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”U” bolts are fixing elements and they are used to clamp an elastic joint. From the past, they still looking as an old design and unfortunately, suspension engineers are not specialists in fasteners and elastic joints. That is why we will show important assumptions and concepts to design and specifications this clamp element “U” bolt and its influence over leaf-springs. Currently, “U” bolt is used to clamp an elastic or elastic-plastic joint of heavy duty suspension, formed by leaf-spring, axle, spring pad, “U” bolt plate. This kind of suspension is typically used to trucks, buses and trailers. We are wondering, which one important assumption that an engineer must be careful when designs a new suspension changing from old designs to an updated technology. We provide a theoretical analysis and a FEA analysis to compare torque efficacy x leaf-spring reactions and what are effects this relationship can cause in a suspension.

Understanding customer expectations is critical to satisfying customers. Holding customer clinics is one approach to set winning targets for the engineering functional measures to drive customer satisfaction. In these clinics, customers are asked to operate and interact with vehicle systems or subsystems such as doors, lift gates, shifters, and seat adjusters, and then rate their experience. From this customer evaluation data, engineers can create customer loss or preference functions. These functions let engineers set appropriate targets by balancing risks and benefits. Statistical methods such as cumulative customer loss function are regularly applied for such analyses. In this paper, a new approach based on the Taguchi method is proposed and developed. It is referred to as Taguchi Customer Loss Function (TCLF).

This paper presents a fatigue criterion based on stress invariants for the frequency-based analysis of multiaxial random stresses. The criterion, named “Projection-by-Projection” (PbP) spectral method, is a frequency-based reformulation of its time-domain definition. In the time domain PbP method, a random stress path is first projected along the axes of a principal reference frame in the deviatoric space, thus defining a set of uniaxial random stress projections. In the frequency-domain approach, the damage of stress projections is estimated from the stress PSD matrix. Fatigue damage of the multiaxial stress is next calculated by summing up the fatigue damage of every stress projection. The criterion is calibrated on fatigue strength properties for axial and torsion loading. The calculated damage is shown to also depend on the relative ratio of hydrostatic to deviatoric stress components.

Vehicle dynamics is a discipline of mechanical engineering that benefited of significant improvements thanks to the progress of computational engineering. Vehicle dynamics engineers are using CAE for the development of a vehicle with MBS and FEA. The concurrent use of these two technologies is a standard in the automotive industry. However the current simulation process is not fully efficient because local geometrical and material nonlinearities are not accurately modeled in classical MBS software. This paper introduces a methodology for vehicle dynamics simulation integrating MBS capabilities in one single nonlinear FEA environment enabling an accurate modeling of nonlinearity in vehicles.

Buick engineers are well pleased with their '69 Chassis. Benefits of a unique front suspension camber curve are documented. The effects of various suspension parameters on ride and handling are explained. These were varied independently of one another in the course of evaluating over 30 suspension configurations.

THE usefulness of planetary gear trains and the engineering techniques necessary for optimum design are discussed in this paper. A simple method for calculating planetary gear ratios is described which can be used to determine quickly the potential usefulness of any planetary configurations. The author lists criteria which help to evaluate the potential of a planetary gear train schematic from the standpoints of gear noise and structural viewpoint. Detailed design of individual members include spacing of the pinions, mounting considerations, thrust direction, lubrication, and stress evaluation.

Truck and bus manufacturers have been constantly facing an issue to disassemble the rear axle shaft from the hub when transporting the truck from the factory to the dealership. In addition to that, the dealerships have the very same problem every time they have to replace the brake pads in some truck models, which leads to excessive service time, extra costs and aftermarket complaints. The current problematic fastening system is composed by a lock nut, a flat washer and a coned slotted bushing. The concept of this 30 year old design involves the coned slotted bushing being pressed against a tapered hole on the shaft’s flange. After tightening the lock nut, the bushing clamps towards the stud and it gets stuck in between the shaft and the stud generating the problem described above. This paper shows the R&D process that Tekfor used to come up with the 1-piece fastener named iLokTM nut that replaces the problematic 3-piece fastening system.

This paper describes a vehicle-level simulation model for climate control and powertrain cooling developed and currently utilized at GM. The tool was developed in response to GM's need to speed vehicle development for HVAC and powertrain cooling to meet world-class program execution timing (18 to 24 month vehicle development cycles). At the same time the simulation tool had to complement GM's strategy to move additional engineering responsibility to its HVAC suppliers. This simulation tool called “e-Thermal” was quickly developed and currently is in widespread (global) use across GM. This paper describes GM's objectives and requirements for developing e-Thermal. The structure of the tool and the capabilities of the simulation tool modules (refrigeration, front end airflow, passenger compartment, engine, transmission, Interior air handling …) is introduced. Model data requirements and GM's strategy for acquiring component data are also described.

The process considerations, manufacturability, corrosion properties, paintability, weldability, and formability of nominal 9 to 15 percent electrodeposited zinc-nickel (Zn-Ni) alloy-coated sheet steels for automotive applications were reviewed. Zn-Ni coatings were selected for use in automobile body panels by several automakers because of their ease of manufacturing, forming, and welding. Although Zn-Ni coatings may be easily manufactured into autobody panels without a change in production procedures, these coatings exhibit poor paintability and poor corrosion resistance, and would be risky to expose in the U.S. automotive environment at the specified 20 to 40 g/m2 coating weights. Zn-Ni coatings will not provide the cosmetic corrosion protection of zinc or zinc-iron (Zn-Fe) coatings, particularly on exterior autobody panels in a fully painted condition.

Zinc-manganese alloy electroplated has been developed for automotive body panel applications. The product is manufactured on a conventional electrogalvanizing line using an electrolyte containing zinc sulfate, manganese sulfate and sodium citrate. Electroplated steel with an alloy content of 30-50% manganese exhibits excellent corrosion resistance both as-produced and after painting. Zinc-manganese coatings also show good workability and voidability. Accordingly, this product is suitable for both unexposed parts and the interior surfaces of exposed parts. Finally, zinc-manganese electroplated steel displays good wet adhesion and anti-cratering characteristics so that the product can also be used for exposed applications as automotive body panels.

Many papers have been written for SAE on electrochemical metallizing, a modern term for “selective” or “brush” plating. These papers have dealt primarily with the aerospace industry, including the use of non-embrittling cadmium LHE® coatings for corrosion protection on aircraft. Shadowed by 30 years of successes in the aerospace industry, electrochemical metallizing corrosion protection in the automotive industry is often overlooked. Specifically, the use of selectively applied zinc coatings for corrosion protection on wheel hubs during manufacture has proven integral at several European automotive manufacturers. In the past, environmental conditions have corroded both the hubs and wheels of automobiles. Quite often the corrosion is in the microscopic gap between the hub and the wheel, which over time causes the wheel to seize and prevents removal. This has been frustrating to both stranded motorists and shop mechanics.

This paper sets up a simplified dynamic model for simulating the yaw/roll stability of heavy tractor-semitrailer using Matlab/Simulink. A linear quadratic regulator (LQR) based on partial-state feedback controller is used to optimize the roll stability of the vehicle. The control objective for optimizing roll stability is to be reducing the lateral load transfer rate while keeping the suspension angle less than the maximum allowable angle. The simulation result shows that the LQR controller is effective in the active roll stability control of the heavy tractor-semitrailer.

Two methods for calculating speed from curved tire marks were investigated. The commonly used critical speed formula and a computer simulation program were evaluated based on their ability to reproduce the results of full-scale yaw tests. The effects of vehicle braking and friction coefficient were studied. Twenty-two yaw tests were conducted at speeds between 70 and 120 km/h. For half of the tests, about 30% braking was applied. Using the measured sliding coefficient of friction, both the critical speed formula and the computer simulations under-predicted the actual speed of the vehicle. Using the measured peak coefficient of friction, both methods over-estimated the actual speed. There was less variance in the computer simulation results. Braking tended to increase the speeds calculated by the critical speed formula.

In this paper, a gain-scheduling optimal control approach is proposed to enhance yaw stability of articulated commercial vehicles through active braking of the proper wheel(s). For this purpose, an optimal feedback control is used to design a family of yaw moment controllers considering a broad range of vehicle velocities. The yaw moment controller is designed such that the instantaneous tractor yaw rate and articulation angle responses are forced to track the target values at each specific vehicle velocity. A gain scheduling mechanism is subsequently constructed via interpolations among the controllers. Furthermore, yaw moments derived from the proposed controller are realized by braking torque distribution among the appropriate wheels. The effectiveness of the proposed yaw stability control scheme is evaluated through software-in-the-loop (SIL) co-simulations involving Matlab/Simulink and TruckSim under lane change maneuvers.

In this paper a yaw stability control algorithm along with an emergency roll control strategy have been developed. The yaw stability controller and emergency roll controller were both developed using linear two degree-of-freedom vehicle models. The yaw stability controller is based on Lyapunov stability criteria and uses vehicle lateral acceleration and yaw rate measurements to calculate the corrective yaw moment required to stabilize the vehicle yaw motion. The corrective yaw moment is then applied by means of a differential braking strategy in which one wheel is selected to be braked with appropriate brake torque applied. The emergency roll control strategy is based on a rollover coefficient related to vehicle static stability factor. The emergency roll control strategy utilizes vehicle lateral acceleration measurements to calculate the roll coefficient. If the roll coefficient exceeds some predetermined threshold value the emergency roll control strategy will deploy.

From the beginning of 1995 on, RB will start the production of the Vehicle Dynamics Control System. A key part of this system is the Yaw Rate Sensor described in this paper. The basic requirements for this sensor for automotive applications are: mass producibility, low cost, resistance against environmental influences (such as temperature, vibrations, EMI), stability of all characteristics over life time, high reliability and designed-in safety. Bosch developed a sensor on the basis of the “Vibrating Cylinder”. The sensor will be introduced into mass production in beginning of 1995.

In the current Ford Pro-Trailer Backup Assist (TBA) system, trailer hitch angle is determined utilizing the reverse camera of the vehicle. In addition to being sensitive to environmental factors such as lighting conditions and occlusion, the vision-based approach is difficult to be applied to gooseneck or fifth wheel trailers. In this paper, a yaw rate based hitch angle observer is proposed as an alternative sensing solution for TBA. Based on the kinematic model of the vehicle-trailer, an instantaneous hitch angle is first derived by utilizing vehicle yaw rate, trailer yaw rate, vehicle velocity and vehicle/trailer parameters provided by the TBA system. Due to signal errors and parameter uncertainties, this instantaneous hitch angle may be noisy, especially at lower vehicle speed.

A new controllable limited slip differential is proposed and tested in software environment. It is characterized by the employment of a magnetorheological fluid, which presents the property of changing its rheology thanks to an applied magnetic field. A vehicle model has been designed and employed for the synthesis of a sliding controller. The control is based on a double level scheme: the upper controller aims to generate the target locking torque, while the lower controller generates, as control action, the supply current for the controllable limited slip differential. The obtained results show the effectiveness of the device in terms of vehicle dynamics improvement. Indeed, the results reached by the vehicle in presence of the new differential confirm the improved performances for both steady and unsteady state manoeuvres.

Active vehicle dynamics control ensures improved safety. So far, yaw instability is mostly associated with transient steering manoeuvres when driving at a constant speed. However, braking related load transfer affects yaw stability. Intense braking at high friction combined with elevated and forwarded CG amplifies this influence on unloaded tractors. Designing a dynamic stability system to enhance active safety requires fresh insight into braking related yaw instability. This investigation covers a theoretical analysis of braking influence on yaw stability on unloaded 4×2 tractors, being applicable to vehicle braking while cornering, including steering induced by other asymmetrical forces, since it focuses essentially on small steering angles.

Residual stress and hardness in steel due to thermal, mechanical, and fatigue deformations are determined by an X-ray diffraction method. The sharp temperature rise associated with electrical discharge machining causes austenitizing, rehardening, and tempering, and results in high tensile residual stress. Shot-peening quality is evaluated from residual stress and hardness induced by the peening. Rolling contact fatigue of carburized and hardened bearings causes a transformation of austenite to martensite, and thereby generates more residual compression, and also causes permanent fatigue softening. Less softening is observed in inner races of consutrode and cross-forged steels than in air-melted steel, and the former steels exhibit greater fatigue life at early and mean failure levels.