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Equivalent Radiated Power driven optimization for driveline housings using simulation tools to cut-down the project time
ISSN: 0148-7191, e-ISSN: 2688-3627
To be published on November 21, 2019 by SAE International in United States
Event: NuGen Summit
In the field of Automotive industry, being competitive makes you succeed. Industry is moving towards advancement day by day. New technologies to improve fuel efficiency, crash resistance, vehicle noise levels have been trending. At VECV, we have traditionally worked on CAE of driveline housings (clutch housing & transmission housing) based on static, dynamic and transient loadings. Currently, weight optimization technique depends on the structural and dynamic loading conditions, but do not consider acoustic concerns. Powertrain housings are highly prone to vibrations and leads to high level of noise. Noise has been constant issue in the casting components associated to driveline. There have been lot of research going on to reduce the level of noise and vibrations in the vehicle driveline, which ultimately leads to fuel efficiency and ergonomic benefits. Low noise generation can also lead to saving of lot of resources deployed to dampen the noises. In order to capture the acoustic responses of the system and to improve the design based on acoustic responses, a comprehensive analysis of newly developed driveline housings (clutch housing & transmission housing) was simulated. Using Hyper works ERP (Equivalent Radiated Power) tool we have calculated the dB levels on the powertrain components. Excitations are given at the mounting locations to capture noise effects over a frequency range of 0 Hz to 6500 Hz. Based on the results of ERP simulation, areas of high noise generation are identified on the driveline components, where dB values are at peak levels. In the dB vs Frequency graph, peak points are chosen and the locations corresponding to that peak values. In the next step as corrective actions, such high dB zones are modified by adding bead profiles and strengthening the regions using rib patterns at the given locations and similarly the zones for weight optimization are identified. An, improved model is developed using the corrective actions as per the suggestions of ERP simulation. To further strengthen the analysis approach, the components are tested physically and noise levels are measured and significant improvements are observed in the design. Thus a comprehensive and well proven methodology has been developed to design the powertrain components based on acoustic responses.