2011 Audi A6 Style

Most new models arrive with a fanfare of new technologies, safety features, and creature comforts, with the small matter of their increased weight usually uttered as a hushed apology. However, Audi’s revamped A6 has a party piece – it is up to 80kg lighter than its predecessor, with the 3-liter TDI quattro model emitting 30% fewer emissions than the outgoing model. This weight loss is down to a diet of high-strength and ultra-high-strength sheet metal and aluminum components, with much of the body composed of aluminum, and the engine and driveline slimmed down. With a lighter body, items such as the axles and brakes could also be slimmed down as their load demands were consequently reduced. Safety features could also be optimized for the lighter weight, but the safety test program was as heavyweight as ever. The requirements of the A6 were decided using fi ndings from the Audi Accident Research Unit, which studies real-life accidents involving Audis, and analyzes accident databases. More than 4,000 crash simulations were carried out on virtual prototypes, and robustness analyses were calculated using stochastic simulation methods. To ensure that the new, lighter components were crashworthy, an extended series of simulation and validation subcomponents tests was undertaken. Another feature Audi is keen to promote is the latest allwheel- drive technology that features in the A6, with a crown gear center differential and a torque-vectoring function. The range-topping 3-liter V6 models, in both gasoline and diesel guises, feature the higherspec Quattro sport differential, as used in the S4. One of the men charged with ensuring the chassis was light yet able to cope with not just 3-liter powertrains, but also future S and RS variants, was Jörg Starr, project manager for chassis development at Audi. “For the new A6 we used Audi’s longitudinal testing system,” states Starr. “All cars with longitudinally mounted engines are tested in the same way. The A5 was the last product we tested using the longitudinal system and we learned a lot from that.” The A6 test program was an advance in every way over previous programs, but only by a small increment. For example, the A6 program saw increased use of virtual development. However, for Starr and his team, this just enabled them to start physical tests at a more advanced level – there is no substitute for hands-on testing. “We use computer programs at the beginning, and fi nish by hand. Especially with chassis testing, you can’t do that by computer, you have to feel it. “Our test programs don’t get shorter, we just do more fi ne tuning,” he explains. The physical testing was aided by clever use of test mules. Using special welding techniques, the team was able to mount a previous-shape A6 body to the new chassis in such a way that it exactly replicated the feel and stiffness of the new body. The result of all this development? “This is the most advanced Audi you can buy today,” says Starr.


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