Performance Simulation And Part Design Of A Light-Tuck

Application of Virtual prototyping and Finite Element Anlysis method on performance forecast simulation research and parts design during new vehicle development process is very helpful. For this paper, the prototype simulation model is built, and then steady state circular test and ride comfort test simulation are taken for suspension stiffness research, different plans are put forth based on the simulation results, as well, for the new prototype making, FEA method is applied on front axle improving design.And the results obtained is a good reference for new front alxe model development.Main research of this paper are focused on the following aspects:(1) Design parameters and main modifications of the prototype chassis are described, and the problems brought by the changes are concluded.(2) Rigid-flexible vehicle simulation model is built, steady state circular test simulation of the truck under full load situation is performed, using QCT480-1999 steady state circular test evaluation method to comment on the simulation results, and the truck gets 95.232 points, as well,from the angle of prototype ride comfort considering.vibration frequency anlysis of front and rear suspension under empty and full load is taken.The results show the stiffness of suspension need to be improved, therefore, two plans are put forth to improve the full vehicle handling stability and ride comfort performances.for the steady state circular performance simulation,plan 1 gets 85.01 points.and plan 2 gets 90.14 points under 1 ton load. For ride comfort simulation of the truck on Radom input road at speed 42.6km/h.The weighted RMS value of cab seat for the previous plan is 0.499m/s2, plan1 and plan 2 are 9.62% and 15.23% lesser than previous plan separately.For ride comfort simulation of the truck on pulse input road at speed 42.9km/h, the max pulse acceleration value of the seat is 8.088m/s2.And plan 1 and plan 2 are 11.76% and 18.24% lesser than previous plan.These results are helpful to the new truck development.(3) For running system parts of prototype chassis are rich in load under the new full vehicle design load requirement, and the chassis is overweight on the other hand, therefore, Front alxe is selected for improving design.the nominal load of previous alxe is 2400kg, and the new design load is 1800kg.The new axle has to have the same assembly and positioning parameters with the previous alxe. Under the principle of maintaining the stress and strain of front axle at the same level for previous and post models. Base on theoretic analysis. Four key sections of the new front axle are designed. Taking CAD/CAE method to build and check the model.The reulst shows that for nominal load at 1800Kg, when strength and stiffness can satisfy the requirement, the weight reduction is 7.943kg (17.05%), which is a good reference for new front axle development and other chassis parts weight reduction design like rear axle, frame and leaf springs.