NVH CAE Concept Modelling and Optimization at BMW

VECOM-CLEPA Dr. L. Cremers 06.06.
2011 Page 1
VECOM Suppliers Workshop: Vehicle Concept Modeling in the Automotive Sector.
NVH CAE concept modeling and optimization at BMW.

06.06.2011 Dr. L. Cremers VLEVA, Brussels
VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 2
NVH CAE concept modeling and optimization. Overview.

- Introduction to the BMW Group and the structural dynamics and vibrations team. - Global static car body stiffness modeling and optimization with Beams and Shells concept models. - Full vehicle vibro-acoustic comfort modeling. - Structural intensity modeling. - Full vehicle vibration comfort simulation using multibody simulation models - Aero-acoustic modeling.
NVH CAE concept modeling at BMW. Introduction to the BMW Group.

BMW Group brands
Husqvarna BMW Motor-cycles
Mini Mi i
BMW
Rolls-Royce R ll R
Headquarters Munich
Production & assembly
FIZ R&D centre in Munich
Introduction to the team. Structural dynamics and vibrations.

Vehicle architecture and integration Acoustics and vibrations Structural dynamics and vibrations Targeting, analyzing and monitoring static and dynamic car body stiffness and vibration levels for optimal full vehicle NVH performance throughout the complete development phase. Early-phase FE car body concept modeling and optimization. Static car body testing, modal analysis and vibration comfort measurements of complete vehicles, car bodies and components.
local and global car body static stiffness. natural frequencies and mode shapes. Local dynamic stiffness at car body connection points sensitivity analysis based on modal data. FE optimization of the car body structure. analysis of panel vibrations (ERP).

Structural dynamics and vibrations. Activities throughout the development phase.

Project phase/tools:
Concept phase Development phase Series production
Plant quality monitoring
MB/FEM Simulation Hybrid modelling (Assembly and substructuring)

Prototypes and concept cars
Testing (Modal analysis, holography, 4-poster ...)
Structural dynamics and vibrations. FE concept modelling and optimization.

Beams and shells FE concept models
original beam cross section equivalent standard cross section
B
H t1
t2
optimized equivalent cross section
First functional assessments of car body concepts

Goal of the optimisation is to reach a minimal car body weight... weight
considering functional design targets for the complete car
... by varying the constructed space...

e.g. package constraints
... while respecting design constraints
using the beam cross section dimensions height, width and plate thickness as design variables
In the past: Cross Section substituted with equivalent Beam Library property
dim1
dim2
dim4
dim3
Desvars: dim1dim4
State of the art: Exact geometrical description with Nastran PBxSECT

w
t(3)
h t(2)
t(1)
Desvars: w, h, t(1)t(3)
Structural dynamics and vibrations. Beams and shells FE concept models. Example with ABCS-modelling.
original beam cross section geometry!
Beams & shells FE concept model
Optimization, Optimization Nastran sol200 (10

load cases, well over 1500 design variables)
statics dynamics crash roll-over
freq. separation steering wheel
Nastran f06 results file Nastran .f06-file

statics dynamics freq. sep. crash roll-over steering wheel weight
Optimization history
Optimization results
statics dynamics
freq. sep.
crash
roll-over steering wheel
weight

Design model: creation of large number of desvars, geometrical responses and constraints with OptiCenter
Application region
Desvars for outer dimensions and wall thi k ll thicknesses Geometrical responses and constraints

Design model: Creation of functional responses, constraints and objective function with OptiCenter
Responses and constraints for dynamic stiffnesses Responses and constraints for static stiffnesses tiff Weighting factors

Post Processing: Visualization of optimization results
Changes in construction space
Changes in wall thickness

Application case: BMW 3-Series with Al car body
Material switch
Steel Al

Change in weight and functional performance after one-to-one material switch
Masse[kg] Statik[%] Dynamik[Hz]
11,9
64,4
E90Alu E90Aluoptimiert
235,1

Aluminum car body optimization Target: Equal global static and dynamic car body stiffness in comparisson with steel body. Design space: full car body beam structure (red) Geometric constraints: construction space max. +50%



Rocker panel Roof carier

Masse[kg] Statik[%] Dynamik[Hz]
7,2 1,2
11,9
64,4
E90Alu E90Aluoptimiert
At the cost of construction space!

168,6
235,1
in what areas is it usefull to introduce light weight materials?
Full vehicle vibro-acoustic comfort. Sound sources.

Target of NVH engineering: optimal vibro-acoustic comfort for driver and passengers.
Wind excitation
Engine
Exhaust Gearbox Road excitation Drive shaft and differential
10
Full vehicle vibro-acoustic comfort. Vibro-acoustic car body transmission paths.

Important aspects:
local dynamic stiffness at excitation p points. panel radiation acoustic field vibro-acoustic coupling
SPL at drivers ear Panel radiation
Car body excitation
Full vehicle vibro-acoustic comfort. Local dynamic stiffness FE modeling.
Local vibration due to harmonic load at engine mounts (225 Hz)
11
Local resonance problem Point mobility engine mount
x-direction: Red z-direction: Blue Target: Black

x-Richtung
50 100 100 200 -2 0 -6 -2 -3 -4 -3 +6 +8 -2 +4 -4 200 400 0 0 -6 -4 -4 -10 -8 +7 +1 -7 0 -9 50 100 +9 +12 +8 +10 +4 +5 +10 +8 +4 +7 0 +2
y-Richtung
100 200 +18 +12 +8 -1 +3 +12 +11 +7 +4 +8 +2 +1 200 400 +4 +12 +8 -5 +6 +12 +12 +8 +3 +17 +1 +4 50 100 +7 +15 +8 +6 +8 +11 +22 +7 +10 +6 +9 +10
z-Richtung
100 200 +7 +5 +2 +2 +11 +12 +17 +6 +7 +2 +5 +6 200 400 +8 -4 +2 +2 +12 +12 +8 +3 +10 0 0 +6
Frontal Strut Tower Front Axle Mount, Front Screw Front Axle Mount, Middle Screw Front Axle Mount, Rear Screw
+12 -1 -4 -2 -3 0 +2 +8 +9 -2 +7 -22
Target violation in dB Strong targetviolation Target violation, violation check significance
Engine Mounts Gear-box Bridge Drve Shaft Mount Rear Axle Mount, Front Screw Rear Axle Mount, Rear Screw Rear Shock Absorber
OK.
Rear Strut Tower Tunnel bridge screw
12
Full vehicle vibro-acoustic comfort. Panel vibration FE modeling Radiated power.

Example of Panel Vibration at 60 Hz
Full vehicle vibro-acoustic comfort. Panel vibration FE modeling Radiated power.

Example for weak point in floor panel (excitation at gear-box bridge) Sum Floor Panel
Magnitude
Frequency
13
Full vehicle vibro-acoustic comfort. Vibrational energy flow through the car body.
How does the energy flow through the car body from excitation point towards the radiating panels?
SPL at drivers ear Panel radiation
Car body excitation
Structural intensity analysis. Time Domain Measurements.

High Resolution Measurement:
Example: Tube Frame Excitation
14
Structural Intensity Calculation. Time Domain Calculation.

Simulation Vibration Energy Flow.
Structural Intensity Calculation. Example Frequency Domain: Vehicle Underbody.

Initial configuration, real STI, detailed view.
15
Full vehicle vibration comfort simulation. Multi body simulation toolbox.

car body (rigid) car body (flexible)
engine / gearbox drive train
exhaust system (fl ibl ) h t t (flexible) Hinterachse Vorderachse

Tires
Full vehicle vibration comfort simulation. 4-poster test simulation.

Torsion load case
rigid body flexible body
Displacement (mm)
Vibration response at customer relevant car body positions
Frequency (Hz)
Bending load case

Acceleration (m/s2)
rigid body flexible body y
Frequency (Hz)
16
Full vehicle vibration comfort simulation. Engine idle comfort simulation.
[Hz] 16 14 12 10 8 6 4 2 0 0 5-7 Hz 1. MO 0,5. MO 200 400 engine idle rpm 550 600 9-11 Hz 1,5. MO 13 15 13-15 Hz
Engine roll Vehicle lateral Engine lateral / roll Vehicle roll on tire springs
700 800 [1/min]
Aero-acoustic modelling. Isosurface of constant velocity (BMW 3series).
17
Aero-acoustic modelling. Streamlines of the airflow around the car body.
Aero-acoustic modelling. Streamlines of the airflow around the car body.
18
Aero-acoustic modelling. Sound pressure level on the car body surface.
Aero-acoustic modelling. Sound pressure level on the car body surface.
19
Thank you for your attention.
Optimization result Global static and dynamic stiffness
Targets for statics not specified
Modell A
Delta Target
M Modell B
Delta Target
Delta D l A-B
Tunnel Rocker panel Tail center Tail longitudinal carrier Wheel house torsion Engine mount torsion Front vehicle cross bending 1. bending 1. torsion front vehicle torsion
20
Optimization history Global dynamic stiffness

target frequency
target frequency and feasibility region indicator
final frequency and mode number
initial frequency frequency history
weighting factor
Optimization history Global static stiffness

target stiffness
final stiffness and FE node number
target stiffness and feasibility region indicator
initial stiffness
stiffness history
21
Optimization history Weight
weight history
reference weight
Optimization history Pseudo-Crash
stress level reached in maximum loaded element and element number
max. allowable stress level (steel: 400 N/mm) and feasibility region indicator
22
Optimization history Mode separation
final frequency separation in Hz with mode-numbers of modes involved
minimal frequency separation in Hz between two selected modes and feasibility region indicator
Optimization history Steering wheel impedance
maximum normalized amplitude of steering wheel FRF
normalized steering wheel FRF amplitude by excitation between 10 and 40 Hz
23

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VECOM-CLEPA Dr. L. Cremers 06.06.

VECOM Suppliers Workshop: Vehicle Concept Modeling in the Automotive Sector.

NVH CAE concept modeling and optimization at BMW.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 2

NVH CAE concept modeling and optimization. Overview.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 3

NVH CAE concept modeling at BMW. Introduction to the BMW Group.

Husqvarna BMW Motor-cycles

Production & assembly

FIZ R&D centre in Munich

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 4

Introduction to the team. Structural dynamics and vibrations.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 5

Structural dynamics and vibrations. Activities throughout the development phase.

Plant quality monitoring

MB/FEM Simulation Hybrid modelling (Assembly and substructuring)

Testing (Modal analysis, holography, 4-poster ...)

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 6

Structural dynamics and vibrations. FE concept modelling and optimization.

optimized equivalent cross section

First functional assessments of car body concepts

... by varying the constructed space...

... while respecting design constraints

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 7

Structural dynamics and vibrations. FE concept modelling and optimization.

State of the art: Exact geometrical description with Nastran PBxSECT

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 8

original beam cross section geometry!

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 9

Structural dynamics and vibrations. FE concept modelling and optimization.

Beams & shells FE concept model

Optimization, Optimization Nastran sol200 (10

statics dynamics crash roll-over

freq. separation steering wheel

Nastran f06 results file Nastran .f06-file

roll-over steering wheel

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 10

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 11

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 12

Structural dynamics and vibrations. FE concept modelling and optimization.

Changes in construction space

Changes in wall thickness

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 13

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 14

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 15

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 16

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 17

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 18

Structural dynamics and vibrations. FE concept modelling and optimization.

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 19

Structural dynamics and vibrations. FE concept modelling and optimization.

At the cost of construction space!

in what areas is it usefull to introduce light weight materials?

VECOM-CLEPA Dr. L. Cremers 09.05.2011 Page 20

Full vehicle vibro-acoustic comfort. Sound sources.

Exhaust Gearbox Road excitation Drive shaft and differential