Failure Investigation and Geometric Optimization of Torsional Vibration Damper for Enhanced Durability and Noise Reduction in Automotive Drivetrain Systems

Internal Combustion engines exhibit multi-order vibrations caused by the inertial forces of reciprocating masses. These vibrations induce drivetrain resonance, negatively impacting occupant comfort and the durability of drivetrain components. Torsional vibrations, a critical subset of these oscillations, demand efficient damping mechanisms. Torsional Vibration Dampers are instrumental in minimizing such vibrations by tuning mass and frequency characteristics to prevent resonance. By splitting resonant frequencies into avoidable zones within the engine's operational range, TVD enhance vehicle performance and refinement by dampening the vibrations. Structurally, TVD comprise an inertia ring integrated with a damping medium, such as vulcanized rubber, which attenuates torsional oscillations by permitting controlled oscillation of the inertia ring. This study focuses on the failure investigation and the geometric optimization of oscillating masses of TVD for performance and durability improvements as a design correction. Three different shapes (Spreaded, Rectangular, and I-shaped) of oscillating masses were analysed. Analytical and experimental validations were conducted to evaluate the efficiency and durability. The deterioration of vehicle level noise studied at various intervals during test cycle. The recommended geometry demonstrated superior performance in terms of durability life and stress tolerance, attributed to its lower radius of gyration and enhanced load distribution. Additionally, the recommended shape showed minimal geometric package requirements for adapting the design, further contributing to its operational advantages. Results from this investigation underline the significant role of outer mass geometry in enhancing the functional reliability of TVD. The findings provide actionable insights for designing TVD with optimized performance, offering practical benefits for automotive drivetrain systems and improved overall vehicle noise level.