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SNRD at FIAT to predict the risks for S&R in interior assemblies
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SNRD at FIAT to predict the risks for S&R in interior assemblies

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Squeak and Rattle (S&R) is a well-known issue for test engineers and is costly to fix if not investigated in time during the product development phase. Altair presented SNRD at the EATC 2013, a new …

Squeak and Rattle (S&R) is a well-known issue for test engineers and is costly to fix if not investigated in time during the product development phase. Altair presented SNRD at the EATC 2013, a new simulation-based evaluation tool, which can be used to help predict and minimize the risks of S&R. This tool, which is implemented in the HyperWorks environment, is based on the methodology presented in the SAE paper 2012-01-1553, where a new method for S&R correlation in the time domain between test and simulation has been described. In Brazil, due to dynamic conditions on roads that the vehicles are subjected, the “SnR” has been widely studied. At FIAT NVH department in Belo Horizonte (Brazil), NVH simulation and test engineers have been looking into S&R causes using only testing methods. But since development processes are becoming increasingly based on CAE and virtual engineering methods, FIAT engineers have been looking for a simulation based methodology implemented in a tool that ensures fast, robust and flexible pre- and post-processing with large customization capabilities. The need for short iteration and lead times being a key factor in productivity and product quality, FIAT chose SNRD to build up their internal simulation process for S&R, combining their experience and knowledge from testing with Altair’s experience in simulating S&R. This presentation will describe how SNRD combines the different inputs from FIAT’s Experimental Engineering Department, design department, tolerance calculations and NVH simulation to evaluate and predict the risks and root causes for S&R in the interior assembly of a vehicle.

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  • 1. SNRD at FIAT to predict the risks for S&R in interior assemblies Ismail Benhayoun, Altair PD Sweden June 26th , 2014 Co-Authors: Mr. Tiago Ferreira , CAE Engineer, Fiat Automóveis, NVH Mr. Paulo Eduardo Dal Bon Tonett, CAE Engineer , Altair Brazil Mr. Charilaos Zografos, ESG Team Leader, Altair Sweden
  • 2. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Background • Situation : • FIAT encounter S&R issues • CAE Driven Development at Focus • Issues : • S&R is only investigated with testing. • No simulation method available at FIAT • Question : • How can FIAT transpose their S&R knowledge to simulation using Altair’s experience and tools?
  • 3. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Presentation roadmap FIAT & Altair Next Steps • Simplistic explanation • Phenomena occurrence & consequences • Analyzing the phenomena E-Line & SNRD D.I.R.T.F.T. Squeak & Rattle in the Product Development Process NOT a live demo of SNRD
  • 4. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Observing S&R occurrence and its consequences Noise due to Rattle occurrence Ref. SAE 2012-01-1553 Abrasion of paint due to Squeak occurrence BMW 5 series workshop manuals (http://workshop-manuals.com)
  • 5. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Analyzing S&R phenomena • Rule of thumb or established standards • Physical testing Ziegler’s Stick-Slip Test Stand SSP-04 3D Laser Vibrometry equipment (http://asdec.co/)
  • 6. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Product Development Process Testing Development Process Virtual Engineering Validation Simulation Modal Analysis / F.R.A. • First Eigen Frequency • Maximum Displacement • Etc.. S&R Testing • “Quick fix” • High Costs • Too late!
  • 7. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Product Development Process Testing Development Process Virtual Engineering Validation Simulation Modal Analysis / F.R.A. S&R Testing S&R Simulation – Risk Analysis S&R Simulation • Early Identification of risk areas • Drive the Design & Tolerances • Decide on the most robust options • Correlate and Improve • Support the Validation Process
  • 8. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Proposed Process to FIAT NVH Team 1. What do we need to perform such analysis? 2. How much effort is it to obtain the necessary inputs?”
  • 9. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. NVH MODEL Model definition & E-Line Method • Linear Model • No contact definitions • Independent of penetrations and intersections
  • 10. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Semi-Automatic process Analysis process Process Manager Semi Automatic Automatic post-processing S&R FE-Lines OptiStruct Modal Transient Analysis Squeak and Rattle – Director
  • 11. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. FIAT UNO – Trimmed Body In White
  • 12. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. S&R Testing & Simulation Test Simulation Relative Displacement Different road conditions
  • 13. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Instrument Panel at Focus Critical areas Material Combinations Packaging space Static Tolerances Line ID Line type Materials pair min-max Interface name Gap dimension [mm] Tolerance [mm] 1009 Rattle ABS85.180/PP_55.100 0.1-0.2 A1 1.0 0.3 4010 Rattle ABS85.180/PP_55.100 0.1-0.2 A2 1.5 0.3 7129 Rattle ABS85.180/PP_55.100 0.1-0.2 A3 2.0 1.2 10039 Rattle ABS85.180/PP_55.100 0.1-0.2 A4 1.0 0.8 13075 Rattle PP_55.100/PP_55.100 0.7-0.9 A5 1.2 0.5 16029 Rattle PP_55.100/PP_55.100 0.7-0.9 B1 0.8 0.5
  • 14. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Excitation loads MBS Different road conditions Shaker from test lab Generic PSD Time domain loads
  • 15. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Presentation roadmap FIAT & Altair Next Steps • SNRD outputs • Sensitivity studies • Chose of most robust design E-Line & SNRD D.I.R.T.F.T.S&R simulation based on relative displacement due to pseudo-random loads in time domain
  • 16. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Automatic Rattle Evaluation in SNRD Magnitude & Dynamic Tolerance
  • 17. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Automatic Squeak Evaluation in SNRD Material Pairs : ABS85.180/PP_55.100 Impulse Rate Stick Slip Testing (Ziegler)
  • 18. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Automatic Rattle Evaluation in SNRD– Detailed level 1.9 mm 2.5 mm GAP GAP -Tolerance
  • 19. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. HyperMesh → OptiStruct → HyperView SNRD PROCESS AS A STAND ALONE PROCESS…
  • 20. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. SNRD PROCESS HyperStudy Setup Parameter Study HyperMesh Model Setup SNRD Relative Displacement, Dynamic Tolerance , Modal Contribution(frequency),etc… Recognize all your variables automatically Model with the E-Line is prepared Define all variants to be run and automatic call the post- processing in SNRD … THAT INTEGRATES IN A LARGE SCALE PROCESS
  • 21. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. S&R an Iterative process – Sensitivity Analysis IP to Floor Console interface – Effect of Modal Damping 2% 4% 6% 8% 25% Predict and Anticipate the variations of real parts by estimating the consequences in term of S&R issues
  • 22. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Practical benefits - Update of Gap/Tolerances? New
  • 23. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. SNRD made for it SNRDCAD Model SNRD defines the gap and tolerance data as metadata. Therefore: + No need for remodeling + No need to rebuild interfaces + No need to redo analysis 1 h + 0.5 h + 3 h = 4.5 h In SNRD 5 min Vs.
  • 24. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Presentation roadmap FIAT & Altair Next Steps • Improve the capabilities • Extend the applications • S&R a driving load case E-Line & SNRD D.I.R.T.F.T. S&R simulation based on relative displacement due to loads in time domain
  • 25. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. FIAT chose SNRD by Altair • Methodology based on evaluation of relative displacement • Rattle • Provides a calculation of relative displacement along a gap • Compares to the Gap size and Static Tolerance • Provides a calculation of a Dynamic Tolerance • Relative displacement can be directly correlated to Measured Displacement in test • Squeak • Calculation of relative displacement in contact plane • New parameter that correlates to Stick-Slip measurement SNRD offers you the possibility to choose between different technical solutions at an early stage of the development process
  • 26. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. FIAT & Altair PD Next Steps Excitation loads • Loads measured at Xbeam, A-Pillar, Floor • Loads in 3 Directions (X,Y,Z) Material Data • Modal correlation at the part level:  Compare some parts : E-Modulus from supplier vs. manufactured part Correlation • Test vs. Simulation using SNRD • Improve simulation parameters to develop a best practice policy (i.e. modal damping) Dimensioning • Include Gap size and Tolerances in SNRD calculation Stick-Slip • Create a database for the most common materials.
  • 27. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Door Trim FIAT & Altair PD Next Steps Road To Lab To Math (R.L.M.) Create A Best Practice Procedure To Evaluate & Reduce Risks For Squeak And Rattle Issues In Interior Assemblies Test on different tracks Test & Simulation F(t) F(t) IP Accelerometers {X,Y,Z} Test Data a(t)
  • 28. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. From System Level to Full Assembly Validation Interior CAE Team Instrument Panel Door Trim Interior Trim Exterior CAE Team Face/Exterior Closures Evaluation System Level Evaluation Assembly Level NVH CAE Team Trimmed BIW
  • 29. Copyright © 2012 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. Presentation roadmap System to full assembly level Improving the capabilities E-Line & SNRD D.I.R.T.F.T. S&R simulation based on relative displacement due to loads in time domain
  • 30. Copyright © 2013 Altair Engineering, Inc. Proprietary and Confidential. All rights reserved. More success stories about our customers and the usage of SNRD on: http://www.altairproductdesign.se/ Thank you! For more information, please contact: Ismail Benhayoun : Ismail.benhayoun@altair.se Charilaos Zografos : charilaos.zografos@altair.se