Full Vehicle Durability Analysis by Means of the IDIADA Virtual Proving Ground

It is usual that the applied loads on structural elements are in fluctuating situations. Sometimes the component can break under its ultimate or its yield strength. This break situation is due to the fluctuating loads that have been applied for long periods. For this purpose this breaking type is called “fatigue breaking”. Fatigue breaking is a consequence of a crack growth. When no prototypes are available, it is necessary to calculate the life prediction as soon as possible. Simulation through the VPG is being increasingly used for life prediction. The present work shows a methodology that uses a Finite Element Model (FEM) that runs on a proving ground. In this case, no MBS (multi-body software) model is used to obtain the loads on the structure. Because the whole simulation of the finite element model needs a lot of time, a co-simulation is carried out. An implicit FE solver is used for problems in which the response is moderately nonlinear. This implicit method is computationally expensive. On the other hand, an explicit FE solver is ideal for modelling highly nonlinear problems such as changes in contact surfaces. This explicit method is relatively inexpensive. The ideal situation is to use the correct solver where it will be needed. Components with moderate nonlinear behaviour (Body, Suspension) will be solved using the implicit method. Explicit method will be used to model the impacts of the tire against the Virtual Proving Ground. Fundamental parts of this methodology are the digitalization of IDIADA’s proving ground, its implementation as a rigid body and co-simulation.