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The E-LINE™ Method - Integrating Squeak&Rattle Simulation
into the Virtual Design Process at Volvo Car Corporation
Jens Weber, Dr. Patrick Sabiniarz, Dr. Johan Sandström
ÅF
Dr. Casper Wickman
Volvo Car Corporation
6th European
Altair Technology Conference
April, 22nd - 24th, 2013
Turin, Italy Reference: SAE 2012-01-1553
a = f(t)
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E-LINE™ Method
Evaluation line
SAE 2010-01-1423 SAE 2012-01-1553
Squeak - rel disp in contact plane Rattle - rel disp in gap
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Stick-slip
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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0.2 mm
Impulse rate: 5/mm
∆ rel disp per pulse = 1/Impulse rate
Peak to peak amplitude
Stick-slip
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Peak to peak ?
Relative motion plot in contact plane
a = f(t)
x
y
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
Deformation scale factor: 100
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Relative motion plot in contact plane
T = 2 s
x
y
SAR-LINE direction
Main direction
Max principal Peak to Peak amplitude
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Displacement in LCS
along E-LINE (*.pch)
Modal transient
in OptiStruct
Simulation process
a = f(t)
Evaluation program
in Matlab
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Evaluation program
1
Impulse rate
Static (s)
Dynamic (d)
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Evaluation features
Contour plot in HyperView
0.5 1 1.5 2 2.5 3 3.5 40
0.02
0.04
0.06
0.08
0.1
0.12
0.14Displ. mag: mean of 30% highest values, Variant 1(d)
time [s]
dis
pla
cem
ent
[mm
]
1019
3005
5016
101010
103020
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Modal correlation S&R load data Stick-slip test Tolerance analysis
Rattle
Squeak Load definition
Material properties
a = f(t)
E-LINE implementation at VCC
E-LINE™ evaluation E-LINE™ creation
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
Modal correlation
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Mode # 1
Modal correlation
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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#1 #2 #3 #4
Mode # Test Simulation Foam/foil: updated
Young’ modulus
1 27.3 Hz 26.8 Hz
2 44.1 Hz 41.3 Hz
3 50.9 Hz 52.4 Hz
4 55.0 Hz 55.5 Hz
Updated material data for foam/foil
Modal correlation
Modal damping
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Test track A at 40 km/h
Test track B at 50 km/h
Test track C at 30 km/h
Test track D at 80 km/h
Test track E at 100 km/h
…
Recorded Squeak&Rattle load data
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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TABLED1
lc1_6131x.bdf
11
Recorded Squeak&Rattle load data
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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lc1_6131x.bdf
lc1_6132y.bdf
lc1_6133z.bdf
Deformation scale factor: 100
Recorded Squeak&Rattle load data
Test track A at 40 km/h
Test track B at 50 km/h
Test track C at 30 km/h
Test track D at 80 km/h
Test track E at 100 km/h
…
One S&R load case for
E-LINE simulation
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Stick-slip test at VCC
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Impulse Rate: 5.3/mm
Impulse Rate: 5.3/mm 1/Impulse Rate: 0.19 mm Min tolerance
Stick-slip test at VCC
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Impulse Rate: 3.2/mm
Stick-slip test at VCC
Impulse Rate: 3.2/mm 1/Impulse Rate: 0.31 mm Max tolerance
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Max tol
Min tol
Max tol
Min tol
Stick-slip test at VCC Dynamic squeak evaluation: mpP2P, mean value of 5 % HV
Max tol
Min tol
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Tolerance analysis
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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”Gap” direction
E-LINE creation script
Static tolerances Dynamic tolerances
+
”Rattle” direction
z ”Gap” = ”Rattle”
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
Tolerance analysis
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E-LINE creation
mesh based
E-LINE creation
geometry based
Master PID
3D line
Surface strip from tolerance
analysis defines normal direction.
The mesh does not always
represent the normal
direction correctly.
Slave PID
Static and dynamic tolerances
100% aligned!
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
Tolerance analysis
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E-LINE implementation at VCC
Solidity simulation
CAE / E-LINE
GSU
RD&T
Interior design CAD / Catia
Solidity test
Recorded load signal
Impulse rate from stick-slip test
Critical S&R interfaces
Styling
Ergonomics Packaging
Assembling
Tooling
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman
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Thank you for your attention!
J. Weber, Dr. P. Sabiniarz, Dr. J. Sandström
Dr. Casper Wickman