Read TrackA_1_Side_Load_Coil_Spring.pdf text version

Side Load Coil Spring

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Side Load Coil Spring

Side Load Coil Spring Spring

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1959 1970 1974 1977 1980 1987 1991 1996 1997 1999 2004 2005 2006 2008 2011 , ,, A.M.C , 1,000 K.S () ( 91-818) 100PPM HORIKIRI SPRING QS-9000, ISO-90002 - , , TS-16949, ISO-14001 Eye-Forming M/C , () - (MOU) /

/ / /

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(Leaf Spring)

. , ,

(Coil Spring)

, 2 100% .

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LEAF Spring COIL Spring

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Side Load Coil Spring(SLC) ?

. . (Side Load Coil Spring)

Macpherson type suspension

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Side Load Generation Mechanism

SLC

1. Design :

, , . (Spring Part . ) 2. Damper friction force : 3. Vehicle Self Steer (DRIFT): ,

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Side Load Coil Spring

Type of Spring Cylindrical Merits Demerits

Easy to Produce Good Stress Distribution Possibility to have large offset for lower spring seat Easy to Produce Clearance Between Coil (one end coil inside Body at jounce) Possibility to have large offset for lower spring seat Good Stress Distribution Clearance Between Coil (both end coils inside Body at jounce) Easy to Assemble No Axis Parameter Good Stress Distribution Association with tilted Bearing avoid drift phenomenon

Clearance Between Coil

Mono Pigtailed

Need Large Lower Seat

Double Pigtailed

Hot Process : need one more operation to reduce Coils

C and S shape

Possibility to get more Lateral force for very low rate Spring

Local Stress increases significantly Need Special Assembly Axis Parameter difficult to control

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Side Load Coil Spring

Virtual Prototyping

Target Design Factors (INPUTS) Spring Envelope, Spring Force Line, Preload @CVW, Spring Stiffness, ...,etc Basic Spring Calculation Wire Diameter, Coil Diameter, Number of Coils, Max Shear Stress, ... Coil Spring Shape Automation Program (CATIA)

Physical Prototyping

NC Coiling Machine

Correlation

SLC Test Rig Machine

Process Development & Integration (Short Term Development Issues) 3D Scanning Machine

Dynamic Analysis of SLC (ADAMS, Spring Toolkit)

SLC Test Rig

Sensitivity & DOE Analysis

Suspension Test Rig FE Analysis of SLC (HyperMesh, ABAQUS) Knowledge Based Fuzzy System (Long Term Development Issue)

SLC Shape Database (Manufacturing Tolerance) ·Design Spec. ·Scanning Data

Fatigue Analysis (fe-safe)

Correlation

Fatigue Test Machine

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Side Load Coil Spring

Force axis . Stress. . CATIA V5 ABAQUS / fe-safe .

Piercing Point

Damper axis

ideal axis geometrical spring axis

Max shear stress

Fatigue life

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Spring force axis

Force(Fx,Fy,Fz), Moment(Mx,My,Mz) Piercing point

Spring Force Line

200 Target Optimal Z-Axis [mm] 10

150

100 50 P/Point 6 (Force,Moment) -10 0 0

Piercing point evaluation

20 30 Y-Axis [mm]

40

-50

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GAP Check

Pressure on Upper spring seat

Rebound 1800 1600 Design Bump

Contact Pressure

1400 1200 1000 800 600 400 200 0 3.00 3.20 3.40 3.60 3.80 4.00

Spring () Stress (condition) Stress Part(Wheel house) Clearance check. ABAQUS / CATIA V5

Contact Pressure Distribution at Each Load Condition Rebound Design Bump

Clearance check

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Stress Distribution

Spring (turns) Stress (condition) Stress ABAQUS

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­ ABAQUS & fe-safe

Von-Mises Stress

Max shear stress

Fatigue Life

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SLC Design Parameter Study

WHAT-IF Study

DOE Table ( "2-2-2")

What-If Study ( "2-2-3")

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SLC Product type

Item Hot-Forming Cold-Forming

Shape

(Forming)

Material Shape Design Max Stress

SAE9254 POSHIS 120D Cylindrical / Pigtail / Conical 130 /

SHI -180 SHI-200P Both pigtail / S-Shape / C-Shape 120 /

1. .

Merit

1. (C-Type, S-type, etc)

2. (- ) 3. Spring (10%) 4. Strut module .

2. Size . 3. .

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TEST ­

UTM Spring Upper/Lower seat 6 Spring force line

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Fatigue test

Module test

Corrosion & Chiping test

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Spring

Step 1 : Rebound Step 5 : Stroke

Step 7 : Stroke

Step 2 : CVW

Step 3 : GVW Step 4 : F/Bump Step 6 : F/Bump

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Sprig UPR Seat : Shell Element Spring : Solid Element + Shell Element( SKIN Element ) Spring LWR Seat : Shell Element

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Free

Full Bump

Rebound Stroke CVW

Full Bump

GVW

Full Bump

Stroke

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(SPRING, SEAT ) DB - - - ASSY

(ABAQUS)

Input (fe-safe)

-

- : /, , , , , . - (: , , , ) - ABAQUS - -

fe-safe

- - NG

Correlation

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,

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Modeling

Data Import Set position Mesh Edge Check Modify Mesh Quality Check Modify Normal physical properties

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Recheck

Recheck

Mesh Generation Element type define Contact Definition Material Definition Section Definition coordinator Definition Boundary Condition Input data Import

Job

ODB data import Analysis Environment Force check 6-AXIS CHECK Recheck Modify Sampling test

Load Steps

Export (.INP)

Results

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­

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­

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Fatigue - Max Shear Strain ­ Morrow - ABAQUS & fe-safe Design life - 300,000 cycles

300

250

case 1 200 Displacement 150 100 50 Case 2 Case 3 Case 4 Case 5 Case 6 Case 7 Case 8

0

1 2 3 4 5

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Fatigue Life

Case 1 Case 2 Case 3 Case 4

1.2E+06 1.0E+06 8.0E+05 6.0E+05

Case 5

Case 6

Case 7

Case 8

4.0E+05 2.0E+05 0.0E+00 case1 case2 case3 case4 case5 case6 case7 case8

fatigue life

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Information

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30 pages

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