New Material Technologies using Physics A Combination of Acoustic and Thermal Systems Hartmut Kiessig 6.Jun.2011

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1 New Material Technologies using Physics A Combination of Acoustic and Thermal Systems Hartmut Kiessig 6.Jun.2011 Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 1

2 New Material Technologies using Physics A Combination of Acoustic and Thermal Systems Hartmut Kiessig, R+T Business Group SAMEA Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 2

3 Acoustic Heatshield Innovation: RIMIC TM Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 3

4 63.43 RIMIC TM : Rieter Micro-Perforated HS technology Step groove and pull & stretch Stretching means: Open the grooves in three dimensions with embossing rollers. 1) Build grooves AL sheet mm 2) Pull & stretch AL sheet mm t s Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 4

5 Acoustic absorption in alpha cabin Al 1050 / 0.5 mm / RIMIC (1.5:4.5:5), s = 0.02 / 0.04 / 0.06 mm Al 1050 (1.5:4.5:5) t = 0.5 mm t s 0.50 s = 0.02 mm Absorption [-] s = 0.04 mm s = 0.06 mm k 1.25k 1.6k 2k 2.5k 3.15k 4k 5k 6.3k 8k 10k Frequency [Hz] Al mm Rimic type 1,5:4,5:5 s=0.02mm Average Al mm Rimic type 1,5:4,5:5 s=0.04mm Average Al mm Rimic type 1,5:4,5:5 s=0.06mm Average Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 5

6 Low weight Innovation: TRI-FORM TM Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 6

7 Discussion of fatigue results BM 356 BM Fatique life line BM 356 Standard Embossing 0.5mm Forming Dynamic Fatigue Accleration (G) More fatigue resistant if more on the right Triform mm 1.0E E E E E+07 Fatigue Cycles Mass Savings Standard Embossing 0.5 to 0.4mm 12% Frequency Reduction 20% 18% 16% 14% 12% 10% 8% 6% BM 356 at 1g Standard 0.5mm TF mm 4% 2% 0% 0.E+00 1.E+04 2.E+04 3.E+04 4.E+04 5.E+04 6.E+04 No Forming issues Dynamic response similar to Standard TF120 shows improved fatigue life as compared with Standard embossing TF120 generally only exhibits one crack location Replacing Standard 0.5 mm class with TF mm offers mass savings Cycles Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 7

8 Overview: Description of the Innovation Irregular feature arrangement Asymmetric embossing direction Similar stiffness in 3 directions Rib Length = 18mm Rib width = 7.5mm Rib height = 2.5mm Improved fatigue durability Reduced material usage 10 Fatique life line for BM 366 Standard 0.5 mm Standard 0.45 mm Acceleration (G) 1 More fatigue resistant if more on the right TriForm 0.4 mm Part Thickness Reduction BM mm 22.8% BM mm 11.5% Reno mm 28.7% E E E E E E+09 Cycles Reno mm 12.5% BM mm 37.2% Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 8

9 Analysis of DAC heatshield Failure at the bolt point is difficult to detect visually due to washers Fatigue life graph was not created crack detection difficult Durability of part and material combinations was tracked Crack High Stress Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 9

10 DAC heatshield: TF120 Press Forming Prototype Frequency (Hz) Frequency Response Standard 0.5mm TF mm TF mm Dynamic Response Standard 0.5mm and TF mm are close in their dynamic response TF mm shows significantly lower performance than the Standard 0.5mm Frequency Reduction % 10% 8% 6% 4% 2% Mode 1 Mode 2 Mode 3 Mode 4 Mode 5 Durability 1.5G Standard G TF G TF G Durability The Standard 0.5mm and TF mm are very close in performance TF120 exhibits slightly better durability over the fatigue range TF mm exhibits poor durability compared with the other materials 0% 0.E+00 5.E+04 1.E+05 2.E+05 2.E+05 3.E+05 Fatigue Cycles Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 10

11 Result of investigation on fatigue cracks The problem of insufficient vibration resistance on the fixation points was resolved It is possible to work with heatshields Triform 120 with the thickness 0,3mm and pass the mechanical tests Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 11

12 New Hybrid acoustic concept of RIETER Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 12

13 Two main customer groups but same trend to Hybrid Reduce weight Mass spring with decoupler made of foam HYBRID ACOUSTICS Increase insulation RUL ECO type of performance (high absorption) Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 13

14 It would be nice to improve the insulation of a fibrous top layer, but how? Insulation (felt de-coupler) if porous, the insulation is low db dB/Octave Hz add an impervious film like in RUL Flex Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 14

15 Until now the insulation of a fibrous material combined with an impervious film has been poor Poor performance The top layer mechanical properties influence the radiation of noise which results in lack of performance at important frequencies Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 15

16 With the proper dynamic compressional stiffness, we match with a fibrous product the mass-spring insulation Insulation (felt de-coupler) Insulation (felt de-coupler) mass db db RUL RUL ECO ECO 1.2kg/m2 1.2kg/m2 6dB/Octave 6dB/Octave 12dB/Octave 12dB/Octave RUL RUL ECO+ ECO+ 1.2kg/m2 1.2kg/m2 Heavy Heavy layer layer 1.5kg/m2 1.5kg/m2 Hybrid 1.5kg/m2 hybrid Hz Hz Flat sample measurement data 20mm Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 16

17 We can achieve differentiated areas just by playing with compression 40 Absorption control Insertion Loss (db) Dynamic Stiffness Control Absorption control Frequency (Hz) Dynamic Stiffness Control Absorption coefficient (-) Absorption control Insulation control Mass spring: 12dB / octave 1.0 Dynamic Stiffness Control Absorption control Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 17

18 The concept has been validated on the road against a 3.5kg/m 2 heavy layer and foam mass / spring Road 2nd gear slow acceleration db(a) Original 3.5kg/m2 HL + foam Hybird Var4 1.0 kg/m2 + foam Var Lower is better Var Hz Felt is 2mm Felt is 7mm Felt is 15mm Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 18

19 Status Brasil The hybrid concept offers the choice between good insulation and good Absorption in one part and without increasing the weight, thus being more flexible to reduce the noise locally inside a car In Brasil two vehicle projects are being realised using the Technology behind the Hybrid Concept Overview on Technologies May 2011 Hartmut Kiessig, R+T BG SAMEA 19