Development and validation of a fully predictive high-fidelity simulation approach for predicting coarse road dynamic tire/road rolling contact forces

摘要

In this work, a fully predictive high-fidelity numerical approach for the simulation of a car tire rolling with a constant angular velocity over a coarse road surface is presented. A fully nonlinear vibro-acoustic finite element tire model is combined with an Arbitrary Lagrangian Eulerian formulation to describe both the rolling dynamics as well as the interaction between the tire and coarse road surface. A geometrical constraint approach is used to describe the tire/road interaction rather than a constitutive approach in order to keep the proposed method fully predictive, i.e. to not rely on measurement data. As both the use of a nonlinear finite element tire model, as well as the use of the geometrical constraint approach result in large computational costs and simulation times, the nonlinear Multi-Expansion Modal Reduction hyper-reduction method is applied. Numerical costs and corresponding simulation times are reduced by a factor of order of magnitude 100 (from several months to hours), therefore making the proposed approach feasible to use in an industrial design and development process. Two alternative linearized approaches, based on the proposed nonlinear approach, are considered as well. While the proposed nonlinear approach shows a good, consistent qualitative and quantitative correspondence between experimental and numerical simulation results for the entire 0-400 Hz frequency range of interest, with normalized Power Spectral Density differences between 0.1 and 0.2 dB (ref. 1 N/Hz), the linearized approaches are limited to lower frequency ranges of 0-85 Hz and 0-200 Hz and are therefore not suitable for the intended application. The overall performance of the proposed nonlinear approach confirms its use as a possible alternative to standard time-consuming experimental approaches. (C) 2019 Elsevier Ltd. All rights reserved.