"Maximizing the relationship between these two forces results in faster lap times. It also defines the purpose of racing. Dynamic Designer lets us take advantage of the CAD models by assembling endless configurations of suspension components and graphically comparing the kinematics and dynamic response. If we cannot visualize the graphical information, all we need to do is animate the suspension motion. Not only can we interchange suspension components quickly, but we can also change suspension spring rates and shock absorber characteristics in order to optimize and understand wheel motion due to bumps and corner entry/exit maneuvers. Once we are satisfied with vehicle performance, we can export forces directly to FEA software and determine whether component strengths are adequate."

What is the benefit of Dynamic Designer's single-window integration within SolidWorks software?
"Speed defines racing. When performing numerous iterations for suspension development, the time required to export a CAD file, import the file, run the simulation, make geometry changes, and repeat the process adds up quickly. With single-window integration of Dynamic Designer within SolidWorks software, we do not spend time exporting or importing files. There are no file format issues. We can simulate a suspension configuration, determine what changes need to occur within the component geometry or shape, make those changes, and rerun the simulation without leaving the SolidWorks environment. In addition, Dynamic Designer is easy to use since the menu pull downs and toolbars follow the SolidWorks format. This was appealing to our engineering staff, because we wanted to spend our time trying to understand the racecar, not the software."

Provide an example of the type and frequency of analysis provided, and how it impacts your design process.
"We test the cars repetitively on various racetracks to discover which factors increase and decrease performance. For example, the crew chief might compare two sets of spindles during a track test. The image shown here depicts the right front suspension of a typical car. The two spindles are modeled in SolidWorks, and assembled into the current front suspension configuration. Since we collect shock absorber displacement data at every track test, we know the motion of the wheel relative to the track. By exporting this data and using it to create a 'drive file' for the motion of the suspension, we can simulate the exact motion of every wheel for a complete lap.

"What we do not know is the wheel and tire's orientation to the track surface. When simulating the lap, Dynamic Designer creates plots of this orientation, as well as other aspects dependant upon spindle geometry. By comparing the orientation of the wheel due to each spindle, we begin to understand why one spindle is more advantageous to use. Validation of the suspension kinematics would occur using a kinematics and compliance rig, as shown in the attached photograph. This machine measures the six degrees of wheel motion and six degrees of force at the tire patch. Comparing the test measurements with Dynamic Designer simulations, we also begin to understand how much the chassis flexes during application of loads, since the difference between test results and simulation depends upon chassis flex."

Quantify the benefits of using Dynamic Designer in terms of: time saved in the design process, cost reduction, elimination of design errors, speeding time-to-market.
"Previously, a new upper control arm or spindle design process consisted of building the component, based on what we 'speculated' would work. Usually, two iterations were required before a part could be produced without interferences with other components. Since no analysis was performed, many design iterations were made in order to find improved performance. With Dynamic Designer, the new component is assembled to the existing chassis. Clearances are checked through the entire range of wheel travel. In addition, after running the simulation, we can make increasingly accurate predictions concerning performance. At this point we have spent nearly a whole day producing and analyzing the simulations. With the old process, we would have spent two days making the component, and another day testing at the track. If the simulations produce information that guarantees inferior performance, improvements can be made to the part before track testing. Simulation using Dynamic Designer highlights improvement possibilities before we send a part to manufacturing or track testing, saving money, time, and already-limited track time.