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Development and Validation of a Control-Oriented Analytic Engine Simulator

FERRARI S.p.A.-Matteo Cucchi, Nicola Silvestri
University of Bologna-Alessandro Brusa, Nicolo Cavina, Nahuel Rojo
  • Technical Paper
  • 2019-24-0002
To be published on 2019-08-15 by SAE International in United States
Due to the recent anti-pollution policies, the performance increase in Spark Ignition (SI) engines is currently under the focus of automotive manufacturers. This trend drives the control systems designers to investigate accurate solutions and build more sophisticated algorithms to increase the efficiency of this kind of engines. The development of a control strategy is composed by several phases and steps, and the first part of such process is typically spent to define and validate the logic of the strategy. During this phase a light engine simulator is particularly useful, since it allows producing robust combustion synthetic data with a low calibration and computational effort. In the first part of this paper the description of a control-oriented analytic engine simulator (ANESIM) is carried out. The latest results about the zero-dimensional knock model presented in a previous paper and some interesting analytical equations that define the main mean combustion indexes trend (like the maximum in-cylinder pressure, the MFB50, the Indicated Mean Effective Pressure) as functions of the engine speed and load are analyzed for the entire engine…
 

An embedded simulation approach for tolerance analysis on vehicle propulsion subsystem

GM Global Propulsion Systems-Claudio Mancuso, Domenico Cavaiuolo, Giuseppe Corbo
Gamma Technologies LLC-Iakovos Papadimitriou
  • Technical Paper
  • 2019-24-0079
To be published on 2019-08-15 by SAE International in United States
An increasing demand for reducing cost and time effort of the design process via improved CAE (Computer-Aided Engineer) tools and methods has characterized the automotive industry over the past two decades. One of the main challenge regarded the effective simulation of a vehicle’s propulsion system dealing with different physical domains: several examples have been proposed in literature mainly based on co-simulation approach which involves a specific tool for each propulsion system part modeling. Nevertheless, these solutions are not fully suitable and effective to perform statistical analysis including all physical parameters. In this respect, this paper presents the definition and implementation of a new simulation methodology applied to a propulsion subsystem. The reported approach is based on the usage of Synopsis Saber as dominant tool for co-simulation: models of electronic circuitry, electro-mechanical components and control algorithm are implemented in Saber to perform tolerance analysis; in addition, a dynamic link with engine plant model developed in GT-Suite environment has been established via a dedicated procedure. Moreover, a HPC Grid (High Performance Computing Grid) is used with the…
 
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Optimal Pressure Relief Groove Geometry for Improved NVH Performance of Variable Displacement Oil Pumps

Ford Motor Company-Abdelkrim Zouani, Vidya Marri
Published 2019-06-05 by SAE International in United States
Variable Displacement Oil Pump (VDOP) is becoming the design of choice for engine friction reduction and fuel economy improvement. Unfortunately, this pump creates excessive pressure ripples, at the outlet port during oil pump shaft rotation, causing oscillating forces within the lubrication system and leading to the generation of objectionable tonal noises and vibrations. In order to minimize the level of noise, different vanes spacing and porting geometries are used. Moreover, an oil pressure relief groove can be added, at the onset of the high pressure port, to achieve this goal.This paper presents an optimization method to identify the best geometry of the oil pressure relief groove. This method integrates adaptive meshing, 3D CFD simulation, Matlab routine and Genetic Algorithm based optimization. The genetic algorithm is used to create the required design space in order to perform a multi-objective optimization using a large number of parameterized groove geometries. Results of this optimization method are discussed and a design guideline for the oil pressure relief groove is disclosed.
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Investigation and Improvement of a Bouncing Torsional Vibration in Automotive Dual Mass Flywheel by Combining Testing and 1D CAE Modeling Approach

Doshisha University-Nobutaka Tsujiuchi, Akihito Ito
EXEDY Corp.-Yoshihiro Yamakaji, Daisuke Yoshimoto
Published 2019-06-05 by SAE International in United States
Dual mass flywheel (DMF) is a well-known isolation system for vehicle drivetrain. DMF has two typical elastic energy storage systems: long travel arc springs and in-series spring units (including two or more springs) and sliding shoes connected in series. DMF has such complex nonlinear characteristics as torque-dependent torsional stiffness and rotational speed-dependent hysteresis friction due to its dependency of centrifugal force that is applied to components and radial force of springs. Because of this complexity, sub-harmonic vibration (SHV) may occur under certain circumstances, such as under light-load and high-rotational conditions. In general, since SHV’s frequency is 1/2 or 1/3 of the engine’s combustion frequency and may cause human discomfort, DMF must be designed robust against such nonlinear vibration. In this paper to reduce the SHV occurrence and to show a more robust design indicator, the SHV causing the mechanism is researched by testing and 1D CAE modeling. In detail, DMF interior behavior in high-speed rotation is clarified with high-speed cinematography on a test bench, and high-resolution relative torsional angle of DMF is obtained by evaluating…
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Vibro-Acoustic Analysis for Modeling Propeller Shaft Liner Material

General Motors-Rajith R. Jayaratne, Yu Liu, Mark Gehringer, Jeff Rayce, Wallace Hill
Published 2019-06-05 by SAE International in United States
In recent truck applications, single-piece large-diameter propshafts, in lieu of two-piece propshafts, have become more prevalent to reduce cost and mass. These large-diameter props, however, amplify driveline radiated noise. The challenge presented is to optimize prop shaft modal tuning to achieve acceptable radiated noise levels. Historically, CAE methods and capabilities have not been able to accurately predict propshaft airborne noise making it impossible to cascade subsystem noise requirements needed to achieve desired vehicle level performance. As a result, late and costly changes can be needed to make a given vehicle commercially acceptable for N&V performance prior to launch.This paper will cover the development of a two-step CAE method to predict modal characteristics and airborne noise sensitivities of large-diameter single piece aluminum propshafts fitted with different liner treatments. The first step is the use of a traditional CAE software to calculate prop surface response. The second step is a boundary element simulation to calculate prop surface radiated noise under the excitation obtained from the first step. Finally, acceleration and acoustic test data are presented to assess…
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Determination of Vehicle Interior Noise due to Electric Motor

University of Michigan- Dearborn-John G. Cherng
Published 2019-06-05 by SAE International in United States
This paper introduces an approach that uses a statistical energy analysis (SEA) method for prediction of noise in the vehicle cabin from an electric motor sound source placed in the engine compartment. The study integrates three different physics, namely, electromagnetics, harmonics, and acoustics. A 2004 Prius permanent magnet synchronous motor with an interior permanent magnet was used for performing the integrated CAE analysis, as the motor’s design details were readily available. The Maxwell forces on the stator teeth were first calculated by an electromagnetic software package. These forces were then mapped into a finite element model of the motor stator to predict the velocity profiles on the stator frame. Velocity profiles were considered as boundary conditions to calculate sound pressure levels and the equivalent radiated sound power level in the acoustic environment. The calculated sound power was used as an input sound source to perform SEA simulation to determine sound pressure level at the driver’s right ear in the passenger compartment. A sensitivity analysis of the motor design was performed on the sound power level…
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A Process to Improve Passenger Vehicle Sound and Vibration Quality Using a Combination of SPC and CAE Analysis

Altair Engineering-Xiaolei Song
Bruel & Kjaer North America, Inc.-Giovanni Rinaldi
Published 2019-06-05 by SAE International in United States
A manufacturer of automotive equipment set out to implement a process to include sound and vibration quality targets for powertrain and road noise. CAE models have been successfully used in the early phase of the vehicle development process, but the use of these models to assess the customer’s subjective sound and vibration experience is often missing. The goal here was to use a CAE model driven by sound and vibration quality targets for early identification of problem areas based on jurors’ preference. These quality targets were cascaded via Source-Path-Contribution (SPC), and optimizations were performed to meet the targets using the CAE model.
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Experimental Investigation on Gear Rattle Noise Reduction in Passenger Car

Maruti Suzuki India Limited-Devendra Kumar Khare, Abhishek Lakhanlal Vaishya, Archan Sunibhai Pujara, Radhe Krishna, Kingshuk Satpathy, Ved Prakash Choudhary, Anant Pandey
Published 2019-06-05 by SAE International in United States
Gear rattle noise reduction inside the passenger cabin is one of the major challenges for customer comfort enhancement. Therefore, it becomes a prime target during transmission design and development. Gear rattle is generated due to meshing teeth collision of free gears, which is caused due to torsional vibration of engine transferred through clutch. Vibrations are generated due to free gears teeth impact and are transferred to shaft, bearings and transmission housing. The sound absorption and structural vibration of transmission housing was optimized by changing the geometrical features of the transmission housing that affects radiated noise.Experimental approach for gear rattle noise reduction through transmission housing modification is described in this paper. Moreover, CAE method is also incorporated with the experiments for optimization of future vehicle transmission system designs.
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Interior Floor Engineering: The Dynamic-vs-Static-Stiffness Compromise

Autoneum Management AG-Flavio Pezzani, Philippe Godano, Francesca Ronzio, Roberto D'Amico
Published 2019-06-05 by SAE International in United States
When it comes to the design of multi-functional automotive interior floors, engineers face the challenging conflict between a dynamically-soft, NVH performing treatment, and a statically-stiff construction, which increases the perception of solidity. Nowadays, the former requirement is well-specified and advanced CAE tools exist to support performance prediction and engineering of the construction. On the contrary, neither well-established requirements specify the compressional performance, nor defined CAE processes are available to support the engineer in its prediction.In this context, the aim of this paper is twofold. Firstly, insightful conclusions about the compression behavior of typical interior floor materials are drawn by means of tests carried out both at sample- and part-level. Such an analysis allows highlighting a clear direction towards meaningful assessment of the mechanical characteristics of the floor. Secondly, the paper focuses on how CAE tools can support part-level engineering in dealing with the dynamic vs static-stiffness compromise. Specifically, simulation results show that non-linear finite element simulations can support an accurate assessment of the floor deflection during compression, and yet they can be exploited in combination…
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Design Software Identifies a Product's Performance Tradeoffs

  • Magazine Article
  • TBMG-34602
Published 2019-06-01 by Tech Briefs Media Group in United States

Designing any product — from complex car parts to wrenches — is a balancing act with conflicting performance tradeoffs. Making something lightweight, for instance, may compromise its durability.