A comprehensive simulation approach for planning single-axis bench tests of vehicle shock absorbers

An integrated simulation-based approach is proposed for planning single-axis bench tests for evaluating the ability of vehicle shock absorbers to withstand the multi-axis acceleration, deceleration and steering forces produced under real-world driving conditions. In the proposed framework, multi-body dynamic analysis and computer-aided engineering (CAE) simulations are first performed to identify the regions of maximum stress produced in the four-wheel suspension system under seven representative driving conditions. Further finite element simulations are then performed to predict the regions of maximum stress in the shock absorber in three single-axis bench tests performed with the load applied at different positions of the absorber and in different directions. It is shown that, between them, the three single-axis bench tests successfully induce the same regions of maximum stress as those observed in the CAE simulations under the different driving conditions. The simulation results obtained in the bench tests for the variation of the shock absorber deformation with the applied load are used to determine the maximum loading forces and deformations the shock absorber can resist under vertical and lateral loading conditions, respectively. The feasibility of the early-stage shock absorber design can then be evaluated by confirming that the maximum deformation experienced by the shock absorber under real-world driving conditions (multipled by a given safety factor) falls within this maximum loading force range. The method proposed in this study provides a low-cost and systematic approach for planning the single-axis bench tests and evaluation criteria required to confirm the ability of shock absorbers to meet vehicle suspension requirements under real-world driving conditions.