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This work has the proposal of showing the correlation between simulation and field tests’ results for handling maneuvers for Astra and Corsa vehicle platforms. Adams was the main tool used during the modeling development and the correlation was performed for steady state maneuvers (constant radius cornering) and transient maneuvers (series of lane changes at high speed and elk test).

Traditional suspension tuning for ride comfort takes use of a series of physical prototype evaluations by skilled drivers, who analyze the vehicle performance in subjective terms. In this approach, the suspension components (springs, shock absorbers, bumpers, etc) are usually optimized one at a time, regardless of the consequences of the interactions among them in the global suspension behavior – this not uncommonly leads to sub optimized suspension configurations. Another problem with this approach is the fact that it is completely dependent upon physical component prototypes, whose costs and construction lead times can not be afforded in the current tight development cycles. This paper presents an objective approach that has been successfully applied at GMB, based on simulation tools, whose target is to define optimized components for the suspension without the need of physical prototypes.

This paper presents the results of a study about the influence of the suspension manufacturing and assembly induced dimensional variation on the vehicle dynamic behavior for a compound crank rear suspension. A selection of representative vehicle dynamics metrics has been considered for this assessment and each individual dimensional variation has been categorized with respect to its overall effects on the selected metrics. By doing this, it is possible to identify the critical points where the dynamic behavior of the vehicle is more sensitive to the resulting dimensional variation, therefore creating a new criteria to define the appropriate tolerance control for the manufacturing and assembly of the related parts.

The Brazilian automotive market presents special characteristics: at the same time that it demands similar technologies applied in developed markets like USA and Europe for luxury cars, in the sub-compact entry-level segments (a segment where the profit margin is very tight) there are unique characteristics that justify the development of different cars. Taking into consideration the mini cars segment, there is no car developed specifically for the Brazilian market. While the mini cars development for the entry level segment is still rare, every new auto show presents new proposals and some of them are on the streets, but most are mainly focused in the luxury segment. These vehicles currently in the market are in a price range where it is not economically feasible for them to be acquired by someone who is coming from a motorcycle-based usage.

The Formula SAE competition has the purpose to stimulate the engineering students to work in teams to develop a concept, design and build small racing vehicles. In this competition, students are motivated to build a high performance car, reliable and with low development cost. The success of the team in the competition is determined with a detailed analysis of all aspects involved. Considering the frame development, some key points must be considered for the structural performance: stiffness, durability, modal and safety response. This papers focus on the stiffness analysis to verify if the frame torsional stiffness is compatible with the respective suspension for the level of performance required. The study was performed using the frame of 2012 Formula SAE from Instituto Mauá de Tecnologia using beam elements to model the frame structure in a FEA (Finite Elements Model) software to simulate the system stiffness.