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Gear whine can be reduced through a combination of gear parameter selection and manufacturing process design directed at reducing the effective transmission error. The process of gear selection and profile modification design is greatly facilitated through the use of simulation tools to evaluate the details of the tooth contact analysis through the roll angle, including the effect of gear tooth, gear blank and shaft deflections under load. The simulation of transmission error for a range of gear designs under consideration was shown to provide a 3-5 dB range in transmission error. Use of these tools enables the designer to achieve these lower noise limits. An equally important concern is the dynamic mesh stiffness and transmissibility of force from the mesh to the bearings. Design parameters which affect these issues will determine the sensitivity of a transmission to a given level of transmission error.

In the NVH design optimization of automotive structures, the spectral properties of dynamic forces transmitted from rotating machinery to its housing is of primary interest. This paper describes the application of an indirect dynamic force estimation technique, more commonly known as transfer path analysis, to an operational transfer case. Through the implementation of an inverse transfer matrix technique, dynamic forces transmitted to a transfer case housing are estimated at a discrete number of locations. This paper describes the experimental and analytical methodology employed for dynamic force estimation as well as statistical techniques for solution optimization. Good correlation is shown to exist between frequencies of known physical phenomena and estimated dynamic forces for a total of nine (9) operational variations of transfer case speed and torque.

The purpose of this paper is to explain a methodology for diagnosing noise and vibration of internal components of the automatic transaxle and particularly for park disengagement clunk. The method for determining contributing lash is three-fold. First the lash values are physically measured. Secondly, in-vehicle test data is taken using accelerometers, microphones, and stress gages. The data is taken at a baseline condition and then when various lash interfaces are set at zero. Thirdly, component impact testing can be done to identify noise contributing parts. For the condition of park disengagement clunk this method helps to diagnose the source of the noise. When a vehicle is parked on an incline and the transaxle put in park, there is an energy transfer of the weight of the vehicle through the transmission and onto the suspension of the vehicle. When the transmission is pulled out of park, the released energy results in a loud clunk. The clunk has a high and low frequency content.

This paper discusses how the multi-body dynamics approach combined with flexible body effects is being applied to predict the bearing loads, the vibrations of crankshaft, the orbit plots of individual journal, and the performance of bearing (such as minimum film thickness and maximum film pressure) due to structural flexibility. The oil film effects in the journal bearing are implemented using both impedance method and hydrodynamic fluid film with finite element method. An application example of a V6 engine was given in this paper to show this sophisticated simulation model and to predict the dynamic response of the flexible system and loads in the journal bearings.

The effect of suspension system parameters on NVH performance is presented using the results of a design of experiments analysis of a quarter-car model with elastomeric elements. The elastomeric elements are modeled using Maxwell elements with stiffness increasing with frequency. Fourteen design parameters are considered. The force spectrum acting on the sprung mass is partitioned into frequency bands. The amplitude in each frequency band as well as location and amplitudes of resonance peaks in the force spectrum are used as response variables. Major factors that effect each response variable are quantified using sensitivity coefficients. Constrained optimization studies were run to identify the minimum and maximum responses that can be expected. Suspension and bushing designers can use this work to estimate the behavior of design alternatives early in the design process.

A combined finite element method (FEM), multibody system simulation (MSS), and hydrodynamic (HD) bearing simulation technique can be applied to solve for engine crankshaft and cylinder block dynamics. The cylinder block and crankshaft are implemented in the MSS program as flexible FEM structures. The main bearing oil film reaction is described in the MSS program by a pre-calculated reaction force database. The results are displacements and deformations of the crank train parts and the main bearing reaction forces. Verification of the tool was carried out by comparison of main bearing cap accelerations to measured data.

A new approach of estimating the modal parameters of operating piston engines is presented. The developed approach represents a combination of concepts from currently existing analyses such as the natural excitation technique (NExT), conditioned input analysis (CIA), and conditioned source analysis (CSA), and is hence termed “conditioned NExT analysis (CNA)”. NExT analysis can be employed to estimate modal parameters of structures in their naturally excited states. However, the existence of strong combustion induced periodic forcing makes the application of NExT analysis to operating engines difficult, if not impossible. CIA and CSA, built on concepts of partial and virtual coherence respectively, can effectively condition operating engine vibration data so as to remove any periodic energy associated with the process of combustion.

Power train noise reaches the interior through structureborne paths and through airborne transmission of engine casing noise. To determine transfer functions from vibration to interior noise a shaker was attached at the engine attachment points, with the engine removed. A simple engine noise simulator, with loudspeaker cones on its faces, was placed in the engine compartment to measure airborne transfer functions to interior noise. Empirical noise estimates, based on the incoherent sum of contributions for individual source terms times the appropriate transfer function, compared remarkably well with measured levels obtained from dynomometer tests. Airborne transmission dominates above 1.5kHz. At lower frequencies engine casing radiation and vibration contributions are comparable.

Modal Analysis is a well established technique which defines the inherent dynamic properties of the structure. At the same time the experimental harmonic analysis by shaker method is also a very important tool in solving some of the engine induced vibration problems in the automotive structure. Computer simulation technique using finite element methodology has been very effective tool in simulating the problem. However the right combination of these techniques has been a tricky situation. The paper describes the methodology of using right combination of these techniques to reduce the motorcycle chassis vibration which are induced by engine and drive-line excitation in minimum time. The method involves the Finite Element Modelling with shell elements, experimental harmonic analysis with frequency sweep upto 600 Hz, validation of the FE model, animation techniques and find out correct modification to fine tune the structure to eliminate the engine induced vibrations in the frame.

Finite element analysis is a computerized method widely used in industry to model and solve engineering problems relating to complex systems. Perhaps the most common use of finite element analysis is in the field of solid mechanics where it is used to analyze structural problems. To achieve the correct results the component and all mating interfaces must be modeled properly. Previously this was done by performing the analysis, manufacturing a prototype based on this design, and then physically determine the natural frequencies of the prototype attached to the interface structure. Once the actual natural frequencies are determined, the boundary conditions and other modifications of the finite element model are adjusted using a trial and error method until an acceptable correlation with the measured frequencies is achieved.

Several vibration-isolating equipments with metal spring, air spring, rubber spring, a shock absorber and a viscoelastic damper are developed by aiming at the optimum adjustments. The purpose of this paper is to study the new spring-mass system using non-linearity of magneto-spring and instability of float control. The dynamic spring constant and the damping coefficient of magneto-spring are dependent of a motion of amplitude. They are a much better characteristic for the suspension system compared with the current mechanical pairs composed of metal or air spring and a shock absorber. The vibration-isolating structure that combines the non-linear magneto-spring and the linear metal spring has the same effectiveness as a dynamic vibration reducer. For that reason, the suspension system using magneto-spring can reduce the vibration energy with a small stroke.

Brake judder is a forced vibration occurring in different types of vehicles. The frequency of the vibration can be as high as 500 Hz, but usually remains below 100 Hz and often as low as 10-20 Hz. The driver experiences judder as vibrations in the steering wheel, brake pedal and floor. For high frequency brake judder, the structural vibrations are accompanied by a sound. In the present paper the vibration amplitude (in terms of angular deflection, velocity or acceleration) of the caliper has been used as a quantitative measure of the vibration level. Brake Torque Variation (BTV) is the primary excitation for the vibrations. The mechanical effects generating BTV are linked not only to manufacturing tolerances but also to tribological issues. Uneven disc wear as well as Thermo-Elastic Instabilities (TEI) can lead to judder. Especially the effect of the wheel suspension on the transfer of the vibrations to the driver has to be considered.

Stability and structural integrity are extremely important in the design of a vehicle. Structural foams, when used to fill body cavities and joints, can greatly improve the stiffness of the vehicle, and provide additional acoustical and structural benefits. This study involves modal testing and finite element analysis on a sports utility vehicle to understand the effect of structural foam on modal behavior. The modal analysis studies are performed on this vehicle to investigate the dynamic characteristics, joint stiffness and overall body behavior. A design of experiments (DOE) study was performed to understand how the foam's density and placement in the body influences vehicle stiffness. Prior to the design of experiments, a design sensitivity analysis (DSA) was done to identify the sensitive joints in the body structure and to minimize the number of design variables in the DOE study.

This paper will suggest, through the results of the APAMAT Insertion Loss test, the cost and performance benefits of constructing a body component part from laminated damped steel. For the purposes of demonstrating this point, the sample used in the test setup was viewed to be the body component part of interest. The variations of acoustical materials tested were then comparable on a benefit per cost/weight basis. Under the definition for the APAMAT Insertion Loss test, the sample used in this study simulates the excitation a sheet metal part undergoes in the vehicle body and measures the efficiency of the materials to reduce noise. By Integrating vibration damping into the part structure with laminated damped steel, these results will demonstrate potentials in overall vehicle savings in a “take away” of weight, material and manufacturing costs.

Traditionally, vibration analysis in operating conditions (on the road or on a bench) had to be combined with experimental modal analysis in controlled laboratory conditions in order to understand the modal behaviour of the structure. This requires additional measurements, costs and time. However, in many applications, the real operating conditions may differ significantly from those applied during the modal test and hence the vibration modes from the modal test might not be representative for the active modes in operation conditions. The need for a capability of doing a modal analysis on data from operating conditions is obvious. Over the last years, several modal parameter estimation techniques have been proposed and studied for modal parameter extraction from output-only data. Each method needs to make a number of assumptions and has some limitations.

Passenger car customer expects both: low interior noise level and a sound quality, adapted to vehicle driving condition. The latter should be based upon a comfortable sound character without outstanding noise effects. One of the very unpleasant noise characteristics is roughness, also called rap noise or rumbling noise. Beside intake noise and powertrain structure bending, the dynamic crank train behaviour is one of the potential origins of a rough noise pattern. Material properties of the crankshaft and the layout of crankshaft damper can influence roughness as well as the crank train clearances. Subjects of this study, which was performed on a 4-cylinder spark-ignition (SI) engine, were the identification and objectivation of a specific noise concern which occurred during vehicle acceleration. Aim was to evaluate the noise concern sensitivity to the crank train clearances and to define optimum clearance ranges for noise quality improvement.

Distinguishing physical modes from mathematical modes in the modal analysis of complex systems, such as full vehicle structures, is a difficult and time-consuming process. The major tools frequently used are stabilization diagrams, mode indicator functions, or modal participation factors. When closely spaced modes are to be identified, the stabilization diagrams and mode indicator functions are no longer effective. Even the reciprocities of mode shapes and modal participation factors cannot be well satisfied to indicate whether a mode is a physical one, when measurement errors are large. To overcome these difficulties, an optimization procedure is developed, whereby physical modes can be sorted out in a given frequency range while the error between measured and synthesized frequency responses is minimized. An optimal subset selection algorithm is used in this procedure.

A series of system level experiments were conducted using 2 vehicles of identical design to measure, analyze and quantify crank rumble noise from the viewpoint of source strength and path dynamic response. One of the vehicles was known to produce relatively severe crank rumble response (noisy), while the second vehicle was almost free of the annoying response (quiet). Two specific operating conditions most susceptible to crank rumble noise were of interest: (1) no load snaps in neutral and (2) hard acceleration in second gear. For each condition, the vibration and sound pressure responses throughout the vehicle were obtained. The measured data was analyzed critically to determine frequency content and strength of rumble noise at each location. Calculations were also performed from the measured data to determine the modes of transmission and the relative contributions from air-borne and structure-borne paths.

In this paper, we discuss methods used to investigate a clearly audible gear whine problem in a modern automobile. Currently available PC-based computer software, coupled with more traditional engineering tools, such as spectrum analyzers, are employed to efficiently observe noise and vibration phenomena. Jury evaluations are conducted, using in-vehicle noise data, to rank actual gear whine levels. Additional jury studies using synthesized gear whine help us further understand listener preferences. Unloaded gear transmission error testing is explored as a means of predicting gear whine levels under light loads, such as those seen during highway cruising. We finally correlate many results to better understand the source and paths of the gear noise, and make recommendations for further exploration of this type of problem.

Torsional and lateral bending vibrations of cylinder block have a large effect on engine noise. Cylinder block vibration not only causes noise to radiate from the cylinder block itself but it is also the major exciting force to the oil pan and timing belt cover. In order to reduce engine noise, it is important to completely understand the mechanism of cylinder block vibrations. An analysis is conducted using FEM and BEM to compute the influence of crankshaft torsional vibrations on cylinder block vibrations. A crankshaft system for a four cylinder automobile engine was used for analysis. Finite Element model of crankshaft is created using parametric modelling software developed based on ANSYS FEA software. Finite Element model of cylinder block, bearing cap, oil sump is also created using another parametric software developed based on ANSYS FEA software.