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Improvements in component/system design is a daily challenge these days, always looking for high performance, reduced mass and low costs. The source for the best fit between these factors, coupled with adequate durability performance, is crucial to the success of a given product and this is what motivates engineering teams around the world. The demand for efficient projects with short deadlines for validation and certification is huge and simulation tools focused on accelerated durability and virtual validation are increasingly being used. When developing a new spring for commercial vehicles, lessons learned from the actual loads applied to the suspension are the “key” to a successful project. The loads/stresses from the ground (vertical loads, lateral loads, longitudinal and braking loads) are quite high and, consequently, relevant to the proper definition of the design of the suspension components.

In this study an effort has been made to establish a response surface model to predict material thinning in a stamped chassis cross member. Numerical simulations using finite element method were performed to populate the data needed for response surface analysis. The results predicted by the response surface model were compared with the results of numerical simulations and were found to be in good agreement. The effect of corner radius, flange radius and flange height on material thinning was investigated using the response surface model.

Higher demands from automotive customers for quieter vehicles and the reduction of noise and vibration levels from major sources like the engine necessitate better performance of other sources of noise and vibrations in a vehicle. One of these sources that Original Equipment Manufacturers (OEM) demand making quieter is the power steering system. The pressure ripple generated by the power steering pump transfers to the fluid lines where it can generate objectionable noise and vibrations. This can become an excitation force to the structure of a vehicle or the steering gear and can become a source of discomfort to the vehicle occupants. Attenuation of the pressure ripple within the hose assembly can result in significant reduction in noise inside the vehicle. The NVH research team at the Fluid System Products of Dana Corporation has developed “Dana's Virtual Test Rig (DVTR™),” - a hydraulic system simulation software.

A new wheel end concept was designed and developed to allow sport utility vehicles (SUV) and light trucks the possibility of achieving a negative scrub radius. This paper will compare a production vehicle with a scrub radius of 54.8 mm with the same vehicle modified with several alternate scrub radii. The vehicle changes are completed in a way that still packages the brake components and meets the component durability needs of a light truck wheel end load cycle. Quantitative vehicle computer analysis and actual instrumented vehicle performance data will be compared and correlated to analyze the effects of scrub radius.

A transfer case was designed to utilize electronic control. It has a planetary interaxle differential for proportional torque split. An electromagnetic clutch is applied across the differential to enhance mobility when road coefficients allow single wheel or single axle traction loss. The need for clutch actuation is monitored by an electronic module and sensor system, that detects abnormal amounts of differentiation in the interaxle unit. Clutch actuation is signaled and controlled by the module, which is also electrically connected to the rear axle ABS brake system to eliminate any possible simultaneous function compatibility issues. System emphasis is on foul weather mobility when negotiating highway and secondary roads. The family vehicle market was targeted and performance parameters were adjusted toward mobility and driver confidence to complete a given trip.