The E-LINE™ Method - Integrating Squeak&Rattle Simulationinto the Virtual Design Process at Volvo Car CorporationJens Webe...
E-LINE™ MethodEvaluation lineSAE 2010-01-1423 SAE 2012-01-1553Squeak - rel disp in contact planeRattle - rel disp in gapJ....
Stick-slipJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
0.2 mmImpulserate: 5/mm∆ rel disp per pulse = 1/Impulse ratePeak to peak amplitudeStick-slipJ. Weber, Dr. P. Sabiniarz, Dr...
Peak to peak ?Relative motion plot in contact planea = f(t)xyJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickma...
Relative motion plot in contact planeT = 2 sxySAR-LINE directionMain directionMax principal Peak to Peak amplitudeJ. Weber...
Displacement in LCSalong E-LINE (*.pch)Modal transientin OptiStructSimulation processa = f(t)Evaluation programin MatlabJ....
Evaluation program1Impulse rateStatic (s)Dynamic (d)J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
Evaluation featuresContour plot in HyperView0.5 1 1.5 2 2.5 3 3.5 400.020.040.060.080.10.120.14Displ. mag: mean of 30% hig...
Modal correlation S&R load data Stick-slip test Tolerance analysisRattleSqueakLoad definitionMaterial propertiesa = f(t)E-...
J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper WickmanModal correlation
Mode # 1Modal correlationJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
#1 #2 #3 #4Mode # TestSimulationFoam/foil: updatedYoung’ modulus1 27.3 Hz 26.8 Hz2 44.1 Hz 41.3 Hz3 50.9 Hz 52.4 Hz4 55.0 ...
Test track A at 40 km/hTest track B at 50 km/hTest track C at 30 km/hTest track D at 80 km/hTest track E at 100 km/h…Recor...
TABLED1lc1_6131x.bdf11Recorded Squeak&Rattle load dataJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
lc1_6131x.bdflc1_6132y.bdflc1_6133z.bdfDeformation scale factor: 100Recorded Squeak&Rattle load dataTest track A at 40 km/...
Stick-slip test at VCCJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
Impulse Rate: 5.3/mmImpulse Rate: 5.3/mm 1/Impulse Rate: 0.19 mm Min toleranceStick-slip test at VCCJ. Weber, Dr. P. Sabin...
Impulse Rate: 3.2/mmStick-slip test at VCCImpulse Rate: 3.2/mm 1/Impulse Rate: 0.31 mm Max toleranceJ. Weber, Dr. P. Sabin...
Max tolMin tolMax tolMin tolStick-slip test at VCCDynamic squeak evaluation: mpP2P, mean value of 5 % HVMax tolMin tolJ. W...
Tolerance analysisJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
”Gap” directionE-LINE creation scriptStatic tolerances Dynamic tolerances+”Rattle” directionz”Gap” = ”Rattle”J. Weber, Dr....
E-LINE creationmesh basedE-LINE creationgeometry basedMaster PID3D lineSurface strip from toleranceanalysis defines normal...
E-LINE implementation at VCCSolidity simulationCAE / E-LINEGSURD&TInterior designCAD / CatiaSolidity testRecorded load sig...
Thank you for your attention!J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickmanjens.weber@afconsult.com casper...
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The E-LINE™ Method - Integrating Squeak&Rattle Simulation into the Virtual Design Process at Volvo Car Corporation

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

  1. 1. The E-LINE™ Method - Integrating Squeak&Rattle Simulationinto the Virtual Design Process at Volvo Car CorporationJens Weber, Dr. Patrick Sabiniarz, Dr. Johan SandströmÅFDr. Casper WickmanVolvo Car Corporation6th EuropeanAltair Technology ConferenceApril, 22nd - 24th, 2013Turin, Italy Reference: SAE 2012-01-1553a = f(t)
  2. 2. E-LINE™ MethodEvaluation lineSAE 2010-01-1423 SAE 2012-01-1553Squeak - rel disp in contact planeRattle - rel disp in gapJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  3. 3. Stick-slipJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  4. 4. 0.2 mmImpulserate: 5/mm∆ rel disp per pulse = 1/Impulse ratePeak to peak amplitudeStick-slipJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  5. 5. Peak to peak ?Relative motion plot in contact planea = f(t)xyJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper WickmanDeformation scale factor: 100
  6. 6. Relative motion plot in contact planeT = 2 sxySAR-LINE directionMain directionMax principal Peak to Peak amplitudeJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  7. 7. Displacement in LCSalong E-LINE (*.pch)Modal transientin OptiStructSimulation processa = f(t)Evaluation programin MatlabJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  8. 8. Evaluation program1Impulse rateStatic (s)Dynamic (d)J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  9. 9. Evaluation featuresContour plot in HyperView0.5 1 1.5 2 2.5 3 3.5 400.020.040.060.080.10.120.14Displ. mag: mean of 30% highest values, Variant 1(d)time [s]displacement[mm]101930055016101010103020J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  10. 10. Modal correlation S&R load data Stick-slip test Tolerance analysisRattleSqueakLoad definitionMaterial propertiesa = f(t)E-LINE implementation at VCCE-LINE™ evaluationE-LINE™ creationJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  11. 11. J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper WickmanModal correlation
  12. 12. Mode # 1Modal correlationJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  13. 13. #1 #2 #3 #4Mode # TestSimulationFoam/foil: updatedYoung’ modulus1 27.3 Hz 26.8 Hz2 44.1 Hz 41.3 Hz3 50.9 Hz 52.4 Hz4 55.0 Hz 55.5 HzUpdated material data for foam/foilModal correlationModal dampingJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  14. 14. Test track A at 40 km/hTest track B at 50 km/hTest track C at 30 km/hTest track D at 80 km/hTest track E at 100 km/h…Recorded Squeak&Rattle load dataJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  15. 15. TABLED1lc1_6131x.bdf11Recorded Squeak&Rattle load dataJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  16. 16. lc1_6131x.bdflc1_6132y.bdflc1_6133z.bdfDeformation scale factor: 100Recorded Squeak&Rattle load dataTest track A at 40 km/hTest track B at 50 km/hTest track C at 30 km/hTest track D at 80 km/hTest track E at 100 km/h…One S&R load case forE-LINE simulationJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  17. 17. Stick-slip test at VCCJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  18. 18. Impulse Rate: 5.3/mmImpulse Rate: 5.3/mm 1/Impulse Rate: 0.19 mm Min toleranceStick-slip test at VCCJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  19. 19. Impulse Rate: 3.2/mmStick-slip test at VCCImpulse Rate: 3.2/mm 1/Impulse Rate: 0.31 mm Max toleranceJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  20. 20. Max tolMin tolMax tolMin tolStick-slip test at VCCDynamic squeak evaluation: mpP2P, mean value of 5 % HVMax tolMin tolJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  21. 21. Tolerance analysisJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  22. 22. ”Gap” directionE-LINE creation scriptStatic tolerances Dynamic tolerances+”Rattle” directionz”Gap” = ”Rattle”J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper WickmanTolerance analysis
  23. 23. E-LINE creationmesh basedE-LINE creationgeometry basedMaster PID3D lineSurface strip from toleranceanalysis defines normal direction.The mesh does not alwaysrepresent the normaldirection correctly.Slave PIDStatic and dynamic tolerances100% aligned!J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper WickmanTolerance analysis
  24. 24. E-LINE implementation at VCCSolidity simulationCAE / E-LINEGSURD&TInterior designCAD / CatiaSolidity testRecorded load signalImpulse rate from stick-slip testCritical S&R interfacesStylingErgonomicsPackagingAssemblingToolingJ. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickman
  25. 25. Thank you for your attention!J. Weber, Dr. P. Sabiniarz, Dr. J. SandströmDr. Casper Wickmanjens.weber@afconsult.com casper.wickman@volvocars.com

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