Full-Vehicle NVH CAE Conceptual Model. An Integrated Approach to Ride, Vibration and Acoustic Engineering

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IAR FENet 2003 4-5 December 2003 An Integrated Approach to Ride, Vibration and Acoustic Engineering Full-Vehicle CAE Conceptual Model For automotive applications Loads Vehicle Response Christoph

1 IAR FENet December 2003 An Integrated Approach to Ride, Vibration and Acoustic Engineering Full-Vehicle CAE Conceptual Model For automotive applications Loads Vehicle Response Christoph Ortmann Business Development Director Force Structural-Structural Vibration Structural-Acoustics Acoustic-Structural Volume Velocity Acoustic-Acoustic Noise Gabriele Ferrarotti, MSC.Software Gabriele Ferrarotti, MSC.Software Full-Vehicle N&V CAE Conceptual Model and aerospace applications Loads System Force Volume Velocity Acoustic-Acoustic Response Structural-Structural Vibration Full-vehicle 0,2 Structural-Acoustics Acoustic-Structural 0 Noise for predictive FE-based FE-based MBS-based MBS-based FE-based FE-based SEA-based SEA-based based 1

2 Example of Development Process Desired Development Process Vehicle Dynamics Vehicle Dynamics? MBS-Based Full-Vehicle MBS-Based Full-Vehicle ADAMS/Car Ride Relies on ADAMS/Car, the industry standard tool for systemlevel virtual prototyping in the automotive industry Allows usage of scalable prototypes for vehicle dynamics AND ride&comfort Positions predictive up-front in the design process ADAMS/Car Ride Process A validated ADAMS/Car handling model is available Replace rigid bodies (I.e. body) with flexible bodies Include additional flexible bodies (I.e. exhaust system) Replace connection elements (I.e. bushing, tires) with frequency dependent components Perform ride&comfort simulation -related postprocessing 2

MBS-Based Full-Vehicle MBS-Based Full-Vehicle Example: Replace 0,2

FE-based FE-based SEA-based SEA-based based Optimization of Acoustic

Design modification FE-based -level MSC.

of international companies Automotive applications: Engine & powertrain

noise Trim components acoustic characterization Aerospace applications:

3 MBS-Based Full-Vehicle MBS-Based Full-Vehicle Example: Replace 0,2 Full-vehicle 0 for predictive FE-based FE-based MBS-based MBS-based FE-based FE-based SEA-based SEA-based based Optimization of Acoustic Emissions Optimization of Acoustic Emissions Basic design? Design modification FE-based -level MSC.Actran General-purpose vibroacoustic solution Originated from a consortium of international companies Automotive applications: Engine & powertrain acoustic radiation Exhaust & intake systems vibro-acoustic performance Tire noise Trim components acoustic characterization Aerospace applications: Acoustic trimming modeling Trimmed body applications Detailed absorption material modelling Engine noise radiation Design of the intake and the exhaust system 3

4 FE-based -level FE-based -level Acoustic Radiation Solutions Application Engine powertrain Engine auxiliaries (oilpan, manifold, gearbox, ) Engine compartment insulation Excitation Mechanical force at bearings Vibration patterns Physical model Unequal structural & acoustical meshes Mode-by-mode radiation analysis Solvers Fast FRF Krylov solver SuperLU parallel solver Business: Automotive Tier 1 Challenge: Solution: Value: Improve acoustic performance of windshield Rely on MSC.Actran to simulate the acoustic transmission of layered windshield Optimize acoustic transmission. Deliver component model to OEM to be plugged into body prototype for predictive Full-vehicle Simulation FE-based FE-based FE Data from existing vehicle programs Supply Chain Trim Tire 0,2 Full-vehicle 0 FE-based FE-based MBS-based MBS-based SEA-based SEA-based based MBS-Based s MBS-Based s Test-Based s Test-Based s 4

Full-vehicle Simulation Full-vehicle Simulation Unified Environment Preprocessing Full-vehicle assembly Automatic closing of holes in BIW Automatic cavity meshing Simulation Relies on MSC.

Chain Trim Test-Based s Test-Based s Tire Automatic Tasks Full-vehicle Simulation Open ADAMS/Car Assembly Select body to be excluded from export (existing MSC.Nastran model) Model Setup + Map MSC.

5 Full-vehicle Simulation Full-vehicle Simulation Unified Environment Preprocessing Full-vehicle assembly Automatic closing of holes in BIW Automatic cavity meshing Simulation Relies on MSC.Nastran2004 fluidstructure coupling algorithm Dramatic improvement of ACMS performance Postprocessing -related plotting/animation FE Data from existing vehicle programs MBS-Based s MBS-Based s Supply Chain Trim Test-Based s Test-Based s Tire Automatic Tasks Full-vehicle Simulation Open ADAMS/Car Assembly Select body to be excluded from export (existing MSC.Nastran model) Model Setup + Map MSC.ADAMS attachments to MSC.Nastran GRID IDs Run trimming analysis Export System State Matrices Write MSC.Nastran bulk data fragment 0,2 Full-vehicle 0 for predictive MSC.Nastran (S.B.) FE-IFE + MSC.Actran based (S.B. + A.B.) MSC.Nastran (S.B.) + MSC.Actran FE/IFE-based (S.B. Energy + A.B.) Flow Method MSC.Adams MBS-based (S.B.) SEA-based SEA-based based 5

6 In conclusion... Virtual Product Development applied to the N&V process: MBS-based full-vehicle N&V solutions Leverage handling models to ride&comfort engineering Share MBS models with N&V team FE-based component-level N&V General-purpose vibroacoustic solution Enables optimization of component vibroacoustic behavior up-front in the design process FE-based full-vehicle N&V solutions Support assembly of system-level N&V prototype Facilitate collaboration throughout supply chain 6

Virtual Product Development (VPD) deployed on Durability

IAR FENet 2003 4-5 December 2003 Virtual Product Development (VPD) deployed on Durability Christoph Ortmann Business Development Director Agenda Introductions VPD Overview VPD Durability: The Honda ATV