Implementation of Squeak and Rattle Analysis in HyperWorks

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



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Core technology

Rattle Correlation Squeak Correlation

Ref. SAE 2012-01-1553



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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



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SIMULATION

F (t)

Displacement simulated

with modal transient solver

Test configurations

Ref. SAE 2012-01-1553



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Force M1

Force M2

Displacement M1

Displacement M2

Trigger validation

Ref. SAE 2012-01-1553



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Modal damping

Modal correlation

Ref. SAE 2012-01-1553



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Config 1 - correlation in time domain



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Modal transient

F(t )

Modal damping

Config 1 - correlation in time domain

Ref. SAE 2012-01-1553



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GAP

1.03 mm 1.05 mm 1.04 mm

Double click Single click

Config 1 - first contact

Ref. SAE 2012-01-1553



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Contact No Contact No Contact

GAP

Amplitude

Phase

Non Linear Linear Linear

Config 1 – Intensive rattle

Ref. SAE 2012-01-1553



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Single click Intensive rattle

GAP GAP

Rattle correlation

Ref. SAE 2012-01-1553



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Single click Intensive rattle

Gap = Meancrit Gap ---- Mean ----

Rattle correlation

Ref. SAE 2012-01-1553



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Node # 1

M10%HV

Test vs Simulation

Node # 5

Config. 3

Evaluation along a line

Ref. SAE 2012-01-1553



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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



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Ref: SAE 2012-01-1553

Stick Slip phenomenon

P2P relative displacement

in the squeak plane

Squeak correlation

Ref. SAE 2012-01-1553



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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



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S&R FE-Lines

Analysis process

OptiStruct

Modal transient

analysis

Pre-processing Post-processing Analysis

Process Manager Semi-Automatic

Automatic post-processing



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Process Manager : Global Parameters



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Process Manager : Material Mapping



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Process Manager : Creation of SnR lines

A1.01



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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



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Post - Processing



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Post - Processing



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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


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



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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



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Thank you!

Grazie mille!