Vibratiile Din Cutiile de Viteze

Ir.
Peter Segaert Siemens Industry Software nv Leuven, Belgium
Prediction of Gear Noise & Vibration through

3D Vibro-Acoustic Simulation
Siemens PLM Web Seminar - 25.03.2015
Unrestricted Siemens AG 2014 All rights reserved.
Smarter decisions, better products.
AGENDA
Getriebe : Vibro-Akustik & Simulation - Slide 2
INTRO : Gear Noise & Vibration => Rattle & Whine

PART 1 : Source Transfer Receiver Approach in
the Gear N&V Context
PART 2 : Source Modeling => Excitation Forces
PART 3 : Transfer Modeling => Vibration Simulation
PART 4 : Receiver Modeling => Acoustic Simulation
CONCLUSIONS
TECHNOLOGY APPENDIX : Numerical Methods for
Vibro-Acoustic Simulation

Page 2
2015-02-18
Siemens PLM Software
Intro Gear Rattle & Gear Whine
N&V Challenges for Gear Train Development

Rattle Condition
No Rattle Condition
Reduce Gear Rattle
Minimize Bearing Loads
Reduce Torsional Vibrations
Reduce Gear Whine

Page 3
2015-02-18
Intro Gear Rattle & Gear Whine
What is Gear Rattle and Gear Whine?

Whine
Rattle
What?
Stationary noise
Random noise
Load
At all torques
At no load or low torque
Induced by
Torque fluctuation in contact between

powered gears
Teeth impacts due to backlash at nonpowered gears
Key Factors
Transmission error
Variable gear meshing stiffness
Relative mesh phasing
System inertia
Drag torque / damping
Clearances

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2015-02-18
AGENDA

CONCLUSIONS

Page 5
2015-02-18
Part 1 S-T-R Approach for Gear N&V
The Source Transfer Receiver Model (1)

Acoustics = study of generation, propagation and reception of

compressional waves in an elastic medium (fluid or solid)

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2015-02-18
The Source Transfer Receiver Model (2)

Sound Source
Flow-induced
pressure
variations
Mechanical
vibrations
System Transfer
Receiver
FEM Vibro-Acoustics
Standard
BEM Vibro-Acoustics
Advanced
EM forces
RAY Acoustics
Test data

Page 7
2015-02-18
The S-T-R model in context of Gearbox NVH

Source
Transmitter
Receiver
Gear interaction forces

For rattle
Transmission Casing
Vibration
Radiated Noise
Bearing forces
For rattle and whine
Vibration response due to

bearing loading
Acoustic response due to

casing vibration

Page 8
2015-02-18
CAE-based NVH Modeling for Gears-Gearbox

Simulation of gear
interaction forces
1D - 3D - (Test)
Simulation/derivation
of bearing forces
Structural vibrations
3D (Test)
Predict sound radiation

3D FEM/BEM
Page 9
2015-02-18
CAE Systems Approach for Rattle & Whine

=> Source model to obtain tooth interacting forces and
MBS model
bearing loads
1D LMS AMEsim, extended with 3D sub-models (rattle)

3D LMS Virtual.Lab/Motion for rattle
3D LMS Virtual.Lab/Motion for whine
Gear contact models
LMS Samcef Mecano
Structural FE model
=> Structural transmitter model to obtain casing vibrations

3D LMS Virtual.Lab/NVH based on Structural FEM (NX NASTRAN &
LMS Samcef solvers)
=> Acoustic receiver model to obtain radiated noise
Acoustic model
3D LMS Virtual.Lab/Acoustics BEM / FEM AML

Page 10
2015-02-18
Real-life
VA Process Flow Chart


Page 11
2015-02-18
Vibro-Acoustic Simulation Process Flow


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2015-02-18
VA Simulation Process Flow for Gear Trains (1)

Excitation forces => Most important and complex step

Forces between gear teeth
Transmitted to bearings and housing
Obtained from Test, 1D System Analysis or 3D MultiBody Dynamics , mostly in time domain format
Typical cases : gear rattle and gear whine
Structural Transfer Path = structural filter
Structural FE model of gearbox housing
Structural dynamic behaviour described by structural
modes (eigenfrequencies / eigenmodes)
Excitation forces transformed from time to frequency
domain (FFT techniques)
Forced response analysis in frequency domain returns
vibration shape of gearbox housing
Page 13
2015-02-18

Acoustic Transfer Path = geometrical filter

BEM surface mesh or FEM AML mesh to model gearbox
exterior surface interior surface is not relevant for sound
radiation (if no holes are present)
Vibration data is mapped from the structural mesh to the
acoustical mesh only normal component is relevant
Acoustic BEM or Acoustic FEM analysis in frequency
domain
Acoustic Response
ATV [Acoustic Transfer Vector] approach is often used for
gearbox acoustic analysis
Specific methodology for fast analysis of multi-RPM
loadcases (excitation with waterfall spectra) see later
Page 14
2015-02-18


Page 15
2015-02-18
AGENDA

1D Source Modeling with AMEsim
3D Source Modeling with Virtual.Lab Motion

CONCLUSIONS

Page 16
2015-02-18
Part 2 Source Modeling = Excitation Forces

Source
Transmitter
Receiver

For rattle
Transmission Casing
Vibration
Radiated Noise
Bearing forces

bearing loading

casing vibration

Page 17
2015-02-18
Part 2 Source Modeling using 1D Simulation
1D Source Modeling for Rattle (1)

Flow chart
AMEsim
model
Gear contact
forces
Rattle metric
Rattle
assessment
1D AMEsim model of torsional system

Assessment of rattle severity based on rattle metrics (not actual noise level)
No RATTLE
RATTLE

Page 18
2015-02-18
1D Source Modeling for Rattle (2)

Sensitivity study to identify important parameters for rattle (clearances, )
clearance 01
clearance 02
clearance 03
clearance 04
clearance 05
clearance 06
clearance 07
clearance 08
clearance 09
clearance 10
rattle indicator
0.007
0.240
0.001
0.830
0.060
0.280
0.411
0.150
0.214
0.161

Page 19
2015-02-18
1D/3D Source Modeling for Rattle

Source related rattle simulations in 1D (+3D)

Extend 1D Amesim models with 3D sub-models
Allows calculation of bearing forces due to gear interaction forces
Bearing forces can be applied to gearbox casing model
OK for rattle
NOK for whine because TE is function of 3D effects (bending, misalignment,
coupling of casing modes with shaft modes,)
Gear contact
force
Bearing forces
3D sub-model

Page 20
2015-02-18
Lamborghini 1D Driveline Example

Gear Clunk
Paper presented in 2013, in Munich, at the

LMS Automotive conference

Page 21
2015-02-18
Lamborghini 1D Driveline Target settings

Gear Clunk

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2015-02-18
Lamborghini 1D Driveline - Transmission modeling

Gear Clunk

Page 23
2015-02-18
Lamborghini 1D Driveline - Tip-out simulation

Gear Clunk

Page 24
2015-02-18
Lamborghini 1D Driveline Clunk simulation

Gear Clunk

Page 25
2015-02-18
Lamborghini 1D Driveline - Side shafts stiffness

Gear Clunk

Page 26
2015-02-18
Lamborghini 1D Driveline - Clunk test validation

Gear Clunk

Page 27
2015-02-18
Lamborghini 1D Driveline - Clunk test validation

Gear Clunk

Page 28
2015-02-18
AGENDA

1D Source Modeling with AMEsim
3D Source Modeling with Virtual.Lab Motion

CONCLUSIONS

Page 29
2015-02-18
Part 2 Source Modeling using 3D Multi-Body Simulation
Remember Gear Rattle ?

Gear Rattle
Whine
Rattle
What?
Stationary noise
Random noise
Load
At all torques
Induced by

powered gears
Key Factors
Transmission error
System inertia
Clearances

Page 30
2015-02-18
What is Gear Rattle (1) ??

Gear Rattle
Rattle Condition
No-Rattle Condition
Rattle is an audible phenomenon common among manual gearboxes

Experiments show it occurs at low RPM range and high load conditions
Sound pressure colormaps show the rattle as wide band frequency range
Page 31
2015-02-18

Gear Rattle
Gear rattle is caused by the uncontrolled vibration of loose gears

Non-power transmitting gears are free to move within boundary limits
- tangential clearance (backlash) between the teeth of different gears
- radial and axial clearance between gear and shaft.
- The movement of these gears is stopped by the presence of other gears

and/or shaft and causes metal-to-metal impacts.
- The impact forces generate a wideband frequency content.
Impacts are transferred to the shaft bearings which excite the gearbox
housing, which starts to vibrate and acts as a noise radiator.
The directly radiated noise which is generated at the gear teeth is neglected by the
filtering effect of the gearbox housing
It is supposed that the tangential impacts are most important in the excitation
mechanism.
Page 32
2015-02-18

Gear Rattle
Driving force = rotational speed fluctation caused by combustion pulsations
100 % fluctuation (rattle)
0 % fluctuation (no rattle)

Housing vibrations due to rattle
100% fluctuation leads to maximum rattle

0% fluctuation leads to an ideal performance
Area in between defines rattle intensity
Page 33
2015-02-18
Gear Rattle Simulation for FIAT Manual Gearbox

Rattle Simulation

Page 34
2015-02-18
Gear Rattle Simulation (2a) Loading forces

Rattle Simulation
Loading forces on bearings/housing calculated by

Multi-Body Dynamics Model in Virtual.Lab Motion
5th gear is engaged
Flywheel rotation speed is enforced
to model fluctuations
Wheel/road interaction represented
by applied torque
Sampling freq. = 10kHz

Page 35
2015-02-18
Gear Rattle Simulation (2b) Loading forces

Rattle Simulation
3D Multi-Body Modeling : gear modeling incl. micro-geometry

Micro-geometry
Misalignments
Preprocessing: detailed gear meshing analysis
static TE = f (T, , , d)
Meshing Stiffness Table
Assembly Multibody model
T = transmitted torque
= position on mesh cycle
= misalignment in plane of
action
d = center distance
Post-processing

Page 36
2015-02-18
Gear Rattle Simulation (3) Excitation forces

Rattle Simulation
Multi-Body Dynamics model excited by experimental data

Page 37
2015-02-18
Gear Rattle Simulation (4) Housing vibrations

Rattle Simulation
Surface vibrations computed using Forced Response on structural

model of gearbox housing
Housing vibrations can be monitored by placing virtual
accelerometers (point of interests) on the housing
flexible body
simulation

Page 38
2015-02-18
Remember Gear Whine ?

Whine Simulation
Whine
Rattle
What?
Stationary noise
Random noise
Load
At all torques
Induced by

powered gears
Key Factors
Transmission error
System inertia
Clearances

Page 39
2015-02-18
What is Transmission Error ?

Whine Simulation
Transmission error (TE)

Primary cause of whine noise
Defined as the difference between
actual and theoretical contact position
Typically measured through a
specialized test-up for a specific gear
pair
Te = rpmout rpmout ,theoretical = rpmout rpmin tr

Page 40
2015-02-18
Variable Gear Mesh Stiffness

Whine Simulation
Modifications w.r.t. involute geometry can be used to counter the effect of

variable gear meshing stiffness
Transmission error
Transmission error, unmodified profile
Profile modification was optimized for this

torque
Transmission error, tip and root relief

Increasing torque
Page 41
2015-02-18
Roll angle (= proportional to time)

Manufacturing and Assembly Errors

Whine Simulation
Planetary Gears
Ring eccentricity error

sidebands at multiples of planet carrier

Page 42
2015-02-18
Ring-planet gear contact force [dB]
Sun eccentricity error

sidebands at multiples of sun planet carrier
GMF
Frequency
Advanced Gear Modeling with Virtual.Lab Motion

Whine Simulation
Gear whine is caused by:

Deviations from theoretical involute profile
Dedicated tool to mesh teeth + Variable meshing stiffness
standard LMS Virtual.Lab
meshing
Tooth continuously loaded at different radius

Gear meshing frequency and harmonics
Variable flexibility of supporting structure
Frequency sidebands
Solving in LMS
Virtual.Lab Motion
Gear force (dB)
Dedicated tool:
Driving NX Nastran
Automatic postprocessing
Frequency
Page 43
2015-02-18
AGENDA

CONCLUSIONS

Page 44
2015-02-18
Part 3 Transfer Modeling = Surface Vibrations

Source
Transmitter
Receiver

For rattle
Transmission Casing
Vibration
Radiated Noise
Bearing forces

bearing loading

casing vibration

Page 45
2015-02-18
Gear Rattle Simulation Process Flow Chart

Rattle Simulation

Page 46
2015-02-18

Rattle Simulation
Surface vibrations computed using Forced Response on structural

model of gearbox housing
Housing vibrations can be monitored by placing virtual
accelerometers (point of interests) on the housing
flexible body
simulation

Page 47
2015-02-18

Rattle Simulation
Waterfall image of virtual acceleration at housing surface

Page 48
2015-02-18
AGENDA

CONCLUSIONS

Page 49
2015-02-18
Part 4 Receiver Modeling = Sound Radiation

Source
Transmitter
Receiver

For rattle
Transmission Casing
Vibration
Radiated Noise
Bearing forces

bearing loading

casing vibration

Page 50
2015-02-18
Gear Rattle Simulation Process Flow Chart

Rattle Simulation

Page 51
2015-02-18
Gear Rattle Simulation (6) BEM ATV analysis

Rattle Simulation
Acoustic BEM analysis using Acoustic Transfer Vectors

Boundary Element method for external
radiation
Simplified surface mesh for gearbox housing
Geometry details , e.g. small ribs, have been
removed
Holes are closed
Acoustic Transfer Vector approach

Compute ATVs once depends on surface
geometry, frequency and microphone locations
Re-use ATVs data for each RPM case with
different vibration frequency spectrum
Efficient for waterfall-type excitation spectra

Page 52
2015-02-18

Rattle Simulation
Acoustic BEM analysis using Acoustic Transfer Vectors
p( ) = j [ MATV ( )] {MPF( )}

Page 53
2015-02-18

Rattle Simulation
Waterfall image of sound pressure in virtual microphone location
Rattle frequency band is captured with comparable sound pressure level

Page 54
2015-02-18
SUMMARY
VibroAcoustic Simulation of Gearbox Noise
Full system vibro-acoustic simulation

= everything from source to receiver is modeled
MBS model
Full system simulation allows to simulate changes on

Source, e.g. clearances
Transmitter, e.g. structural casing modifications
Structural FE model
Full system vibro-acoustic simulation requires

MBS model (LMS Virtual.Lab Motion)
Structural FE-model (NX Nastran, Ansys,)
AcousticFEM/BEM model (LMS Virtual.Lab Acoustics)
Full system simulations are typically used for whine analyses
because TE is sensitive to 3D effects (bending, misalignment,
coupling of casing modes with shaft modes,)
Acoustic model

Page 55
2015-02-18
SUMMARY
VibroAcoustic Simulation of Gearbox Noise
Vibro-acoustic simulation using FEM/BEM methods is a tool to predict

noise radiation from gear trains and transmissions
Typical NVH analysis process is to study a single phenomenon, e.g. gear
rattle or gear whine, and to compute radiated noise from the gearbox
housing as the final step
Crucial and most difficult step is accurate description of excitation
forces (gear contact forces, tooth stiffness & geometry etc..)
Therefore, transmission noise analysis mostly involves specialists from
multiple disciplines :
Multi-Body Dynamics
Structural Analysis
Vibro-Acoustics
Page 56
2015-02-18
AGENDA

CONCLUSIONS

Page 57
2015-02-18
Technology Appendix
Finite Element & Boundary Element Techniques

FEM-BEM
FEM => Acoustic Finite Element Method

Wave acoustics = numerical solution of discretized form of wave equation (time
domain) or Helmholtz equation (frequency domain)
Volume discretization of acoustic domain (3D solid elements)
Natural choice for interior acoustics see later for exterior acoustics
Sparse matrix formulation => Computationally less intensive with respect to computer
resources
BEM => Acoustic Boundary Element Method

Wave acoustics = numerical solution of discretized form of wave equation (time
domain) or Helmholtz equation (frequency domain)
Discretization of acoustic domain bounding surfaces only (2D surface elements)
Natural choice for exterior acoustics (infinite domain !)
Dense matrix formulation => Computationally very intensive with respect to computer
resources
Page 58
2015-02-18
Technology Appendix
FEM-BEM : What are the differences (1) ??

FEM-BEM
Finite Element Method
Higher modeling effort (3D mesh)

Modal-based approaches possible
Sparse matrix formulation
Well-known formalism
Heterogeneous fluid
Boundary Element method
Lower modeling effort (2D mesh)

No modal-based approach
Dense matrix formulation
Less-known formalism
Homogeneous fluid only

Page 59
2015-02-18
Technology Appendix

FEM-BEM
BEM mesh for exterior acoustic radiation

simulation
Modeling effort = only boundary mesh
representation needed for the vibrating
surfaces
Accuracy = Sommerfeld radiation condition
at infinity is guaranteed by use of Greens
kernel function - no radiated power will be
reflected from infinity
Solver Performance
No need to model the air volume =>
relatively small models (+), typically
10,000 to 40,000 elements
BEM 2D surface mesh for a

PKW engine
Fully populated dense system matrix (-)

Page 60
2015-02-18
Technology Appendix

FEM-BEM
o FEM mesh for exterior acoustic radiation

simulation
o Modeling effort for exterior radiation
o vibrating engine surface representation (BEM mesh) +
o an outer boundary limit of the FEM domain +
o fill volume in between with 3D fluid elements
o
Accuracy = Sommerfeld radiation condition is

satisfied by a special treatment applied at the
outer FEM boundary, representing the infinite
domain of the air around the engine => See later!
Solver Performance
o
FEM outer boundary usually far away from

engine => larger models (-), typically 100,000
to 500,000 elements
FEM 3D volume mesh for a

PKW engine
Sparsely populated system matrix (+)

Page 61
2015-02-18
Technology Appendix
The Acoustic Transfer Vector [ATV] concept

ATV-MATV
Since acoustic system can be considered as a linear system:

ATV= linear input-output relationship between:
- mechanical surface vibrations
- sound pressure at a point in space
ATV depends on following parameters:
Geometry of the vibrating surfaces
p () = <ATV()> {vn () }
Acoustic treatment of the surface

Microphone (field point) location
Frequency
Physical properties
ATV is independent of structural

vibrations => Independent of RPM
load case
Page 62
2015-02-18
Technology Appendix
The Acoustic Transfer Vector [ATV] concept

ATV-MATV
p () = <ATV()> {vn () }
Needed data
Acoustic model (mesh, field point, symmetry planes)

Acoustic Transfer Vector
Velocity BC based on structural results
Results
Function curves: pressure, velocity, power

Waterfall maps (results depending onfrequency and the RPM)
Same ATVs are re-used for each RPM case

Page 63
2015-02-18
Technology Appendix
Extension to Modal ATVs

ATV-MATV
p () = <ATV()> {vn () }
{vn () } = j {un () }
= j [] {MRSP}
p () = j <ATV()> [] {MRSP}
p () = <MATV()> {MRSP}
Required data
Acoustic model (mesh, field point, symmetry planes)

Acoustic transfer vector computed by SYSNOISE
Structural modal participation factors
Structural modes
Results
Function curves: pressure, velocity, power

Waterfall maps (results depending onfrequency and the RPM)
Same Modal ATVs are re-used for each RPM case

Page 64
2015-02-18
Technology Appendix
Modal ATV Process Flowchart

ATV-MATV
Structural
Loads
Vibration
Response
prediction
Structural
Modes
Structural
Mapping
Transfer Data
Case
Transferred
Structural
Modes
MRSP
FE model
Mesh
Preprocessing
Acoustic
mesh
ATV
SOLVER
MODAL ATV
Acoustic
Response
response
ATV

Page 65
2015-02-18
Technology Appendix
Modal ATV Process Flowchart (2)

ATV-MATV
Structural
Loads
Structural
Mesh
Structural
Modes
Vector
Processing
Vibration
Response
Fast Multiplication of
new Loads X System
Transfer (ATV)!
structural
acoustical
Acoustic Boundary
Conditions
BEM Mesh
Field Point
Mesh
ATVs
Pressure
Response
Unit Velocity BC for each

frequency
Can be re-used for all
RPMs!

Page 66
2015-02-18

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Ir.

Peter Segaert Siemens Industry Software nv Leuven, Belgium

Prediction of Gear Noise & Vibration through

Smarter decisions, better products.

INTRO : Gear Noise & Vibration => Rattle & Whine

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Intro Gear Rattle & Gear Whine

N&V Challenges for Gear Train Development

Reduce Gear Rattle

Minimize Bearing Loads

Reduce Torsional Vibrations

Reduce Gear Whine

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Intro Gear Rattle & Gear Whine

What is Gear Rattle and Gear Whine?

At no load or low torque

Torque fluctuation in contact between

Teeth impacts due to backlash at nonpowered gears

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

INTRO : Gear Noise & Vibration => Rattle & Whine

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V

The Source Transfer Receiver Model (1)

Acoustics = study of generation, propagation and reception of

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V

The Source Transfer Receiver Model (2)

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V

The S-T-R model in context of Gearbox NVH

Gear interaction forces

Vibration response due to

Acoustic response due to

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V

CAE-based NVH Modeling for Gears-Gearbox

Predict sound radiation

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V

CAE Systems Approach for Rattle & Whine

=> Source model to obtain tooth interacting forces and

1D LMS AMEsim, extended with 3D sub-models (rattle)

=> Structural transmitter model to obtain casing vibrations

=> Acoustic receiver model to obtain radiated noise

3D LMS Virtual.Lab/Acoustics BEM / FEM AML

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V

VA Process Flow Chart

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V

Vibro-Acoustic Simulation Process Flow

Unrestricted Siemens AG 2014 All rights reserved.

Siemens PLM Software

Part 1 S-T-R Approach for Gear N&V