Increasing demand for simulation accuracy often leads to increased finite element model complexity, which in turn, results in higher computational costs. As a provision, component mode synthesis approaches are employed to approximate the system response by using dynamic substructuring and model reduction techniques in linear systems. However, the use of available model reduction techniques in nonlinear problems containing the contact type of nonlinearities remains an interesting topic. In this paper, the application of a component mode synthesis method in squeak and rattle nonlinear simulation has been investigated. Critical regions for squeak and rattle of the side door model of a passenger car were modelled by nonlinear contact definition in finite element simulation. Craig-Bampton model reduction method was employed to substructure the finite element model while keeping the nonlinear contacts in the model. The model response was evaluated using the modal assurance criterion, frequency response analysis and contact force magnitude in comparison with the baseline model. Results showed that a great reduction in computational time (about 98%) can be achieved while the accuracy of the system response was maintained at an acceptable range for the intended application for squeak and rattle simulation. Although the prediction of impact events in time was done accurately, the contact force magnitude was estimated with average error of 2.5% to 22%, compared with the baseline results. The outcomes of the study show that to empower squeak and rattle prediction by including contact interfaces in finite element simulations, implementation of the model reduction approach can compensate the simulation cost.
