Distributed by ANSYS, Inc.

ANSYS Motion
CAR
Tutorial
ANSYS, Inc.
 Distributed by ANSYS, Inc.

Contents
1. General Half Car Analysis .....................................................................................................................................1
1.1. The structure of Car Models .....................................................................................................................1
1.2. What you are going to learn ......................................................................................................................1
1.3. Open Car Work/Model ..............................................................................................................................2
1.4. Before Modeling operation ........................................................................................................................4
1.5. Creation of Car Force Property .................................................................................................................6
1.5.1. Creation of Spring Force Property ................................................................................................6
1.5.2. Review Car Force Property Files. .................................................................................................9
1.6. Creation of a Suspension Template ........................................................................................................12
1.6.1. Creation of Macpherson Type Suspension Template .................................................................12
1.7. Creation of Suspension Subsystem ........................................................................................................52
1.8. Working with A Half Car Assembly ..........................................................................................................54
1.9. Simulation of a Half car assembly ..........................................................................................................56
1.9.1. Suspension analysis using multiple Load cases ........................................................................56
1.9.2. Parallel Travel analysis ...............................................................................................................59
1.9.3. Vertical load analysis ..................................................................................................................59
1.9.4. Updating the Suspension model and re-running the Vertical load analysis ...............................60
1.10. Post-processing Half car results .............................................................................................................62
1.10.1. Post-Processing Parallel Travel analysis ....................................................................................62

1.10.2. Post-Processing Vertical load analysis .......................................................................................66

1.10.3. Comparing two Parallel Travel results: Baseline and the updated model ..................................68
2. A Full Vehicle Analysis ........................................................................................................................................68
2.1. Create Subsystems.................................................................................................................................69
2.1.1. Create A Body subsystem ...........................................................................................................69
2.1.2. Create a Steering subsystem......................................................................................................71
2.1.3. Create a front suspension subsystem ........................................................................................73
2.1.4. Create a rear suspension subsystem .........................................................................................76
2.1.5. Create Front wheel subsystems .................................................................................................80
2.1.6. Create Rear wheel subsystems ..................................................................................................81
2.2. A Full Car Assembly and its analysis ......................................................................................................82
2.2.1. Step Steer analysis .....................................................................................................................84
2.2.2. Add Powertrain subsystem and Acceleration analysis in Full Car ..............................................85
2.2.3. Parameter updates and re-run an analysis.................................................................................88
2.3. Post process of Full car simulation results .............................................................................................89
2.3.1. Play Animation ............................................................................................................................89
2.3.2. Plot Step Steer Results ...............................................................................................................91
2.3.3. Plot Acceleration Results ............................................................................................................93
2.3.4. Plotting two or more simulation results: Baseline and an updated model. .................................94
 Car Tutorial ANSYS, Inc.

1. General Half Car Analysis

1.1.The structure of Car Models

In this tutorial, you are going to build a couple of suspensions and a full vehicle model. And you
are going to run a simple K&C analysis using one of the suspension models. A vehicle dynamics
simulation will be done with the full vehicle model. Creating a suspension model needs several
steps: building templates, creating subsystems from templates, and defining force connections
(force vs deflection relation) between suspension parts. A template is a parametrized subsystem
framework. A subsystem is created from the template with suspension parameters such as hard
points and force versus deflection curves for bushings, shocks, springs, and jounce bumpers. An
assembly is a minimum number of subsystems put together to define a suspension and a full
vehicle for vehicle dynamic simulation. Once you have built an assembly, you are ready to run a
simulation with the assembly and a test-rig.

1.2. What you are going to learn

A suspension analysis is a simple example to help users to learn how to create templates,
subsystems and run an analysis using ANSYS Motion Car.
You are going to build two suspension subsystems and a full vehicle model. Building and updating
models, analyzing the models will be covered by step-by-step processes.

⚫ Description of the example half car model

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The first task is to build a MacPherson front suspension. The MacPherson suspension subsystem
has multiple parts: subframe, upper_strut, lower_control_arm, spindle, knuckle, tierod, drive_shaft,
etc. Parts are connected by joints and force elements such as bushings, springs, dampers, jounce
bumpers, and rebound bumpers. These force elements provide the suspension unique kinematic
and compliance characteristics. A test-rig and tire models for half car analysis are automatically
created and hooked up to a suspension assembly when it is ready.

< Assembled half car model >

1.3.Open Car Work/Model

A “Work” is an extensive concept of managing vehicle dynamic models. The Work could have
multiple assemblies, subsystems, templates, various force elements, and mesh and CAD files.
The structure and contents of the Work are laid out in Work navigator. A Model has folders of
subsystems, meshes and parts and so on. The section 1.4 Work and Models in Ansys Motion
Preprocessor Manual will help you understand Work/Model in detail.

< Concept of Work and Model >

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All functions and capabilities of ANSYS Motion/CAR is best utilized in Work environment. Users
are recommended to create a Work when he/she starts to build a vehicle model.
The Work contains Models. Each Model has Templates, Subsystems created from Template,
Assemblies, force properties and others. The Work/Model helps you manage those files easily in
Navigator. (This tutorial provides an example of the Work/Model).
Please copy ‘Standard Work.zip’ file from ‘ANSYS INSTALL_PATH\Motion\Document\’. Unzip the
file in your directory that you want to build tutorial models. The unzipped folder has Standard Work
and Model. The unzipped folder will be called to “USER DIR” next time in this tutorial.

Open A Car Work.

1. Double click ANSYS Motion Preprocessor icon.

< ANSYS Motion Preprocessor icon >

< ANSYS Motion Preprocessor >

2. Click Open Model as shown below.

< Open Model >

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3. Select Car_Standard_Work.dfwork.file in the path (USER DIR \Standard Work).

< Open Car_Standard_Work.dfwork >

4. Click the Work Navigator tab at the left bottom of the screen. Work Navigator will appear

as below.

(You can manage and open easily various files about ANSYS Motion/CAR using Work
Navigator.)

< Work Navigator >

1.4.Before Modeling operation

You are encouraged to review a few manual sections below to better understand this tutorial.

1.1.2. Terminology : This describes Preprocessor GUI such as Main Categories, Menus, Dialogs,
Buttons, Entities, Check Boxes, Input Fields and so on.

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1.3.1. Layout of Main Window : This explains ribbon menu, navigator window, sub-entity
window, property window and others in Main window.

1.3.6. Setting : Setting defines the program default value to control the data precision (single or
double precision), view control, the time for model autosave and so on.

1.3.11. Subsystem Navigator : This describes Subsystem Navigator and operations in there.

1.3.13. Work Navigator : This describes Work Navigator and operations in there.

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1.5. Creation of Car Force Property

In this section, you are going to create a spring element in a suspension.

1.5.1. Creation of Spring Force Property

1. To create a new spring property file, click New File button.

< Click New file icon >

2. Select Car, Spring in New File creation dialog window. Check 'Add to model' to add to

the Model.

< Select File (Spring) type >

3. Click the OK button. The “Create Car Property” window will open. The first step is to

set up the unit. Select MMKS unit and click the Finish button.

< Select MMKS units >

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You can review and update the Spring Property file in Work navigator. For example, you can
update the spring force versus deflection curve using a Spring Spline, or a constant stiffness
spring. You can also change Free Length/preloads to match suspension trim conditions and
complete Spring Property file.

< Created Spring Property file >

< Created Spring Property >

4. For Spring Spline data, enter "SPL_SPRING" in the Spline name field. Then copy the

spring spline data (e.g., from excel spreadsheet) and paste them. Make sure to click

the check button , otherwise the data would not be updated.

< Creation spring Spline >

-110 -10750

-100 -8000

-90 -4500

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-80 -4000

-60 -3000

-40 -2000

-20 -1000

0 0

20 1000

40 2000

60 3000

80 4000

90 4500

< Spring Spline data>

5. Click Left arrow button at the right end of the window. The spring spline plot will be
brought up.

6. In Work Navigator, pick “Spring1” and input “206” for Free Length.

< Created Spring Property >

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7. Click Save Button. It will save the spring property. The spring property creation is
done.

< Saving Spring Property >

1.5.2. Review Car Force Property Files.

You are not going to build individual force elements one by one. Many forces elements are already
built to save your time. Next steps will give you an idea how to review those elements available.
1. In Work Navigator, double click vm_default.cpfdxml in Dampers folder.

< Dampers file >

2. Check “spl_vm_default” in “Damping Spline”.

< damper property >

3. Select the Spline tab in Sub-Entities at the bottom of the window. Then, pick
“spl_vm_default” in Spline list.

< damper Spline >

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4. click button on right side to review the damper spline curve.

< damper spline curve >

5. In the same way, open vm_001.cpfbsxml in Bump_stops, vm_001.cpfrbsxml in
Rebound_stops, and vm_001.dfpfbxml in Bushings. Then, review force versus
deflection plots.

< Bump_stop property >

< Rebound_stop property >

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< Bushing property >

(Spring, Damper, Bump stop, and Rebound stop are one dimensional element that require
a spline for a nonlinear representation or a constant parameter for a linear representation.
A bushing/mount has three translation and three rotational degrees of freedom between
parts: stiffness and damping characteristics in 6 directions either by constant linear
parameters or by nonlinear splines.)

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1.6. Creation of a Suspension Template

A Template is a framework to build multiple subsystems that has the same layout but different
parameters. For an example, McPherson suspension is very popular for automotive front
suspensions due to simplicity, well known characteristics, and reasonable cost to build. Many
vehicle OEMs have McPherson front suspensions in their application. Although their layouts are
same, their designs in details are not same: hard points, spring stiffness, jounce bumper design,
tie rod location and so on. One template can be used to build multiple subsystems of McPherson
front suspensions used in many automotive companies. One McPherson suspension template
can build many McPherson suspension subsystems for small cars, mid-size car and even large
vehicles.

In this section, you are going to build a McPherson suspension template. The key to building a
template is parametrization. Parameters for hard points, part geometries, axis and orientation will
be used to build a suspension subsystem in detail. Thus, the first step is to create parameters
and design entities in Ansys Motion: design variable, design point and design frame before we
build entities such as bodies, joints, forces.

1.6.1. Creation of Macpherson Type Suspension Template

Design points are parametrized points representing locations. Design frames have additional
features of orientation on top of locations (Design Points). For examples, bushings and shocks
need positions and orientations to define their attributes. A Design Frame can serve both needs.
In this section, you are going to build Design Points, Design Frames, bodies, joints, and forces
components for the MacPherson suspension.
Some of outputs such as joint forces, bushing forces, displacements of parts, and so on are
automatically created so that you do not need extra efforts to build them.

1.6.1.1. Create New Template File

1. To create a new suspension template, click New File buttons.

< Click New file icon >

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2. Select Car in the Group window, Suspension Template in the Type window. Change the

file name to 'Macpherson_Tutorial' and check 'Add to model' to add to the Model.

< Select File type >

3. Click OK button. “Create Car Template” window will appear. Select MMKS unit and click

Finish button.

< Select MMKS units >

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Template Working window appears as below. You can see the new template file in Work Navigator.

< Working window >

< Work Navigator >

1.6.1.2. Create design parameters

Design points and design frames are essential for parametrizing the template. The first step in
building the template is to create design points and design frames. Design points have X, Y, Z
position data and design frames have position and orientation data.
(‘Creation_of_DesignPrameter.dfjnl’ file in Journal folder helps you to create design
parameters quickly. The journal file has been built to create design parameters (design
variables, points, frames) necessary for next steps. Executing the Journal file
automatically create design parameters. The section 1.3.5. Journal Record and Stop of Ansys
Motion Preprocessor Manual will help you to understand how to use Journal files)

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< Execute External Module File button >

< Execute journal file >

This tutorial will guide you a step-by-step procedure to create design parameters. Save the journal
file execution for an advanced step in the future. If you created the Design Parameters by the
Journal recording, skip to next chapter (1.6.1.3 Create Bodies).

Create design points

1. Click Design point menu tab and select Symmetric Type as Left.

< Design Point >

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(Most of suspension structures are symmetric. Left and Right in “Sym. Type” assume a
pair of data is being created. None in Sym. type creates a single design point.)

2. Put ‘dp_lca_front’ in name and ‘-200, -450, 150’ in value.

< Created design point 'dp_lca_front' >

* For a design point update, click the value cell, type in new data, and press enter key.

⚫ Create design points in the table below.

Name X, Y, Z Symmetric Type

dp_lca_front -200, -450, 150 Left
dp_lca_outer 0, -750, 150 Left
dp_lca_rear 200, -450, 150 Left
dp_tierod_outer 150, -750, 300 Left
dp_tierod_inner 200, -400, 300 Left
dp_wheel_center 0, -800, 300 Left
dp_strut_lwr_mount 40, -650, 600 Left
dp_knuckle_spindle_in 0, -775, 300 Left
dp_knuckle_spindle_out 0, -825, 300 Left

⚫ Create design variables

1. Click ‘Toe-Camber Angle’ under the Run button.

< Click Toe-Camber Angle >

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2. Enter values in Toe Angle and Camber Angle.

< Edit Toe-Camber Angle >

3. Review the design variables, 'toe_angle' and 'camber_angle' in Design Variable tab.

< Design Variable >

Create an additional Design Variable using values in the table below.

Name Value Symmetric Type
dv_drive_shaft_offset 50.0 Left

⚫ Creation of a Design Frame (df_wheel_center)

Title Value
Name df_wheel_center
Option Point And Orientation
Point dp_wheel_center:L by Design Point
Orientation Toe : toe_angle:L, Camber: camber_angle:L by Toe Camber
Symmetric Left

1. Click Design Frame menu tab.

< Design Frame >

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1. Enter ‘df_wheel_center’ in name cell and Click Picker button.

2. Transform Picker will appear.

(Transform picker defines position and orientation)

3. Select “Point and Orientation ”.

< Select Point and Orientation option >

4. Click “Point button” and then a Point Picker window will open.

(Point picker defines position of design frame.)

5. Select “Design Point” among filter and then pick ‘dp_wheel_center:L’. The position

of the Design Frame has been assigned. Click Parent button.

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< Select Design Point >

6. You are going to define an orientation in next few steps. Click Orientation at the bottom

of the Transform Picker. An Orientation Picker window will open.

(Orientation picker defines orientation of design frame.)

7. Select “Toe Camber” among filters and then type ‘toe_angle:L’ and

‘camber_angle:L’. Click Parent button.

< Orientation Picker >

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8. Click OK in the Transform Picker.

* You can update design frames by clicking button any time.

Create a design frame (df_drive_shaft_otr) as below.

Title Value
Name df_drive_shaft_otr
Option Point And Orientation
df_wheel_center:L + Use Delta + Use DF + ∆Z : -1.0 *
Point
dv_drive_shaft_offset:L by Design Frame
1st point : df_wheel_center:L + Use Delta + Use DF + ∆Z : -1.0 *
Orientation dv_drive_shaft_offset:L by Design Frame, 2nd point : df_wheel_center:L by
One Direction and Two points
Symmetric Left

1. Click Design Frame menu tab and enter ‘df_drive_shaft_otr’ in the name cell

2. Click button and then a Transform Picker window will open. Click ‘Point And

Orientation’ button even if the button is highlighted already.

3. Click Point and then a Point Picker window will open.

4. Select “Design Frame” among filters and then pick ‘df_wheel_center:L’.

5. Check “Use Delta” and “Use DF”. Type ‘-1.0 * dv_drive_shaft_offset:L’ in ∆Z cell for an

offset point.

< Point Picker >

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6. Click Orientation in the Transform Picker and then Orientation Picker window will open.

7. Click “One Direction” among filters and then click button.

< Click One Direction >

8. A Direction Picker window will open.

9. Click “Two Points” among filters

(“Two points” defines Z-axis from the 1st point to the 2nd point.)

< Click Two Points >

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10. Select the position in the same manner as steps 4 and 5 as in the 1st point definition

< 1st point >

11. Select ‘df_wheel_center:L’ for the 2nd point and click the Parent button.

12. Click the Parent button again in the Orientation Picker. Click OK button in the Transform

Picker.

⚫ Create more design points in the table below.

Name X, Y, Z Symmetric Type

dp_drive_shaft_inr 0, -200, 225 Left
dp_spring_lwr_seat 40, -650, 600 Left
dp_top_mount 57.5, -603.8, 800 Left
dp_subframe_front -400, -450, 150 Left
dp_subframe_rear 400, -450, 150 Left

⚫ Create a design frame (df_top_mount_ext)

Title Value
Name df_top_mount_ext
Option Point And Orientation
Point dp_top_mount:L + Use Delta + Use Global + ∆Z : 50 by Design Point
Orientation Euler Angle: ‘ZXZ’+ Z : 0, X : 0, Z : 0 by Euler Angle
Symmetric Left

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1. Open the Design Frame creation window.

2. Select Left for “Sym. Type” and enter ‘df_top_mount_ext’ in the name cell.

3. Click button and Click the “Point And Orientation” button in the Transform Picker.

4. Click “Point”. Then a Point Picker window will open.

5. Select “Design Point” among filters and select ‘dp_top_mount:L’. Check “Use Delta”

and type ’50.0’ in delta Z. Click the Parent button.

6. Click the Orientation button. Then an Orientation Picker window will open.

7. Click “Euler Angle” in the Orientation Picker.

8. Select ‘ZXZ’, type Z : 0, X : 0, Z : 0, and Click the Parent button.

< Orientation Picker >

9. Click the OK button in the Transform Picker.

Create a design frame (df_shock_tube) as below.

Title Value
Name df_shock_tube
Option Point And Orientation
Point dp_strut_lwr_mount:L (Design Point)
1st point : dp_strut_lwr_mount:L, 2nd point : dp_top_mount:L by One
Orientation
Direction and Two points
Symmetric Left

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1. Click Design Frame menu tab and enter ‘df_shock_tube’ in the name cell

2. Click button and then a Transform Picker window will open. Click the ‘Point And

Orientation’ button

3. Click the “Point” button. Then a Point Picker window will open.

4. Select ‘dp_strut_lwr_mount:L’ for Design Point and Click the parent button.

5. Click “Orientation” in the Transform Picker. An Orientation Picker window will open.

6. Click “One Direction” among filters and then click button.

< Click One Direction >

7. A Direction Picker window will open.

8. Click “Two Points” among filters

(“Two points” defines Z-axis from the 1st point to the 2nd point.)

< Click Two Points >

9. Select ‘dp_strut_lwr_mount:L’ and ‘dp_top_mount:L’ for positions. Then click the Parent

button.

10. Click the Parent button again in the Orientation Picker. Click the OK button in the

Transform Picker.

⚫ Add design points using Design Frame option in below table

Name X, Y, Z Symmetric Type

df_shock_tube:L + Use Delta + Use DF + ∆Z : Left
dp_shock_tube_up 80 by Design Frame
(46.795741, -632.05924, 677.66561)
df_shock_tube:L + Use Delta + Use DF + ∆Z : - Left
dp_shock_tube_down 50 by Design Frame
(35.752662, -661.21297, 551.45899)
1.6.1.3. Create Bodies (components)
In this chapter, you will create bodies (parts) for the suspension system using the created design
parameters.

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(‘Creation_of_Body.dfjnl’ file in Journal folder help you to create the bodies for
Macpherson suspension quickly. The journal file has been built to create all bodies
necessary for next steps)
Execute the Journal file and then the bodies will be created automatically

< Execute journal file >

In this tutorial, you are going to create bodies step-by-step. If you created the Bodies by the
Journal, go to next chapter. (1.6.1.4 Create Constraints).

⚫ Create Tri-Plate geometry

1. Click the Tri-Plate icon in the Body menu.

< Click Tri-Plate icon >

2. A “Create Tri-Plate Dialog” will open.

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< Create Tri-Plate >

3. Select “Design Point” for 1st Position and select 'dp_lca_front:L'.

< Select Design Point >

(A Design point can be selected either by using mouse right click in subsystem navigator
or by clicking the point on the screen.)

4. Select 'dp_lca_outer:L' for 2nd Position and 'dp_lca_rear:L' for 3rd Position

5. Enter 10.0 in Height.

6. Enter ‘lower_control_arm’ in Name.

7. Choose a color as you want.

8. Select “Left” for Symmetric.

9. Click button. A body with Tri-plate geometry will be created. Subsystem

navigator shows ‘lower_control_arm’ in the Body group.

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< Create Tri-Plate >

Create a tierod body

⚫ Create a cylinder geometry

1. Click the Cylinder icon in the Body menu.

< Click the Cylinder icon >

2. The “Create Cylinder” Dialog will open. Enter data as in the table below.

Title Value
Bottom position dp_tierod_outer:L(Design Point)
Top position dp_tierod_inner:L(Design Point)
radius 8.0
name tierod
Symmetric type Left

3. Click the button. A cylinder body will be created. Subsystem navigator shows

‘tierod’ in the body group.

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< Create Cylinder >

Create a Knuckle body

A knuckle body has seven geometries (five cylinders & two spheres). They are combined to make
one Knuckle body using a Boolean operation.
You are creating five cylinders and two spheres under the same name of Knuckle.

⚫ Create cylinder geometries

Create a cylinder geometry using values in the table below.

Title Value
Bottom position dp_wheel_center:L(Design Point)
Top position dp_strut_lwr_mount:L (Design Point)
radius 10
name knuckle
Symmetric type Left

Create cylinder geometries by Boolean using values in the tables below.

Title Value
Bottom position dp_lca_outer:L (Design Point)
Top position dp_wheel_center:L (Design Point)
radius 10
create option Boolean
name knuckle:L using body icon
Symmetric type Left

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Title Value
Bottom position dp_wheel_center:L (Design Point)
Top position dp_knuckle_spindle_in:L (Design Point)
radius 10
create option Boolean
name knuckle:L using body icon
Symmetric type Left

Title Value
Bottom position dp_wheel_center:L (Design Point)
Top position dp_knuckle_spindle_out:L (Design point)
radius 10
create option Boolean
name knuckle:L using body icon
Symmetric type Left

Title Value
Bottom position dp_wheel_center:L (Design Point)
Top position dp_tierod_outer:L (Design point)
radius 10
create option Boolean
name knuckle:L using body icon
Symmetric type Left

⚫ Create sphere geometries by Boolean

1. Click sphere icon in body menu.

< Click sphere icon >

2. The Create Sphere Dialog Appear.

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< Create sphere >

3. Input below table data.

Title Value
Center Position dp_lca_outer:L(Design Point)
radius 7.5
create option Boolean
name knuckle:L using body icon
Symmetric type Left

4. Click Apply button. A sphere body will be created.

Create a sphere geometry by Boolean using values in below table.

Title Value
Center Position dp_tie_rod_outer:L (Design point)
radius 10
create option Boolean
name knuckle:L using body icon
Symmetric type Left

Create sphere geometries using values in tables below.

Title Value
Center Position dp_tierod_inner:L (Design point)
radius 10
name Intp_tierod_to_steering
Symmetric type Left

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Title Value
Center Position dp_drive_shaft_inr:L (Design point)
radius 10
name Intp_tripot_to_differential
Symmetric type Left

Title Value
Center Position dp_top_mount:L (Design point)
radius 10
name Intp_strut_to_body
Symmetric type Left

Title Value
dp_lca_front:L + dp_lca_front:R + dp_lca_rear:L + dp_lca_rear:R by
Center Position
Multi Point Center
radius 10
name Intp_subframe_to_body
Symmetric type None

< Multi Point Center >

Create spindle

⚫ Create a cylinder body using values in the table below.

Title Value
df_drive_shaft_otr:L + Use Delta + Use DF + ∆ Z : 50.0 by Design
Bottom position
Frame
Top position df_drive_shaft_otr:L (Design Frame)
radius 30
name spindle
Symmetric type Left

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< Setting of Bottom Position >

(You can select a design frame by using Point Picker. It is similar to design point selection.)
(Select “Design Frame” among filter in the Point Picker and then check “Use Delta” and
“Use DF”. Type ’50.0’ in ∆ Z.)

➢ Create drive shaft

⚫ Create cylinder geometries using values in the tables below

Title Value
Bottom position df_drive_shaft_otr:L (Design Frame)
Top position dp_drive_shaft_inr:L (Design Point)
radius 15
name drive_shaft
Symmetric type Left

Title Value
Center Position df_drive_shaft_otr:L (Design Frame)
radius 30
create option Boolean
name drive_shaft using body icon
Symmetric type Left

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Create tripot

⚫ Create a sphere geometry using values in the table below

Title Value
Center Position dp_drive_shaft_inr:L (Design Point)
radius 8
name tripot
Symmetric type Left

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Create upper strut

⚫ Create a cylinder geometry using values in the table below.

Title Value
Bottom position dp_strut_lwr_mount:L (Design Point)
Top position dp_top_mount:L (Design Point)
radius 12
name upper_strut
Symmetric type Left

Create shock tube

⚫ Create a cylinder geometry using values in the table below.

Title Value
Bottom position dp_shock_tube_up:L (Design Point)
Top position dp_shock_tube_down:L (Design Point)
radius 20
name shock_tube
Symmetric type Left

Create subframe

⚫ Create cylinder geometries using values in the tables below

Title Value
Bottom position dp_subframe_rear:L (Design Point)
Top position dp_lca_rear:L (Design Point)
radius 5
name subframe
Symmetric type None

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Title Value
Bottom position dp_lca_rear:L (Design Point)
Top position dp_lca_front:L (Design Point)
radius 5
create option Boolean
name subframe using body icon
Symmetric type None

Title Value
Bottom position dp_lca_front:L (Design Point)
Top position dp_subframe_front:L (Design Point)
radius 5
create option Boolean
name subframe using body icon
Symmetric type None

Title Value
Bottom position dp_subframe_rear:R (Design Point)
Top position dp_lca_rear:R (Design Point)
radius 5
create option Boolean
name subframe using body icon
Symmetric type None

Title Value
Bottom position dp_lca_rear:R (Design Point)
Top position dp_lca_front:R (Design Point)
radius 5
create option Boolean
name subframe using body icon
Symmetric type None

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Title Value
Bottom position dp_lca_front:R (Design Point)
Top position dp_subframe_front:R (Design Point)
radius 5
create option Boolean
name subframe using body icon
Symmetric type None

Title Value
Bottom position dp_lca_front:L (Design Point)
Top position dp_lca_front:R (Design Point)
radius 5
create option Boolean
name subframe using body icon
Symmetric type None

Title Value
Bottom position dp_lca_rear:L (Design Point)
Top position dp_lca_rear:R (Design Point)
radius 5
create option Boolean
name subframe using body icon
Symmetric type None

1.6.1.4. Create Constraints

In this chapter, you will create constraints for the suspension system using design parameters
and bodies.

(‘Creation_of_Constraint.dfjnl’ file in journal folder help you to create constraints for

Macpherson suspension quickly. The journal file has been built to create all constraints
necessary for next steps.)
Execute the Journal file and then the constraints will be created automatically

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< Execute journal file >

This tutorial will guide you a step-by-step procedure to create Constraints. If you created the
Constraints by the Journal, go to next chapter (1.6.1.5 Create Interface parts).

Ground – subframe (Fixed joint)

⚫ Create a Fixed joint

1. Click the Fixed icon in the Constraints menu

< Click the Fixed icon >

2. A “Create Fixed” window will open.

< Create Fixed >

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3. Enter data in the tables to create fixed Joints. Click Button. Then the fixed joint

will be created.

Title Value
Base body Intp_subframe_to_body
Action body subframe
dp_lca_front:L + dp_lca_front:R + dp_lca_rear:L + dp_lca_rear:R by
Point
Multi Point Center or Intp_subframe_to_body.CM(Design Frame)
Name fix_subframe_rigid
Symmetric None

knuckle – shock_tube (Fixed Joint)

Title Value
Base body knuckle:L
Action body shock_tube:L
Point dp_strut_lwr_mount:L (Design Point)
Name fix_knuckle_shock_tube
Symmetric Left

subframe – lower_control_arm:L (Revolute Joint)

⚫ Create revolute joints

1. Click the Revolute icon in the Constraints menu.

< Click Revolute icon >

2. Enter the data in the tables and Click Button. Then the revolute joint will

be created.

Title Value
Base body subframe
Action body lower_control_arm:L
Point dp_lca_front:L + dp_lca_rear:L by Multi Point Center
Direction 1st point : dp_lca_rear:L, 2nd point : dp_lca_front:L by Two Points
Name rev_lca
Symmetric Left

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knuckle – spindle (Revolute Joint)

Title Value
Base body knuckle:L
Action body spindle:L
Point df_wheel_center:L (Design Frame)
Direction df_wheel_center:L (Design Frame)
Name rev_spindle_knuckle
Symmetric Left

Intp_tirpot_to_differential:L – tripot (Translational Joint)

⚫ Create a translational joint

1. Click the Translational icon in the Constraints menu.

< Click the Translational icon >

2. Input data in the table and Click Button then the Translational Joint will be

created.

Title Value
Base body Intp_tirpot_to_differential:L
Action body tripot:L
Point dp_drive_shaft_inr:L(Design Point)
1st point : dp_drive_shaft_inr:L, 2nd point : dp_drive_shaft_inr:R by Two
Direction
Points
Name tran_tripot_to_differential
Symmetric Left

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Shock tube – Knuckle (Cylindrical Joint)

⚫ Create a cylindrical joint

1. Click the Cylindrical icon in the Constraints menu

< Click Cylindrical icon >

2. Input data in the table and Click Button. Then the Cylindrical Joint will be

created.

Title Value
Base body upper_strut:L
Action body shock_tube:L
Point dp_top_mount:L + dp_strut_lwr_mount:L by Multi Point Center
1st point : dp_strut_lwr_mount:L, 2nd point : dp_top_mount:L by Two
Direction
Points
Name cyl_strut
Symmetric Left

Knuckle – Tierod (Ball Joint)

⚫ Create ball joints

1. Click the Ball icon in the Constraints menu.

< Click Ball icon >

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2. Enter data in the table and Click Button. Then the Ball Joints will be created.

Title Value
Base body knuckle:L
Action body tierod:L
Point dp_tierod_outer:L (Design Point)
Name ball_tierod_outer
Symmetric Left

lower_control_arm – knuckle (Ball Joint)

Title Value
Base body lower_control_arm:L
Action body knuckle:L
Point dp_lca_outer:L (Design point)
Name ball_lca_balljoint
Symmetric Left

Ground – upper_strut (Universal Joint)

⚫ Create a universal joint

1. Click the Universal icon in the Constraints menu.

< Click Universal icon >

2. Input data in the table and Click Button. Then the Universal Joint will be

created.

Title Value
Base body Ground
Action body upper_strut:L
Point dp_top_mount:L(Design point)
Base X-axis 1st point : dp_top_mount:L, 2nd point : df_top_mount_ext:L by Two Points
Action X-axis 1st point : dp_top_mount:L, 2nd point: dp_strut_lwr_mount:L by Two

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Points
Name univ_top_mount_kinematic
Symmetric Left

drive_shaft – tripot (Constant Velocity)

⚫ Create constant velocity joints

1. Click the Constant Velocity icon in the Constraints menu.

< Click the Constant Velocity icon >

2. Enter data in the table and Click Button. Then the Constant Velocity joints

will be created.

Title Value
Base body drive_shaft:L
Action body tripot:L
Point dp_drive_shaft_inr:L(Design Point)
1st point : dp_drive_shaft_inr:L, 2nd point : df_drive_shaft_otr:L by Two
Base X-axis
Points
1st point: dp_drive_shaft_inr:L, 2nd point: dp_drive_shaft_inr:R by Two
Action X-axis
Points
Orthogonal -
Arbitrary
axis
Name conv_drive_sft_int_jt
Symmetric Left

spindle – drive_shaft (Constant Velocity)

Title Value
Base body spindle:L
Action body drive_shaft:L
Point df_drive_shaft_otr:L (Design Frame)

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1st point : df_drive_shaft_otr:L, 2nd point : dp_wheel_center:L by Two

Base X-axis
Points
1st point: df_drive_shaft_otr:L, 2nd point: dp_drive_shaft_inr:L by Two
Action X-axis
Points
Orthogonal -
Arbitrary
axis
Name conv_drive_sft_otr
Symmetric Left

Intp_tierod_to_steering – tierod (Constant Velocity)

Title Value
Base body Intp_tierod_to_steering:L
Action body tierod:L
Point dp_tierod_inner:L (Design Point)
Base X-axis 1st point: dp_tierod_inner:L, 2nd point: dp_tierod_inner:R by Two Points
Action X-axis 1st point: dp_tierod_inner:L, 2nd point: dp_tierod_outer_L by Two Points
Orthogonal -
Arbitrary
axis
Name conv_tierod_inner
Symmetric Left

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1.6.1.5. Create interface parts

An Interface is a tool to communicate data between two subsystems. For example, in a front
suspension, tie rods are attached to the steering rack in a steering system, but it is not defined in
the front suspension. In this case, dummy bodies (Interfaces) are defined in the suspension to
serve as the steering rack. In a vehicle assembly process, the dummy bodies (Interfaces) are
replaced by the steering rack. Since the interface is the essential tool to assemble many
subsystems in vehicle model, it should be defined at the level of template modeling.

< Assembly of suspension and steering subsystems >

< Concept of interface >

A dummy body in the suspension template is created to replace the steering rack in the steering
template as shown in the figure. A spherical joint has been created to connect the tie rod and the
dummy body. Turn on the interface option in property of the dummy body. Define an interface
name of the body. The dummy body will be replaced by the body of the interface name when the
subsystems are assembled.

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In the suspension system, following bodies are defined as interface bodies.

A body attached between tierod and steering rack (Intp_tierod_to_steering)
A body attached between tripot and differential (Intp_tirpot_to_differential)
A body attached between strut and chassis (Intp_strut_to_body)
A body attached between cradle or subframe and chassis (Intp_subframe_to_body)

< Interface body in suspension >

⚫ Create an interface body

1. Click “Subsystem Navigator” at the bottom left of the preprocessor window. Right

mouse click ‘Intp_tierod_to_steering:L’ and select “Property”.

< Subsystem Navigator >

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2. In the Property dialog window, check the Interface check box and click OK button.

< Properties of body >

3. Now you can see the interface bodies in the “Interfaces” folder in Subsystem Navigator.

< Subsystem Navigator >

4. Click the Interface icon in the Home menu.

< Click the Interface icon >

5. An Interface dialog window will open. Enter ‘rack’ and ‘chassis’ in matching names.

Click OK button.

(The matching names both for “Intp_tierod_to_steering:L”, “Intp_tierod_to_steering:L”

are rack and chassis. The interface bodies will be replaced with the bodies of the matching
names. In this case, Intp_tierod_to_steering:L & R will be replaced with 'rack' or 'chassis'
during an assembly process. 'rack' is the first replacement option. If ‘rack’ is not available,
Ansys Motion picks ‘chassis’ for the replacement.)

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< Interface >

(You can define several matching names for an interface part.)
The minor role further defines subsystems to search matching names from front, rear,
trailer or inherit. A Matching name is searched in subsystems of the same Minor Role. The
Inherit minor role search matching names in all subsystems. The Minor Role of a
subsystem is defined when it is created.

Create interface parts as below.

1. interface Body : Intp_tirpot_to_differential:L/R, Intp_strut_to_body:L/R,

Intp_subframe_to_body

2. Matching(Interface) Name : Intp_tirpot_to_differential:L -> diff_output:L, chassis

Intp_tirpot_to_differential:R -> diff_output:R, chassis

Intp_strut_to_body:L -> chassis

Intp_strut_to_body:R -> chassis

Intp_subframe_to_body -> chassis

1.6.1.6. Create Car Forces

In this section, you are going to build a few Car Force elements. Car Force property files have
been previously created. They will be used to define the Car Force Elements.

shock tube – upper_strut (Spring)

⚫ Create a spring force

1. Click the Spring icon in the Force menu.

<Click the Spring icon >

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2. Enter data in the table and Click Button. Then the Spring element will be

created.

Title Value
Spring Force Property file vm_0001.cpfsxml in User DIR\Standard Work\Springs.
Base body shock_tube:L
Action body upper_strut:L
Base Position dp_strut_lwr_mount:L (Design Point)
Action Position dp_top_mount:L (Design Point)
Name spr_ride_spring
Symmetric Left

3. Open the Spring Property window and type 0 in Preload.

< Modification of Spring Property >

shock tube – upper_strut (Damper)

⚫ Create a damper force

1. Click the Damper icon in the Force menu.

< Click the Damper icon >

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2. Enter data in the table and Click Button. Then the damper element will be

created.

Title Value
Damper Force Property file vm_0001.cpfdxml in User DIR\Standard Work\Dampers.
Base body shock_tube:L
Action body upper_strut:L
Base Position dp_strut_lwr_mount:L (Design Point)
Action Position dp_top_mount:L (Design Point)
Name dam_ride_damper
Symmetric Left

shock tube – upper_strut (Bumpstop)

⚫ Create a bumpstop (jounce bumper) force

1. Click the Bumpstop icon in the Force menu.

< Click the Bumpstop icon >

2. Enter data in the table and Click Button. Then the Bumpstop element will be

created.

Title Value
Bump Stop Force Property vm_0001.cpfbsxml in User DIR\Standard
file Work\Bump_Stops.
Base body upper_strut:L
Action body shock_tube:L
Base Position dp_top_mount:L(Design Point)
Action Position dp_strut_lwr_mount:L(Design Point)
Name bump_ride_bumpstop
Symmetric Left

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shock tube – upper_strut (Reboundstop)

⚫ Create a reboundstop force

1. Click the Reboundstop icon in the Force menu.

< Click the Reboundstop icon >

2. Enter data below and Click Button. Then the Reboundstop element will be

created.

Title Value
Rebound Stop Force vm_0001.cpfrbsxml in User DIR\Standard
Property file Work\Rebound_Stops.
Base body upper_strut:L
Action body shock_tube:L
Base Position dp_top_mount:L(Design Point)
Action Position dp_strut_lwr_mount:L(Design Point)
Name reb_ride_reboundstop
Symmetric Left

Reference

You can build bushing forces by following steps below.

⚫ Create a bushing force

1. Click the Bushing icon in the Force menu.

< Click the Bushing icon >

2. A Property file browser will open. From the Bushing folder, Select a Bushing Force

Property file (*.cfpfbxml).

3. A “Create Bushing” Dialog will open.

4. Select a Body to define Base Entity.

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5. Select a Body to define Action Entity.

6. Define position by Point Picker.

7. Define symmetric type and name.

8. Click Button. Then the Bushing force will be created.

1.6.1.7. Activating or deactivating Driveline systems

A full car model needs driveline systems to transmit powertrain torques to tires/wheels. The
driveline system is defined by default in a suspension subsystem. For an example, a front wheel
drive vehicle should have a driveline activated in the front suspension, while the driveline in the
rear suspension should be deactivated. It is beneficial to add driveline elements in the
driveline_active group in the suspension for further manipulation. If the driveline_active group is
not defined, and if the drive shaft of the suspension is not connected to the differential output of
the powertrain (non-active), all components associated with the driveline must be individually
deactivated in the suspension system before the full car model analysis. If the driveline_active
group is defined, deactivating the driveline_active group will make the driveline disabled.

< driveline_active group >

1. In Subsystem Navigator, right mouse click “driveline_active” to open a “Property

dialog window”.

< driveline_active Group >

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2. Click add button.

3. Click add button in Multi General Picker.

4. Select drive_shaft:L In Subsystem Navigator or in the working window.

5. Select drive_shaft:R, tierod:L, tierod:R, conv_drive_sft_otr:L, conv_drive_sft_otr:R,

conv_drive_sft_int_jt:L, conv_drive_sft_int_jt:R, tran_tripot_to_differential:L,

tran_tripot_to_differential:R like as drive_shaft:L by add and Subtraction

button

< Added elements related in driveline_active Group >

1.7.Creation of Suspension Subsystem

A Subsystem can be created from a Template. Let’s create a Subsystem from the Macpherson
Suspension Template.

1. Click the New File icon.

2. Select Suspension “Subsystem from Template”. Enter ‘Macpherson_Tutorial_Sub’ in

File name. Check “Add to model” to add the suspension subsystem to the current Model.

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< Select File type >

3. Click OK button. You can see the Car Template Selection dialog window. Click the

Browse button and select ‘Macpherson_Tutorial.dfcsust’ from the file browser.

< Select Macpherson_Tutorial.dfcsust >

4. The window will switch to the Subsystem working window. You can see the newly

created Subsystem file from Work Navigator.

(Design entities, property files, car force elements, and body properties can be updated in
Subsystems. The rest of entities should be updated in templates.)

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< force property >

< joint property >

1.8. Working with A Half Car Assembly

An Assembly is a basic vehicle model to run an analysis. The assembly has several subsystems
and ready for test rig connection for further analysis. In this section, you are guided to create a
half car assembly to run a suspension analysis.

1. Click the New File icon.

2. Select Car in Group, Assembly in Type, and Half Car in Assembly.

Type ‘Macpherson_Tutorial_Assy’ for the name and check “Add to model” to add the

assembly to the current Model.

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< Select File type >

3. Select ‘Macpherson_Tutorial_Sub’ in the Suspension Subsystem cell. Make sure

“_HALF_TESTRIG.dfctrt” in the “Suspension Test Rig” cell, and then click Finish button.

(Click Next instead of Finish button to set unit of system.)

(At least, a Suspension subsystem and a test rig subsystem should be included in a
Suspension assembly. To use a subsystem like a steering subsystem, check Squarebox
for Steering Subsystem.)

< New Suspension Assembly >

4. The assembly file has been created and you can see the assembly in Work Navigator.

< Work Navigator >

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1.9. Simulation of a Half car assembly

1.9.1. Suspension analysis using multiple Load cases

In this section, you will try an External File analysis to simulate multiple load cases

1. Click the Simulation Menu, then the Suspension Simulation window will appear. Enter

values as shown in figure below. To create a dflc.xml, click Export in analysis dialog.

(An External file analysis needs a dflc.xml file. A dflc.xml file contains simulation
parameters as used in Parallel wheel travel and Vertical Force analysis. You are going to
create one for next steps)

< Click Export button >

2. Enter “Parallel_Tutorial” in File name and click the Save button.

< Export *.dflc.xml file >

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3. Click the Export Files icon in the Suspension Analysis menu.

< Click the Export Files icon >

4. Enter Result name as you want. The Result name determines the head of analysis result

name.

5. In the External files tab, click button.

< Add external files >

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6. Select load case files (*.dflc.xml) in the file browser.

< Select Load Case Files >

< Export Files >

7. Click Simulate.

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1.9.2. Parallel Travel analysis

1. To run an analysis, click Simulation Tab in the Ribbon menu and then click Parallel

Travel.

< Click Parallel Travel >

2. A Suspension Simulation window will open. Type in data as below. Then click Simulation

to run a simulation.

< set the simulation parameters >

1.9.3. Vertical load analysis

1. To run an analysis, click Simulation Tab in the Ribbon menu and click Static Load.

2. Type “Macpherson_Tutorial_Assy_Verforce” in Result name. Click Simulation to run

the analysis.

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< Simulation parameters >

1.9.4. Updating the Suspension model and re-running the Vertical

load analysis
1. In Subsystem Navigator, Right Mouse Click ‘Macpherson_Tutorial_sub’. Then select

“Open This File”. It will open the ‘Macpherson_Tutorial_sub’ model.

< Opening subsystem >

2. Open Spring Property (spr_ride_spring:L) in the Macpherson_Tutorial_sub model. Click

button and pick a new property file of ‘vm_125_300.cpfsxml’ in the springs folder.

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< Spring Force >

< Selection of Spring Force Property file >

3. Right mouse click “bump_ride_bumpstop:L” in Macpherson_Tutorial_sub and pick

“Property”. The “Bumpstop Force” window will open. Enter 35 in Clearance.

< Bumpstop Force >

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4. Update design points as the table below.

Name X, Y, Z
dp_wheel_center 0, -800, 280
dp_strut_lwr_mount 40, -670, 550
dp_knuckle_spindle_in 0, -775, 280
dp_knuckle_spindle_out 0, -825, 280

< Modified suspension geometry >

5. Once you have made the updates, go back to the Assembly window. Run a Static Load

using the same parameters as 1.9.2 with and result name =’

Macpherson_Tutorial_Assy_Verforce_Parameter’.

1.10. Post-processing Half car results

1.10.1. Post-Processing Parallel Travel analysis

In this section, you are going to post-process the results from the half car simulation.

1. After the analysis, Ansys Motion post-processor will automatically open and display the

animation window.

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< Post-process >

Try animation control buttons to see how the suspension moves. Animation buttons are hidden.
They will appear as you move the cursor around the bottom of the window. See the picture below.
You can play, fast forward, play by a frame forward or backward, stop and even record the
animation.

< Animation view >

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2. Ansys Motion Post-processor has pre-defined suspension characteristics (many K & C

parameters) available to plot. You are going to plot a few of them. Click the 'Create ch

art' icon on the Tool bar

< click Create Chart icon >

< Plot window >

3. From the object navigator, select Model and select 'TestRig_Results'.

(A filter makes it easier to find a data channel from results)

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< Object Navigator >

4. Click “Add Curve” at the top. Select 'toeangle’, ‘camberangle’, and ‘sideviewangle' in

Characteristic, and select “Value” in Component. The click “+”

< < click Add Curve icon >

< Select Characteristic and Component >

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5. Click the Curve on the Plot window.

< Plot camber angle >

1.10.2. Post-Processing Vertical load analysis

1. In Ansys Motion Post-Processor, click at the left upper corner. Then Click Import

and Result. Pick “Macpherson_Tutorial_Assy_Verforce.dfr” and click Open button.

< Import Result >

< Selection of Macpherson_Tutorial_Assy_Verforce.dfr >

2. Select ‘Macpherson_Tutorial_Assy_Verforce’, type “test” in the filter to pick

‘TestRig_results’. Then select ’wheel_load_vertical_force_L’ in Characteristics and

click “+”. Now you see the vertical force on the wheel.

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< Plot wheel vertical force >

(Through Draw Curve window, you can set X-axis. Default setting of X-axis is Time. User
can change the x-axis from Property Panel so you can define x-axis other than Time.)

3. Select the curve and move the cursor around X: time in Property Panel. As the cursor

is almost at the end of the field, button will show up. Click button in the source

property to change x-axis from time to wheel travel.

< Selecting x-axis >

4. Select names sequentially to change the title of x-axis. ’TestRig_Results’,

‘wheel_travel_L’, ‘Value’, ‘Inertia’ and check button.

< Changing x-axis >

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< Plot Vertical force and wheel displacement >

1.10.3. Comparing two Parallel Travel results: Baseline and the

updated model
1. Click , Import – Result and open “Macpherson_Tutorial_Assy_Verforce_Parameter.dfr”.
2. Plot Wheel Load Vertical versus Wheel Travel.

< comparing results >

2. A Full Vehicle Analysis

In this chapter, a full vehicle model will be built using the Work/Model. You are going to use
templates from Ansys Motion and the Macpherson suspension template you have created. The

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Work/Model has templates required for full car models such as Suspension template, Body
template, Wheel templates, Steering templates and so on.
(Path : ANSYS INSTALL_PATH\Motion\Document\Standard Work)

2.1.Create Subsystems
In this section, you will create subsystems like Body, Suspension, Steering, Wheel to build a full
car assembly. Templates available to use are listed in the Template folder in Work Navigator.

2.1.1. Create A Body subsystem

1. Click the New File icon.

< Click New File icon >

2. Select Body in “Subsystem from Template” in Car group. Enter “Body_Tutorial_Sub” in

File name and click OK.

< Select File type >

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3. Select a Body Template (rigid_chassis_It.dfcbt)

< Select Body Template >

4. Body_Tutorial_Sub.dfbxml will be created as below.

< Working window >

5. Update ‘dp_front_wheel_center’ and ‘dp_rear_wheel_center’ as below

Name X, Y, Z to be Modified

dp_front_wheel_center 50, -800, 330

dp_rear_wheel_center 2880, -800, 330

< Modified Design Point >

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2.1.2. Create a Steering subsystem

1. Click the New File icon

2. Select Steering in “Subsystem from Template” in Car group. Enter

“Steering_Tutorial_Sub” in File name and click OK.

< Select File type >

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3. Select Steering Template(rack_pinion_steering.dfcstt)

< Select Steering Template >

4. Steering_Tutorial_Sub.dfstxml will be created as below.

< Working window >

1. Move the steering position by updating design points as the table below.

Name X, Y, Z
dp_rack_house_mount 250, -400, 300
dp_tierod_inner 250, -430, 300
dp_intermediate_shaft_forward 450, -300, 500
dp_intermediate_shaft_rearward 600, -300, 600
dp_pinion_pivot 250, -300, 300
dp_steering_wheel_center 950, -300, 700

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2.1.3. Create a front suspension subsystem

1. Click the New File icon

2. Select Suspension in “Subsystem from Template” in Car group. Enter

“Front_Suspension_Tutorial_Sub” in File name and click OK.

3. Select “Macpherson_Tutorial.dfcsust” in Suspension Template. Pick “Front” in Minor

role.

< Select Suspension Template >

4. Front_Suspension_Tutorial_Sub.dfsusxml will be created as below.

< Working window >

5. Setting toe_angle and camber_angle.

(Click the Toe-Camber angle Icon and then change Toe angle and Camber angle.
Alternatively, they can be updated in the design variable window)

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< Click Toe-Camber angle >

< Edit Toe-Camber Angle >

(Toe, Camber angles can be updated by design variables or by through Toe-Camber dialog.
Design variables of Toe and Camber are defined symmetrically only. Asymmetric Toe and
Camber can be defined in Toe-Camber dialog.)

< Edit Toe-Camber Angle in Design Variable>

< Modified Toe-Camber Angle >

6. Updating spring elements

(Mouse right-click ‘spr_ride_spring:L’ of force category in Work Navigator or Mouse right-

click on the spr_ride_spring:L in the working window)

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< Open Spring Force Property >

7. Click button in the spr_ride_spring property dialog and then select

“vm_125_300.cpfsxml” in Property file.

(In the same manner, you can change property in force elements such as Bush, Bumpstop,
Reboundstop, Damper.)

< Spring Force Property >

< Select a Property File >

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8. Move the suspension to front position by updating design points as the table below.

Name X, Y, Z
dp_lca_front -150, -450, 150
dp_lca_outer 50, -750, 150
dp_lca_rear 250, -450, 150
dp_tierod_outer 200, -750, 300
dp_tierod_inner 250, -400, 300
dp_wheel_center 50, -800, 300
dp_strut_lwr_mount 90, -650, 600
dp_knuckle_spindle_in 50, -775, 300
dp_knuckle_spindle_out 50, -825, 300
dp_drive_shaft_inr 50, -200, 225
dp_top_mount 107.5, -603.8, 800
dp_subframe_front -350, -450, 150
dp_subframe_rear 450, -450, 150

2.1.4. Create a rear suspension subsystem

1. Click the New File icon

2. Select Suspension in “Subsystem from template” in Car group. Enter

“Rear_Suspension_Tutorial_Sub” in File name and click OK.

3. Select “double_wishbone.dfcsust” in Template and select Rear in Minor role.

< Select Suspension Template >

4. Rear_Suspension_Tutorial_Sub.dfsusxml will be created as below.

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< Working window >

5. Right Mouse click “fix_subframe_rigid” in Subsystem Navigator. Select “Disable” to

make “fix_subframe_rigid” disabled.

< disable fix_subframe_rigid>

6. Right mouse click “spr_ride_spring:L” to open the Spring Force Property Dialog.

< Open Spring Force Property >

7. Click button in the ‘spr_ride_spring’ property dialog and then the “Select Property

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File” window will open. Select vm_125_300.cpfsxml in File name. (in User

DIR\Standard Work\Springs folder)

< Select Property File >

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8. Enter 240 in ‘Installed Length’.

< Set the Spring Property >

9. Update force property files as the table below.

Force Name force property file\ note

dam_ride_damper Dampers\vm_default.cpfdxml
Impact Setting :
bump_jounce_stop Bump_Stops\vm_default.cpfbsxml
Clearance Value : 25
bush_lca_front Bushings\vm_lwr_control_arm.dfpfbxml
bush_lca_rear Bushings\vm_lwr_control_arm.dfpfbxml
bush_lwr_strut Bushings\vm_damper_lwr_mount.dfpfbxml
bush_subframe_front Bushings\vm_subframe.dfpfbxml
bush_subframe_rear Bushings\vm_subframe.dfpfbxml
bush_top_mount Bushings\vm_damper_upr_mount.dfpfbxml
bush_uca_front Bushings\vm_upr_control_arm.dfpfbxml
bush_uca_rear Bushings\vm_upr_control_arm.dfpfbxml

10. Move the suspension aft by updating design points as the table below.

Name X, Y, Z
dp_drive_shaft_inr 2880, -200, 230
dp_lca_front 2680, -400, 150
dp_lca_outer 2880, -750, 100

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dp_lca_rear 3080, -450, 150

dp_lwr_strut_mount 2880, -600, 150
dp_subframe_front 2480, -450, 150
dp_subframe_rear 3280, -450, 150
dp_tierod_inner 3080, -400, 300
dp_tierod_outer 3030, -750, 300
dp_top_mount 2920, -500, 650
dp_uca_front 2980, -450, 530
dp_uca_outer 2920, -675, 530
dp_uca_rear 3130, -490, 530
dp_wheel_center 2880, -800, 300
Intdp_arb_pickup -50, -700, 350

2.1.5. Create Front wheel subsystems

1. Click New File icon

2. Select Wheel in “Subsystem from Template”. Enter “Front_Wheel_Tutorial_Sub” in File

Name and click OK.

(Name : Front_Wheel_Tutorial_Sub)

< Select File type >

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3. Select “handling_tire.dfcwst” in Suspension Template and select Front in Minor role.

< Select Suspension Template >

4. Front_Wheel_Tutorial_Sub.dfwxml will be created as below.

< Working window >

2.1.6. Create Rear wheel subsystems

1. Click New File icon

2. Select Wheel in “Subsystem from Template”. Enter Rear_Wheel_Tutorial_Sub in File

Name and click OK.

3. Select “handling_tire.dfcwst” in Suspension Template and select Rear in Minor role.

4. Rear_Wheel_Tutorial_Sub.dfwxml will be created as below.

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< Select Suspension Template >

2.2. A Full Car Assembly and its analysis

In this chapter, you will create a full car assembly file using the subsystems created in chapter
2.1.

1. Click New File icon

< Click New File icon >

2. Select Full Car in Assembly in Car group. Type in “Full_Car_Tutorial_Assy” in File Name

and click OK.

< Select File type >

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3. Select Subsystems as below and then click Finish button

(Click Next instead of Finish button to set unit of system.)

< Select each Subsystem >

4. Full_Car_Tutorial_Assy.dffcassy will be created as below.

< Full_Car_Tutorial_Assy >

5. To disable the driveline in the suspension subsystem, click the “Driveline Active and

Inactive” icon.

(A Driveline in suspension subsystems is bodies connecting the powertrain and wheels. If

the model does not have a powertrain system in this tutorial, you should disable the
driveline.)

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(You can update design parameters using “Modify Design Parameter. You can also change
properties of bodies and forces using “Modify Modeling Parameter”)

< Click Driveline Active and Inactive icon >

6. Check “Driveline Inactive” in Front Suspension and Rear Suspension and click OK.

< Check Driveline Inactive >

2.2.1. Step Steer analysis

1. Click Modify below Run or Click analysis ICON in the Full-Vehicle Analysis for a full car

analysis

< Click Modify icon >

2. Select Open-loop steering in the Analysis Category and select “Step Steer” in Analysis

Type.

3. Enter input values for Step Steer and click Simulation button.

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< Define input value >

2.2.2. Add Powertrain subsystem and Acceleration analysis in Full

Car
1. Click “Replace Assembly” in Full Car Model.

< Replace Assembly >

2. Check Powertrain subsystem and select ‘Powertrain_lt.dfptxml’ file created in Section

2.2.1. Click OK.

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< Re-Assembly for Full Car >

< Full car model added Powertrain >

3. To enable the driveline in the rear suspension subsystem, click the “Driveline Active and

Inactive” icon.

< Click Driveline Active and Inactive icon >

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4. Check Driveline Active in Rear Suspension and click OK.

< Driveline active of Rear Suspension>

5. Click Modify below Run or Click analysis ICON in the Full-Vehicle Simulation

< Click Modify icon >

6. Select Straight-line in the Analysis Category and select Acceleration in the Analysis

Type.

7. Enter input values for Acceleration and result name(Full_Car_Tutorial_Assy_Acc).

Click the Simulation button.

< Define input value >

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2.2.3. Parameter updates and re-run an analysis

1. Click Right Mouse at ‘Front_Suspension_Tutorial_sub’ subsystem from Subsystem

Navigator and click Open This File.

2. Update the mass after opening chassis property.

3. Enter 950 in Mass.

< opening body property >

< Modifying mass of chassis >

4. Open ‘Powertrain_lt’ in Subsystem of Subsystem Navigator and enter 150 in mass after

opening body property.

< Modifying mass of powertrain >

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5. Click the full car assembly and enter ’Full_Car_Tutorial_Assy_Acc_Parameter’ in

Result Name to run “simulate Straight Line, Acceleration”. Use the same parameters as

in Section 2.2.2.

2.3.Post process of Full car simulation results

2.3.1. Play Animation

1. An animation window in Post processor will automatically open after an analysis.

< Post processor >

2. Move the cursor around the bottom center of the window then the animation men

u will show up. Click button to play animation.

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< Animation view >

3. Play animation
(You can play a specific section of animation using From/To.)

< Animation view >

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2.3.2. Plot Step Steer Results

1. Click “Chart” and click the “Create Chart” icon to create a plot window.

< Click Create Chart icon >

2. Select *.dfr in the Database Navigator and select “User Subroutine” in entity filter. and

select “steering_results” in Object Navigator.

(The section 1.3.2. Database Navigator and 1.3.3. Object Navigator of Ansys Motion
Postprocessor Manual will help you to understand Database Navigator and Object
Navigator. You can search data channels more easily using the search filter. Type a
keyword in Search Filter, then Object Navigator lists output data with the keyword.)

Search filter

< Database Navigator and Object Navigator >

3. Go back to the top menu and click “Add Curve”. A new menu will open. Select

“Steering_wheel_angle” in Characteristics, “value” in Component, “inertia” in Coord

inate System. Then click “+” to add the curve.

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< Select Characteristic and Component >

4. The Steering Wheel Angle curve will be created.

< Plot Steering result >

5. Plot lateral velocity of chassis by selecting the following data.
’Full_Car_Tutorial_Assy’, ’Body_Tutorial_Sub/chassis_resuts’, ‘velocity_lateral’, and click the
Add (+) button.

< Plot Chassis result >

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2.3.3. Plot Acceleration Results

1. Open Full_Car_Tutorial_Assy_Acc.dfr and select Body_Tutorial /chassis_results. Select

“velocity_longitudinal” and click add (+).

< The longitudinal velocity of the chassis >

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2.3.4. Plotting two or more simulation results: Baseline and an

updated model.
1. Open Full_Car_Tutorial_Assy_Acc_Parameter.dfr. Check longitudinal velocity in

Body_Tutorial / chassis_results and click add (+) in the plot window.

< Comparison of Full Car results >

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