EDware. Squeak & Rattle Forum, Würzburg, 2012

Transcription

1 EDware Squeak & Rattle Forum, Würzburg, 2012

2 PLM Vision COLLABORATIVE PRODUCT DEVELOPMENT system design HDB, AHP, VAVE, FAST OEM & TIER - 1 component target setting surrogate system MDO component & system design prototype & testing manufacturing process cost and weight design for manf. & assy. MIDDLEWARE DFMEA - PFMEA customer response & strategies surrogate prototype testing Hybrid Surrogate Siml. DOE NASTRAN, ADAMS, DADS, Etc. NASTRAN, LSDYNA, ADAMS, ABAQUS, DOE, GENESIS, Etc. NASTRAN, LSDYNA, ADAMS, ABAQUS, OPTRIS, GENESIS, Etc. PLMWARE OEM & TIER - 1 production tooling & pilot run PDM KDM PLM - ECOSYSTEM BDM SDM Folie 2 Copyright 2012 EDAG GmbH & Co. KGaA. All rights reserved.

3 Numerical Simulation of S&R using Stick-Slip Information of Material Pair Databases Folie 3

4 Common Shop Floor Expressions of Noise KNOCK PING CLANG FLAPPING SCREECH TAP CLANK PO P CLUNK SIZZLING BUZZ GRINDING HUM SQUEAK CHIRP GROAN GRUNT CLICK ROAR RUMBLE CLACK HISS WHISTLE RATTLE WHIR WHINE BOOM SCRAPPING Folie 4

5 Metrics of Comfort a Feeling COMFORT Body Mind Vibrations Sound Sight Objective Acoustic db Sone Phon Tactile Velocity Acceleration Energy Metrics Hz Etc., Subjective Feeling Feeling Folie 5

6 S&R Technology Objective and Measurable Definitions Collaborative Product Development OEM & Tier 1 Virtual Predictive Technology Vehicle Classification Luxury and Economy Driving Conditions Autobahn and City Driving Perception Subjective Psycho Acoustics So what is the challenge? Folie 6

7 Current Virtual S&R Prediction Technology FEA Standard Tool at OEM Objective metrics can be standardized and measured Attributes Displacement, Velocity, Acceleration, Energy Permanent Set, Creep, Tolerance, etc., Acoustic Response, Assembly Variations, etc., Stick Slip, Etc., Maturity Level Normal Force Contact Rattle Tactile Friction Coeff. Of Acoustic X Restitution Normal Force Contact Squeak Tactile Transverse Force Acoustic X Friction Maturity Level Maturity Level Folie 7

8 Complexity of Squeak & Rattle Problem The Vibration response of Squeak Phenomenon History dependent frictional loading Relative motion between structures in contact Interface tribology Temperature & humidity Local stiffness Elastic-plastic instabilities Radiation Local stiffness Transmission and dynamic amplification Etc. Vibration response of the Rattle Phenomenon Transient characteristics Duration of impact Contact stiffness Coefficient of restitution Relative velocity Overall structural stiffness Resonant behavior of the surrounding structure Etc. The Noise response of the Rattle phenomenon Pressure wave in the air gap Radiation from structural surfaces due to transient vibrations Excitation of surrounding surfaces to acoustic wave(s) Transmission and dynamic amplification Etc. Folie 8

9 Index and Ranking Squeak & Rattle Controlling Factors Induced structural vibrations Load dependent Design gap variation Manf. & Assy variation Environmental Temperature & Humidity Pre Load Installed and designed conditions Creep Aging due to fastener relaxation Material Variation in natural material Why Ranking Index.. Definition of annoying sound? Subjective threshold for noise comfort? Noise bandwidth optimization based on class of vehicles? Allowable cost for noise control? Need for a relative index for a problem Normalized Index Basis for Ranking.. Frequency & time domain Absolute and relative interference (Design Gap) Frequency content Energy content Impact velocity Material properties (Hardness, Stick & Slip) Objective Index Develop historical database Specific customer design practices, Choice of materials & loads Corporate metrics for S&R Develop objective Index Hybrid Index Folie 9

10 Simplified Mathematical Solution S&R u Modal Superposition N T n 0 n ( t) = t Φ 2 n= 1 Ωn F Φ ω ω cos 2 M t+ t t+ t ( k ) U U ( k ) Implicit Integration = t + K U t+ t U ( k 1) ( k ) = t+ t + U R ( k ) t+ t F ( k 1) Structure Response - kinetic Energy, impact velocity - max. interference - number critical frequencies Material Effects - Stick Slip Character - Coefficient of Restitution - Hardness, Etc., Ranking f + B + c C ( k ) ( k ) ( k ) ( a A b...) = I SAR Folie 10

11 SQUEAK & RATTLE Prediction Software EDware.SAR U.S./International Patent #10/016,813 Structural Noise Source Predictor Folie 11

12 Basic Condition - Squeak & Rattle Part II w Q Rattle v u Squeak GAP P Part I Effective Design GAP = Design gap +/- Installed deformation +/- Environmental deformation (Thermal) +/- GD & T and assembly stack up Dynamic GAP = Relative Dynamic deformation between P &Q if (Dynamic GAP > Effective Design Gap) ---- S&R Folie 12

13 EDware S&R Tool Simulation Complexity Design Position in CAD G = Initial Design GAP in CAD Rattle location & direction A Point Pair from 3DCS Simulation in FEA Mid Surface Solid (Neg.) Initial Gap = Design Fit or Preload Condition B Correction for FEA Mid Surface representation Shell Effective Dynamic GAP from Simulation G = 3.6 (Design Gap) 3DCS Assembly Simulation G = Initial Design GAP in CAD Max DT = Area Under Intersecting Points Over Frequency Range of Interest C Six Sigma Variation from 3DCS Ranking : Effective Minimum Dynamic Distance Between Point Pairs = f { [A][B][C] } Folie 13

14 S&R Technology Input Output Geometry PLMXML IGES STL Static distance, part pairs and locations Typical FE Models Fasteners MSC/Nastran NX/Nastran Abaqus (Durability, NVH or Safety) Pre load in assemblies Installation forces clips & snaps Bolt torques Fastener DB Eigen Values & Mode Shapes Dynamic distance, part pairs & locations Forced Response Results Population density of S&R points Critical ranking based on S&R index Typical FE Solutions MSC/Nastran NX/Nastran Abaqus STD Presentation ready graphic results file High Fidelity Objective & Subjective Index Material Matrix Ziegler Ziegler Material Data Module Squeak Data Base Synthetic Tactile and Acoustic Signatures Effective Sound at Drivers & Passenger Under Development Folie 14

15 Process Flow Material Pair Data Base USER Loads Output Set for Response Analysis Original Model, Loads & BC s Create FE Solver Modal Analysis FE Solver Forced Response Analysis Thermal Sub-assemblies Modal Results Forced Response Results EDware.SAR Installed Sub Assembly Report EDware Mapping Module Squeak & Rattle Data Base Vehicle level Report Folie 15

16 Future. Synthesizing Sound 0.3 Dipole + Plate Noise Radiation Max SPL = db Sound Pressure Pa Dipole + Plate Noise Radiation Max SPL = db Time (s) Sound Pressure Pa Plate Noise Radiation Max SPL = db Time (s) Sound Pressure Pa Time (s) Folie 16

17 Vielen Dank! Folie 17