halfshaft Angle Optimization Using 12 Degree of Freedom Analytical Model

2017-06-05
2017-01-1770
This paper describes the development of an analytical method to assess and optimize halfshaft joint angles to avoid excessive 3rd halfshaft order vibrations during wide-open-throttle (WOT) and light drive-away events. The objective was to develop a test-correlated analytical model to assess and optimize driveline working angles during the virtual design phase of a vehicle program when packaging tradeoffs are decided. A twelve degree-of-freedom (12DOF) system model was constructed that comprehends halfshaft dynamic angle change, axle torque, powertrain (P/T) mount rate progression and axial forces generated by tripot type constant velocity (CV) joints. Note: “tripot” and “tripod” are alternate nomenclatures for the same type of joint. Simple lumped parameter models have historically been used for P/T mount optimization; however, this paper describes a method for using a lumped parameter model to also optimize driveline working angles.
Technical Paper

Design Enhancement of the Rear Composite Structure for the 2005 Chevrolet Corvette Coupe and Z06

2005-04-11
2005-01-0467
This paper describes the design and development of the rear compartment structure of the sixth generation Corvette, C6, which starts in the 2005 model year. The improved design integrates the rear compartment packaging to address issues seen on fifth generation Corvette, C5. The molded composite fiberglass reinforced, tub and surround panels are similar to the C5. These large panels are modified to fit the new styling theme of the C6, while also addressing the packaging requirements of the updated underbody structure and exhaust system. New composite side support brackets and cross car reinforcement combine to address several desired improvements. These side support brackets are designed to package the rear audio speakers, electrical modules, wiring and cable routing while also addressing build variation and localized stiffness improvement. The side brackets support the surround panel increasing the manufacturing control of the surround panel.
Technical Paper

GM's Evolving Epsilon Midsize Car Platform

2005-04-11
2005-01-1028
This paper reviews the history of the General Motor's Epsilon Platform from a Body Structure perspective. From the time that it was conceived in 1996 to the present, the platform has evolved to meet many changing requirements. The focus of this paper will cover basic body requirements such as crash performance, modal requirements, packaging issues, changes for wheelbase and powertrains, mass, different body styles, etc, including the differences between European and US requirements. It will demonstrate that this globally developed platform met all its initial requirements and continued to evolve over time to meet additional changing requirements.
Technical Paper

Impact of Ultra Thinwall Catalyst Substrates for TIER2 Emission Standards

2003-03-03
2003-01-0658
The impact of ultra thinwall catalysts on TIER2 emission performance, packaging and total system cost was evaluated. The primary focus was to compare ultra-thinwall and thinwall cell configurations (400/3, 400/4, 600/2, 600/3, 600/3 hex, 900/2, and 1200/2) with a baseline 600/4 at constant substrate volume, washcoat and PGM loading. Other areas investigated included the evaluation of decreasing catalyst volume while maintaining constant or increased mass transfer capabilities while holding washcoat and PGM loadings constant. The emissions impact of varying washcoat and PGM loading was measured on specific substrates, including a comparison of square to hex cell. Backpressure for each configuration was calculated with the Corning substrate pressure drop modeling tool. Converters were rapid aged on dynamometers reflecting approximately a 50,000 mile aged performance. Emission testing was completed using the FTP test cycle.
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