Durability and NVH Analysis

1999 Japanese ADAMS User Conference 1

Durability
and
NVH Analysis
Michael Hoffmann
Senior Vice President
Worldwide Sales & Service
Durability and NVH Analysis
I Durability Testing in the Automotive Industry
I Multibody Simulation within the Durability Design Process
I Critical Modeling Elements for Durability and NVH
Analysis
I Application Examples of NVH Analyses
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 2
Test Lab Test Lab Test Track Test Track
Real World Real World
Usage Usage
Durablity Testing in Automotive
Replicating Durability Testing in the Virtual World
Environment Spindle Loads Component Loads Fatigue Life
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1999 Japanese ADAMS User Conference 3
Multibody Simulations within the Durability Design Process
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Case A:
I Measure spindle loads by field tests
I Use the measured spindle loads to drive a virtual fatigue test rig
I The virtual fatigue test rig delivers component loads which can be used
N for component durability testing, or
N for component durability analysis
Multibody Simulations within the Durability Design Process
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Case B
I Perform the field test virtually using virtual motorcycle, driver, and road
I Use the measured loads to drive durability tests
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 4
Multibody Simulations within the Durability Design Process
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Case C
I Perform the field test virtually using virtual motorcycle, virtual driver,
and virtual road
I Use the component loads
N for component durability testing, or
N for component durability analysis
Improve Process through Correlation with Test Results
Satisfied
No
Yes
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 5
Virtual Test Lab
I Dynamic Models of MTS Systems
N Mechanical, Hydraulic, and Control Systems
I Test Engineers & Analysts can evaluate a large number of
conceptual design permutations
I Designed to help analysts validate models
N Request better tests & minimize incorrect tests
N Virtual validation must emulate physical validation
I Eliminate Repeat Testing for additional Info
Application Example
I Rough road simulated on a virtual 4-post test rig
N actuator displacement as test input
I Characteristics of the vehicle model
N flexible frame
N standard bushing and damper formulation
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 6
Estimated damage
Application Example: Vertical Wheel Forces
Frequency
Time
PSD
Force
Actual damage
= 1.5
Application Example: Body Mount Vertical Force
Estimated damage
Frequency
Time
PSD
Force
Actual damage
= 0.5
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 7
Refining the virtual prototype
I Critical elements for improving the correlation for durability
and NVH analysis
N Flexibility
N Bushings
N Dampers
N Tires
Hydromount modeling by Paulstra
Ref.: 1998 European ADAMS User Conference, E. Vandervorst
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 8
Damper Modeling by Monroe
Ref.: 1998 European ADAMS User Conference, S. Duym
Tire Modeling by Continental / Cosin
-2000
0
2000
2000
4000
2000
4000
-2000
0
2000
Obstacle crossing
40 km/h
120 km/h
Vertical Tire Load Longitudinal Tire Load
Ref: 1999 International ADAMS User Conference, M. Gipser
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 9
MTS
Equations Equations
Empirical Dynamic Model from MTS
I Physical Testing Generates Data for Model Creation
N Black Box, Characteristic, and Concept Model
Ref.: 1999 Japanese ADAMS User Conference, A. Barber
EDM: How Does it Work?
I Neural Networks
I Frequency Response
Functions
I Polynomial Curve Fits
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 10
EDM: How Well Does It Work?
I Bi-axial Elastomer Load versus Stroke
N BlackBox Generated Model Prediction
N Predicts Amplitude Dependence and Hysteresis
Hysteresis is a Frequency Dependent Effect
Physical Test Model Prediction
Examples of Vibration Analyses
I Engine Mount Design
I Rear Suspension
I Full Vehicle Obstacle Passing
I Brake Noise
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 11
Vibration Analysis by Paulstra
Ref: 1998 European ADAMS User Conference, E. Vandervorst
Longitudinal Accelerations
Vertical Accelerations
0 20 40 60 80 100
f [Hz]
Vibration Analysis of a Rear Suspension
I Crawl - walk - run approach
N Build-up the complete system step-
by-step
N Validated each step by tests to
gain confidence in modeling
approach (and measuring
technique)
N Used the experience gained to
make design recommendations
Durability and NVH Analysis
1999 Japanese ADAMS User Conference 12
Obstacle Passing Maneuver
I Full vehicle model with
N Flexible bodies
N Frequency dependent
bushings and engine
mounts
N Comfort tire
CASE FILE: Bosch Automotive
Eliminating disc brake moan through simulation
Ref: 1997 International ADAMS User Conference, W. Stringham
ADAMS Simulation Run#2, Outer Pad Tangential
-2,0
-1,5
-1,0
-0,5
0,0
0,5
1,0
1,5
2,0
2,5
0 0,1 0,2 0,3 0,4 0,5
Time (seconds)
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Durability and NVH Analysis
1999 Japanese ADAMS User Conference 13
ADAMS as Integration Platform
ADAMS/Car
Database
Packaging
Handling
Durability
Ride / NVH
Controls