Passenger car steering pull and drift reduction considering suspension tolerances

Pull to side, Steering wheel misalignment and Drift leeward are handling anomalies affecting passenger cars travelling on straight paths. They represent a cost factor in the automotive industry, occurring in small but not negligible percentage of the overall car production. The present contribution is aimed at understanding which are their causes in terms of suspension tolerances, and at reducing their extent, in the specific case of vehicles with front Double wishbone suspension and rear Five arms suspension. The most influential parameters on handling irregularities have been identified through a design of experiment analysis. Then, after performing a sensitivity analysis by multibody virtual modelling, a correlation with experimental data from presetting and wheel aligner benches has provided sufficient information for setting tolerance thresholds, able to keep the handling anomalies under study within acceptable bounds. Pull to side and Steering wheel misalignment have been found to be mainly related to the set up phase of wheel angles (front camber angles influencing Pull to side, front and rear toe angles influencing Steering wheel misalignment), while the main cause of Drift leeward has been identified with (rear) ride steer.