3D Simulation Acoustics and Vibration Powertrain. KO... · 3D Simulation Acoustics and Vibration – Powertrain Seoul, Thursday April 2nd, 2015 . 2015-XX-XX ... Fuel injection Transmission

Restricted © Siemens AG 2015 Realize innovation.

3D Simulation Acoustics and

Vibration – Powertrain Seoul, Thursday April 2nd, 2015

2015-XX-XX

Restricted © Siemens AG 2015

Page 2 Siemens PLM Software

3D Simulation – What’s New on Acoustics and Vibration

Agenda

Introduction

Standard Solutions

Customization and Automation

1

3

4

Advanced Engineering Solutions 2

2015-XX-XX



Powertrain Noise

Fuel injection

Transmission

Turbo-charger

Air intake Exhaust Engine cooling

Alternator

Engine mechanical / combustion noise Fuel / Oil / water pump

Electric motor

2015-XX-XX



3D Simulation

Solutions at different levels

Standard Product Offering,

customization and related

deployment services

Engine radiation, Intake noise

Exhaust noise, Interior

Acoustics

Structural Engineers

Working on powertrain

programs

Standard Product Offering

Technology transfer for

specialized applications

Electric Motors, Injector Systems,

Engine cooling, Turbo-charger,…

NVH Engineers

Working on powertrain programs

Advanced Engineering

Projects with Subsequent

Product Offering

Example: Composites and

NVH, Lightweight gears

Focus on Advanced

Engineering, research

Long term horizon

2 1 3

2015-XX-XX




Agenda

Introduction

Standard Solutions


1

3

4


2015-XX-XX



Advanced Engineering Projects: gear noise

Why gears are important?

They are used in pretty much every machine

They can cause vibrations, noise and can fail in operating conditions

2015-XX-XX



Gear modeling:

Applications

Gear Joint Semi-empirical Advanced FEA 3D contact

Low High Model complexity/fidelity

Kinematics System Level Operational conditions/High fidelity

Stress Gear pair

System Level Nominal conditions

Transmission

Gear pair

Transmission ratio, Power flow analysis, Efficiency, Shiftability

Durability, Root stress

Gear whine

Gear rattle, clunk noise

2015-XX-XX



Contact modeling

Contact modeling =

1. Detecting contact + computing amount of required deflection

+

2. Translate deflections into contact loads

2015-XX-XX



Detecting contact + computing amount of required

deflection

+ Efficient

- Only for gears, not for arbitrary shapes

(also feasible for bearings, cams, …)

‘Classical’ Unloaded Tooth Contact Analysis

Non-linear FE

Exploiting intrinsic geometric properties of gears

- ‘Brute force’ slow

+ Any geometry

2015-XX-XX



Gear modeling

Aspects of contact detection and its relevance

What? In-plane relative

translations

Axial relative

translation

Profile

modifications

Profile errors

Mesh phasing Rotational

misalignment

Flank line

modifications /

errors

Full topological

modifications /

errors

What is it

relevant for?

Backlash as

function of load

Frequency

sidebands due to

eccentricity

Gear rattle

(helical gears)

Gear whine

Frequency

sidebands due

to errors

‘Ghost’ noise

Planetary

transmissions

Twin

countershafts

Collector gear

System-level

dynamics

Gear whine

Tooth loading

Durability

Gear whine

Tooth loading

durability

RTD solver currently in

development

Standard

product

2015-XX-XX



Profile and indexing errors = deviation from involute due to manufacturing errors

Frequency

Gear

co

nta

ct

forc

e (

dB

)

Without indexing errors

With indexing errors sidebands appear

2015-XX-XX



Manufacturing and assembly errors:

Gear eccentricity

Gear eccentricity and run-out, microg-eometry errors, tooth spacing errors, …

give rise to frequency sidebands

E.g. Planetary transmission stage of automatic transmission

Sun eccentricity error

sidebands at multiples of ωsun – ωplanet carrier

Ring eccentricity error

sidebands at multiples of ωplanet carrier

Frequency

x

y

Rin

g-p

lan

et ge

ar

con

tact fo

rce [d

B]

GMF

2015-XX-XX



Contact modeling

Contact modeling =

1. Detecting contact + computing amount of required deflection

+

2. Translate deflections into contact loads

2015-XX-XX



Contact compliance modeling:

exploiting intrinsic physical properties

Away from contact Near contact

Geometry complex simple

Deformation gradients gentle strong

FE preprocessing analytical solution

= +

2015-XX-XX



Gear mesher/tooth stiffness calculation

Gear manufacturing plan

or Gear geometry

Gear FE mesh 2

Gear blank geometry

1

3

Gear blank compatible

mesh

4

Load cases and

boundary conditions*

5

NX NASTRAN SOL 101

6

Post-processing (xls)

7 LMS Virtual.Lab

Motion

8

4

2015-XX-XX



What can we capture:

Unique capability to predict NVH of lightweight gears

Frequency

Ge

ar

co

nta

ct

forc

e (

dB

)

L

S

Novel approach

Captures

frequency sidebands

Best possible

using

conventional

methods

2015-XX-XX



Dedicated Siemens PLM – Unical – KU Leuven gear test rig

Key features

• Gear sizing, loads and speeds correspond to

automotive applications

• Heavily instrumented

• Controllable misalignment and center distance

• Family of high-precision gears with various

microgeometry modifications

Angular

Parallel

2015-XX-XX



Correlation simulation –test rig (solid-disk spur

unmodified gears)

2015-XX-XX



Gear test rig and validation:

next steps

Helical gears Lightweight gears Offset web

Lightweight gears Holes without

integer multiplicity

Lightweight gears Holes with

integer multiplicity

2015-XX-XX



Transmission builder GUI

2015-XX-XX



Transmission builder GUI NX/Virtual.Lab

Virtual.Lab Motion NX CAE

Scripting / parametric CAD templates

2015-XX-XX



Gear Noise Simulation

Non-linear FE Conventional

MB technology

New VLMotion

Solution

Pre-processing computation N/A N/A 1 hr / flex gear

Solving days minutes minutes

Captures effect of holes in web?

System-level simulation?

2015-XX-XX




Agenda

Introduction

Standard Solutions


1

3

4


2015-XX-XX



Prime needs

Max Boost!

THE primary reason for

the existence of the

turbocharger = boost

engine torque

Industry solutions:

• Variable turbine vane

geometry to optimize

compressor working point

of the turbo

• Tuning of inlet runners

after the compressor to

increase cylinder fill rates

Structure Borne

Whine

Housing and connected

ducts vibrate and

radiate sound

Industry solutions:

• Shaft Balancing and use

of floating bearings

• Modifications (stiffening)

of turbocharger housing

and of intake and

exhaust ducts

Air Borne

Pulsation Noise

The duct walls

between turbo and

intercooler are excited

by resonances

Industry solutions:

Resonators in the duct

between compressor and

intercooler take away

energy from the main

duct duct walls less

excited lowered

vibration and noise

Aero-Acoustic

Noise

Blow and Surge Noise (clearance) Hissing Noise (Wastegate) Buzz saw (supersonic blade tip speed)

Industry solutions:

Increase quality of

Manufacturing process to

reduce clearances and

avoid reversed flow

(surge)

Low Noise Emission During Operation

2015-XX-XX



LMS 3D Solutions

Structure Borne

Whine

Bearing loads are applied

to Virtual.Lab NVH for

vibration prediction.LMS

Virtual.Lab FEM

Acoustics with AML for

fast computation of

Acoustic Radiation

Air Borne

Pulsation Noise

LMS Virtual.Lab

(Coupled) FEM Vibro-

Acoustics to compute

Acoustic Power

Attenuation of

resonators (and radiated

acoustics from a

vibrating duct)

Fast Assessment

of Structural

Modifications

LMS Virtual.Lab NVH

Modification Prediction

enables making

elementary structural

changes

LMS Virtual.Lab 11

Acoustics’ Vibro-

Acoustic Structural

Solver allows assessing

effect of more in depth

design or material changes

Correlation

LMS Virtual.Lab

Correlation and

Updating enables to

increase the accuracy of

the structural FE Models

used for turbo-housing and

connected (rubber) hoses

2015-XX-XX



Noise attenuation of a turbocharger muffler system

2015-XX-XX



Powertrain Noise

Fuel injection

Transmission

Turbo-charger

Air intake Exhaust Engine cooling

Alternator

Engine mechanical / combustion noise Fuel / Oil / water pump

Electric motor

2015-XX-XX



Prime needs

Optimal Combustion

THE primary reason for the

existence of highly

responsive and accurate

injection systems = to

ensure good combustion

and optimal power output

Industry solutions:

• Piezo-stack injector

increases

responsiveness

• Common Fuel Rail kept

at 1500 bar and higher

for responsiveness and

good atomization of the

fuel

Low Force Excitation

of Injector House and

Cylinder Head

Contact of valves and

injector Needle when

slapping

against

injector

housing

Industry solutions:

• Design of Injector

Components

• Signal Design of

Injection Pulse(s):

Speed of Attack,

Sustain, Speed of

Release

Low Vibration of the

Fuel Rail / Hoses and

Cylinder Head

Forces act on injectors

which transfer energy to

fuel rail

and

cylinder

head

Industry solutions:

• Gasoline: O-ring defines

stiffness of coupling

between injector and

cylinder head

• Diesel: Fixed (rigid)

connection between

injector and cylinder

head

• Fuel Rail design for

sufficient stiffness

Low level of

propagated noise

Vibrations of the Fuel

Rail and Engine

Surfaces

Radiate

Noise

Industry solutions:

• Structural

modifications to

render cylinder

head and Fuel rail

more stiff on itself

and more isolated

from the injector

excitations

• Engine Bay Sound

Proofing

Low Noise Emission During Operation

2015-XX-XX



LMS 3D Solutions

LMS Imagine.Lab (AMESim)

1D model for piezo injector

Fast simulation of:

• detailed coupled electro-

hydro-mechanical injector

system

• with simplified modeling

for the (mechanical

cylinder head) boundary

condition

LMS Virtual.Lab Acoustics

3D structural-acoustical model

Coupled Vibro-Acoustic

Simulation:

• Requires fuel velocity

pulses and valve and

needle contact forces on

injector housing

• provides structural

vibrations in frequency and

time domain (IFFT)

High freq Sound Pressure

Response:

• Time Domain Analysis (TD

BEM)

• Frequency Domain Analysis

(new FEM solver with AML

perfectly matched layer)

LMS Virtual.Lab Acoustics

3D acoustical model

2015-XX-XX



Noise from Injector

Structural FE Model

1D Model

Injection System

Measurement

Uncoupled

Coupled (2% damp)

Coupled (0% damp)

Vibro-Acoustic Model

Source: “Driving NVH Refinement of Next Generation Powertrains through Virtual Design”,

Mario Felice, Ford, 2008 LMS Conference on Virtual and Physical Prototyping

http://images.google.be/imgres?imgurl=http://z.about.com/d/autorepair/1/5/P/3/-/-/fuel-rail-bosch.jpg&imgrefurl=http://autorepair.about.com/od/glossary/ss/how-it_fuel-inj_3.htm&h=334&w=400&sz=129&hl=en&start=5&um=1&tbnid=veOlKPv81I42uM:&tbnh=104&tbnw=124&prev=/images?q=fuel+injection+rail&ndsp=21&um=1&hl=en&rlz=1T4SUNA_enBE262BE262&sa=N

2015-XX-XX




Agenda

Introduction

Standard Solutions


1

3

4


2015-XX-XX



Typical picture at A-OEMs

For Engine Noise and Intake/Exhaust noise

Current situation

5 Virtual.Lab Acoustic seats

15 users worldwide (US, EMEA, China, Japan, Korea,..)

‘NVH Specialist users’

Working from a set of clear procedures

One simulation could take them ‘one full day’

Objective

Speeding up and Scaling up: how can one get much more, faster out of

simulation? How can we use Virtual.Lab Acoustics earlier in the development

process and to be used by many more, non-specialist engineers?

2015-XX-XX



Virtual.Lab Acoustics for Engine/Intake Noise

Project with major OEM

• Customization on top of Virtual.Lab

Packaged with LMS Virtual.Lab

• Adding Value and Reducing Cost

• Users focus on value-add analysis

resulting in higher quality products

• 1Day user work is reduced to 30min,

significantly reducing costs.

• Novice, non-expert users do perform

powertrain noise analyses. Growing

from 15 to 30 regular users.

2015-XX-XX



Virtual.Lab Acoustics for Powertrain Noise

• Easy to Use Black Box

• Aligned exactly with OEM Process

• Embedded User Help

• Drive Via .Txt

• Drive Via GUI

• Status Ribbon

• Run Local or on Cluster (NIC)

2015-XX-XX



Application 1: Powertrain Radiation

• Dedicated GUI

• Fully controlling LMS Virtual Lab

Acoustics

• Virtual.Lab completely running in

batch

• Choice of input GUI Fields or .txt

template

• Intuitive design:

• Tab 1: Structural: (surface

velocities)

• Tab 2: Acoustic ATV Analysis

• Tab 3: Acoustic ATV Response

• Tab 4: Post Processing

2015-XX-XX



Application 2: Acoustics Vector Processing Case

• Dedicated GUI

• Fully controlling LMS Virtual Lab

Acoustics

• Virtual.Lab completely running in

batch

• Choice of input Fields or .txt

template

• Intuitive design:

• Tab1: Structural: (surface

velocities)

• Tab2: Post Processing

• Number of critical RPMs

• Number of Peaks

• Octave selection

• Sum options

2015-XX-XX



Application 3: Acoustics Post Processing

• Post Processing: Clean and Easy : all

automatic, NO SINGLE user

interaction

• Creation of MS PowerPoint

• Plot generation

• Auto peak selection

• Corresponding contour image creation

• Articulation Index (AI)

• Subfolder file organization (Searchable)

• Data dumping to Excel

2015-XX-XX



Powertrain Acoust

2015-XX-XX



LMS Virtual Lab Acoustics

Automation = Scalability

Documents

3D Simulation Acoustics and Vibration Powertrain. KO... · 3D Simulation Acoustics and Vibration – Powertrain Seoul, Thursday April 2nd, 2015 . 2015-XX-XX ... Fuel injection Transmission