The E-LINE™ Method - Integrating Squeak&Rattle Simulation into the Virtual Design Process at Volvo Car Corporation

The E-LINE™ Method - Integrating Squeak&Rattle Simulation

into the Virtual Design Process at Volvo Car Corporation

Jens Weber, Dr. Patrick Sabiniarz, Dr. Johan Sandström

ÅF

Dr. Casper Wickman

Volvo Car Corporation

6th European

Altair Technology Conference

April, 22nd - 24th, 2013

Turin, Italy Reference: SAE 2012-01-1553

a = f(t)

E-LINE™ Method

Evaluation line

SAE 2010-01-1423 SAE 2012-01-1553

Squeak - rel disp in contact plane Rattle - rel disp in gap

J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström

Dr. Casper Wickman

Stick-slip


Dr. Casper Wickman

0.2 mm

Impulse rate: 5/mm

∆ rel disp per pulse = 1/Impulse rate

Peak to peak amplitude

Stick-slip


Dr. Casper Wickman

Peak to peak ?

Relative motion plot in contact plane

a = f(t)

x

y


Dr. Casper Wickman

Deformation scale factor: 100

Relative motion plot in contact plane

T = 2 s

x

y

SAR-LINE direction

Main direction

Max principal Peak to Peak amplitude


Dr. Casper Wickman

Displacement in LCS

along E-LINE (*.pch)

Modal transient

in OptiStruct

Simulation process

a = f(t)

Evaluation program

in Matlab


Dr. Casper Wickman

Evaluation program

1

Impulse rate

Static (s)

Dynamic (d)


Dr. Casper Wickman

Evaluation features

Contour plot in HyperView

0.5 1 1.5 2 2.5 3 3.5 40

0.02

0.04

0.06

0.08

0.1

0.12

0.14Displ. mag: mean of 30% highest values, Variant 1(d)

time [s]

dis

pla

cem

ent

[mm

]

1019

3005

5016

101010

103020


Dr. Casper Wickman

Modal correlation S&R load data Stick-slip test Tolerance analysis

Rattle

Squeak Load definition

Material properties

a = f(t)

E-LINE implementation at VCC

E-LINE™ evaluation E-LINE™ creation


Dr. Casper Wickman


Dr. Casper Wickman

Modal correlation

Mode # 1

Modal correlation


Dr. Casper Wickman

#1 #2 #3 #4

Mode # Test Simulation Foam/foil: updated

Young’ modulus

1 27.3 Hz 26.8 Hz

2 44.1 Hz 41.3 Hz

3 50.9 Hz 52.4 Hz

4 55.0 Hz 55.5 Hz

Updated material data for foam/foil

Modal correlation

Modal damping


Dr. Casper Wickman

Test track A at 40 km/h

Test track B at 50 km/h

Test track C at 30 km/h

Test track D at 80 km/h

Test track E at 100 km/h

…

Recorded Squeak&Rattle load data


Dr. Casper Wickman

TABLED1

lc1_6131x.bdf

11



Dr. Casper Wickman

lc1_6131x.bdf

lc1_6132y.bdf

lc1_6133z.bdf

Deformation scale factor: 100


Test track A at 40 km/h

Test track B at 50 km/h

Test track C at 30 km/h

Test track D at 80 km/h

Test track E at 100 km/h

…

One S&R load case for

E-LINE simulation


Dr. Casper Wickman

Stick-slip test at VCC


Dr. Casper Wickman

Impulse Rate: 5.3/mm

Impulse Rate: 5.3/mm 1/Impulse Rate: 0.19 mm Min tolerance



Dr. Casper Wickman

Impulse Rate: 3.2/mm


Impulse Rate: 3.2/mm 1/Impulse Rate: 0.31 mm Max tolerance


Dr. Casper Wickman

Max tol

Min tol

Max tol

Min tol

Stick-slip test at VCC Dynamic squeak evaluation: mpP2P, mean value of 5 % HV

Max tol

Min tol


Dr. Casper Wickman

Tolerance analysis


Dr. Casper Wickman

”Gap” direction

E-LINE creation script

Static tolerances Dynamic tolerances

+

”Rattle” direction

z ”Gap” = ”Rattle”


Dr. Casper Wickman

Tolerance analysis

E-LINE creation

mesh based

E-LINE creation

geometry based

Master PID

3D line

Surface strip from tolerance

analysis defines normal direction.

The mesh does not always

represent the normal

direction correctly.

Slave PID

Static and dynamic tolerances

100% aligned!


Dr. Casper Wickman

Tolerance analysis

E-LINE implementation at VCC

Solidity simulation

CAE / E-LINE

GSU

RD&T

Interior design CAD / Catia

Solidity test

Recorded load signal

Impulse rate from stick-slip test

Critical S&R interfaces

Styling

Ergonomics Packaging

Assembling

Tooling


Dr. Casper Wickman

Thank you for your attention!


Dr. Casper Wickman

[email protected] [email protected]