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Implementation of Squeak and
Rattle Analysis in HyperWorks
Ismail Benhayoun, Altair
Harris Zografos, Altair
2013 European Altair Technology Conference
Turin, ITALY April 22nd to 24th, 2013
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
• Integrate the technology in a robust and progressive environment
• Create an automated process
• Offer high customization capabilities
Implementation of the methodology in HW environment
SnR Analysis in HyperWorks®
SAE 2010-01-1423
SAE 2012-01-1553
E-Line Method in Squeak and Rattle – Director
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Core technology
Rattle Correlation Squeak Correlation
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Gap size
Relative displacement in a gap
Gap
Force/acceleration
Shaker
3D Laser Vibrometer Gap
Plastic Steel
Laser beam
Pseudo random signal A random signal of a user defined time length is repeated for each measurement (trigger).
Rattle
Rattle Correlation
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
SIMULATION
F (t)
Displacement simulated
with modal transient solver
Test configurations
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Force M1
Force M2
Displacement M1
Displacement M2
Trigger validation
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Modal damping
Modal correlation
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24 Ref. SAE 2012-01-1553
Config 1 - correlation in time domain
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Modal transient
F(t )
Modal damping
Config 1 - correlation in time domain
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
GAP
1.03 mm 1.05 mm 1.04 mm
Double click Single click
Config 1 - first contact
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Contact No Contact No Contact
GAP
Amplitude
Phase
Non Linear Linear Linear
Config 1 – Intensive rattle
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Single click Intensive rattle
GAP GAP
Rattle correlation
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Single click Intensive rattle
Gap = Meancrit Gap ---- Mean ----
Rattle correlation
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Node # 1
M10%HV
Test vs Simulation
Node # 5
Config. 3
Evaluation along a line
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Squeak correlation
Rel disp in contact plane
Peak to peak amplitude
Part I
Part II
P
Q
w
v
u
GAP
Rattle Squeak
X
Y
Z
Contact / gap
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Ref: SAE 2012-01-1553
Stick Slip phenomenon
P2P relative displacement
in the squeak plane
Squeak correlation
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Squeak evaluation
Stick slip machine test data
T = 2 s
x
y
Main direction
Max principal Peak to Peak amplitude
SAR-Line
Direction
Ref. SAE 2012-01-1553
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
S&R FE-Lines
Analysis process
OptiStruct
Modal transient
analysis
Pre-processing Post-processing Analysis
Process Manager Semi-Automatic
Automatic post-processing
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Process Manager : Global Parameters
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Process Manager : Material Mapping
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Process Manager : Creation of SnR lines
A1.01
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Process Manager
Line ID Line type Materials pair min-max Interface name Gap dimension [mm] Tolerance [mm]1085 Rattle MAT1/MAT3 0.001-0.003 A1.01 10 1
4030 Rattle MAT1/MAT3 0.001-0.003 A1.02 10 1
8014 Rattle MAT1/MAT3 0.001-0.003 A1.03 10 1
12005 Rattle MAT1/MAT3 0.001-0.003 A1.04 10 1
16018 Rattle MAT1/MAT3 0.001-0.003 A1.05 10 1
24025 Rattle MAT1/MAT3 0.001-0.003 A1.06 10 1
28043 Rattle MAT1/MAT3 0.001-0.003 A1.07 10 1
32010 Rattle MAT1/MAT3 0.001-0.003 A1.08 10 1
36013 Squeak MAT1/MAT3 0.001-0.003 A1.09 0 0
40010 Squeak MAT1/MAT3 0.001-0.003 A1.10 0 0
44048 Squeak MAT1/MAT3 0.001-0.003 A1.11 0 0
48070 Squeak MAT1/MAT3 0.001-0.003 A1.12 0 0
52010 Squeak MAT1/MAT3 0.001-0.003 A1.13 0 0
56070 Squeak MAT1/MAT3 0.001-0.003 A1.14 0 0
60008 Squeak MAT2/MAT4 0.002-0.004 A1.15 0 0
64013 Squeak MAT2/MAT4 0.002-0.004 A1.16 0 0
68014 Squeak MAT2/MAT4 0.002-0.004 A1.17 0 0
72027 Squeak MAT2/MAT4 0.002-0.004 A1.18 0 0
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Post - Processing
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Post - Processing
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Semi-Automatic process
A2B comparisons
OPTIMIZATION
Analysis process
Process Manager Semi Automatic
Automatic post-processing
S&R FE-Lines
OptiStruct Modal transient analysis
Squeak and Rattle – Director
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Scania CV AB & LeanNova
By courtesy of Scania CV AB
Esupplier = 1950Mpa
Ecorrelation = 4500 MPa
Esupplier = 1950Mpa
Ecorrelation = 2500 MPa
Modal correlation
Current cockpit
Improve the
material
data in the
FE model
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
SnR Analysis
Current cockpit Scania New Cab Generation
A2B comparison
Loads from
Road Tests and
MBA simulations
Forces (Fx, Fy, Fz) applied at:
1. Bushing#1
2. Bushing#2
3. Suspension#1
4. Suspension#2
5. Suspension#3
6. Suspension#4
7. Cross_link#1
8. Cross_link2
Modal Transient
Input loads
Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Ismail Benhayoun, Harris Zografos
Turin 2013-04-22/24
Thank you!
Grazie mille!
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