Finite Elements in Analysis and Design 41 (2004) 31 47

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A simulation approach for prediction and reduction of radiated noise of an air cleaner snorkel
David T. Huang
Department of Mechanical Engineering, Lunghwa University of Science and Technology, Taoyuan 333, Taiwan Received 20 September 2003; accepted 16 March 2004 Available online 8 June 2004

Abstract The objective of this report is to propose a simulation approach for developing and evaluating the die design modications that will minimize the radiated noise from an engine air cleaner snorkel. The procedure is rstly to use a commercial nite element program to compute the structural frequency response of a vibrating snorkel due to uniform internal acoustic pressure pulsation, then to use developed programs to estimate the surface acoustic intensity and mean-square vibration velocity, which are useful in identifying potential noise sources and the e ectiveness of structural modications for reducing vibration and radiated noise, for the vibrating snorkel. Various design alternatives that will minimize the structural breakout noise are considered. Initial alternatives are quickly evaluated using a simplied approach with beam elements representing the ribs. The detailed nite element models are used for nal evaluation. ? 2004 Elsevier B.V. All rights reserved.
Keywords: Air cleaner snorkel; Structural vibration; Radiated noise

1. Introduction When a structure vibrates at small amplitudes, it transmits its vibration energy to the surrounding media through energy radiation in the form of sound waves. This energy transfer mechanism is due to structural-acoustic interaction, where the structural vibration generates radiated acoustic pressure, and the resulting acoustic pressure may also modify the structural motion. For noise control, it is important to study how the acoustic radiation from a vibrating structure would be a ected by certain structural or material changes, namely, sti ness modications and damping. Usually, sti ness modications cause shifts in resonant frequencies but do not reduce the noise levels at resonance too much. Applying damping materials, on the other hand, can e ectively reduce the noise at resonance. However, they need to be applied to every single product. It becomes
E-mail address: tyhuang@mail.me.lhu.edu.tw (D.T. Huang). 0168-874X/$ - see front matter ? 2004 Elsevier B.V. All rights reserved. doi:10.1016/j.nel.2004.03.001

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very expensive. Sti ness modications are the preferred way to reduce noise since the only cost is in changing the die. Usually, a die can work for tens thousand pieces of products. A type X induction system was known to radiate excessive noise from the vibrating surfaces of the snorkel, as evidenced by noise reduction achieved by bolting the upper and lower surfaces together through a spacer. The bolt experiment indicates that the problem is breakout noise due to response to internal acoustic pressure pulsations rather than engine vibrations. The objective of this study is to develop die design modications that will minimize the snorkel breakout noise. To e ectively reduce the radiated noise from the snorkel at its design stage, it is rst necessary to have a model to predict the structural vibration, and then have a method to evaluate the radiated noise. With knowledge of the noise radiation and surface distribution, potential noise sources can be identied and alternate designs can be evaluated before hardware is made. A number of researchers have worked in the eld of structural vibration and noise radiation, and their reports can be found in literature. In the 60s, Chen and Schweiker [1] developed a numerical method for sound radiation analysis. Schenck [2] proposed improved integral formulation for acoustic radiation problems. In the 70s, Alper and Magrab [3], Suzuki and Tichy [4] and Lomas and Hayek [5] studied acoustic radiation produced by structural vibration using a modal approach. Gladwell and Mason [6] developed a variational nite element formulation for the acoustic response of a rectangular panel. In their study, the acoustic pressure was assumed to be constant over an element. Smith et al. [7] developed an acoustic impedance matrix based on shape functions di erent from those used in the structural nite element model. It enables the surface acoustic pressure to vary over each structural element, with the surface acoustic pressure expressed in terms of surface normal velocity. From early 80s up to now, the nite element method and the boundary element method have been widely used by researchers, such as Kagawa et al. [8], Sung et al. [912], Sivakumar et al. [13], Seybert et al. [1416], Agren et al. [17], Lim [18] and Ohta et al. [19], for studying structural vibration and acoustic radiation problems and designing machines with reduced radiated noise. In order to reduce the low frequency noise, stringers or ribs are often used to sti en the panels, plates or shells in machines, equipments and vehicle body structures. Russian scientists, such as Mkhitarov [20], Bernblit [21,22], Ivanov and Romanov [23], analyzed the e ects of ribs on sound radiation from sti ened plates and shells in the 70s. During the last two decades, Mueller [24], Belinskii [25], Takahashi [26], Crighton and Innes [27], Sung [28], Feit and DiPerna [29], Le Moyne et al. [30,31], and Rumerman [32] had studied this and related subjects analytically, experimentally, or numerically. The nite element method is a general numerical method. The FEM programs are general-purpose codes and are nonrestrictive. Semi-analytical methods, such as the boundary element method, the discrete element method, the nite di erence method and other methods, may be more accurate and suitable for certain problems, but they are limited to specic class of boundary value problems. For example, the BEM may be more suitable for this specic acoustic radiation problem, but the BEM programs are special-purpose codes and are not readily available to the design engineers. The ordinary design engineers are more familiar with the FEM and the general procedure for solving di erent kinds of engineering problems. Furthermore, various commercial FEM codes are readily available to the engineers. For this reason, a simulation approach, to compute the structural frequency response of the vibrating snorkel with available commercial nite element program, and to estimate its radiated noise with

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personal computer programs for calculation of acoustic characteristics, is developed. The procedure is summarized as follows: (1) Determine the internal acoustic pressure frequency spectrum for an engine and induction system model at several engine speeds and enveloping the pressures at several internal locations. Evaluate whether a nonuniform pressure distribution must be modeled rather than uniform pressure across the interior surface. (2) Build a linear elastic nite element model for the component and compute its structural frequency response to the internal acoustic pressure spectrum. (3) Process the outputs from the FEM structural frequency response analysis to compute the total sound power and surface acoustic intensity distributions, of the corresponding linear acoustic model without ow, at several resonant peaks. The sound intensity distributions at resonant peaks provide guidance for placement of reinforcement ribs or other design modications. (4). Model proposed design alternatives and repeat the analysis until a satisfactory design is achieved. Initial alternatives can be quickly evaluated using a simplied approach with beam elements representing ribs. More detailed nite element models are used for nal evaluation. The above procedure was used to evaluate the original design, the bolted design, a no-rib baseline design and many design alternatives utilizing various sizes and placements of ribs. Snorkel noise in the frequency range below 400 Hz is of primary concern because of the acoustic transmission loss characteristics from the snorkel to the drivers ear. 2. Formulation and theoretical basis As explained in Ref. [2], to calculate the radiated acoustic pressure due to a vibrating structure, the familiar Helmholtz integral equation has to be solved and the associated dynamic response has to be known. Numerical methods, such as the nite element method, have been widely used to determine the dynamic response of a vibrating structure and the radiated acoustic pressure. The nite element equations of motion, which represent the structural vibration of a snorkel in response to internal pressure pulsations, can be expressed as [M ]{W } + [C]{W } + [K]{W } = {F}; (1) where [M ], [C] and [K] are the mass, the damping and the sti ness matrices of the snorkel, W (x; y; t) = W (x; y)ei! t is the time-dependent displacement response at the grids of the nite el ement model, W (x; y) is the amplitude of displacement response, F(x; y; t) = F(x; y)ei! t is the time-dependent external force vector, F(x; y) is the applied force amplitude, and dots represent derivatives with respect to time. The associated vibration velocity response is V (x; y; t) = W (x; y; t) = (i!) W (x; y; t). When a nite element model is developed for structural dynamic analysis, the surface normal vibration velocities can be expressed in a matrix form {Vn } = i![T ][N ]{W }; (2) where [N ] is the structural interpolation function, and [T ] is a transformation matrix for obtaining the surface normal component of the displacement response [10]. The nite element model of a snorkel is composed of a number of plate/shell elements. Considering each surface element dA, vibrating harmonically with a surface normal vibration velocity Vn , as a

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source of sound, the radiated sound pressure at any point r in space can be evaluated via the Helmholtz integral equation [33]: p(r; !) = i!
A

Vn (r0 ; !)G(r r0 ; !) dA +

p(r0 ; !)

9G(r r0 ; !) dA; 9n

(3)

where ! is the circular frequency of vibration, is the air density, r0 is the location of the surface element dA, and A is the total enclosed vibrating surface area. When r refers to points in the space external to the vibrating body, the radiation e ciency =1:0, when r refers to points on the vibrating surface, = 0:5. The Greens function, G(r r0 ; !), describes the acoustic response at r due to a unit source excitation at r0 , and is given by [33]: G(r r0 ; !) = 1 eik |r r0 | ; 4 |r r0 | (4)

where k = !=c is the wave number, c is the speed of sound in air. The second integral in Eq. (3) contains the unknown surface acoustic pressure p(r0 ; !); thereby it requires an implicit solution procedure to evaluate the Helmholtz integral equation for p(r; !). For a at or slightly curved vibrating surface bounded by an innite, nearly at and rigid ba e, the Helmholtz integral simplies considerably. In this case, if one considers only point r on the vibrating surface A such that R=r r0 , one obtains 9G(R; !) 9G 9R = 0; 9n 9R 9n (5)

since R is perpendicular to or nearly perpendicular to the normal direction n for such surfaces. Therefore, the second integral in Eq. (3) vanishes. The Helmholtz integral reduces to the Rayleigh integral p(r; !) = 2i!
A

Vn (r0 ; !)G(R; !) dA:

(6)

In many practical problems involving the structural vibration, the radiated noise can be accurately predicted by the Rayleigh integral formulation [34,35]. Compared with the Helmholtz integral, the Rayleigh integral in Eq. (6), which neglects the e ect of acoustic di raction, is much simpler to evaluate and is accurate for predicting radiated noise from a nite, at or slightly curved vibrating surface bounded by an innite rigid ba e for which the surface normal velocity Vn is zero. It is approximate, however, when the surface is highly curved or when the e ect of the ba e is neglected. Generally speaking, points on the outside ba e at a large distance R will have little e ect on the radiated noise from points located on the vibrating surface, since the second integral in Eq. (3) will be small. If edge radiation dominates the acoustic response, the second integral may not be small for ba e points near the boundary of the vibrating surface, and the Rayleigh integral must then be applied judiciously. At su ciently high frequency, the Rayleigh integral is a valid approximation to the Helmholtz integral since the acoustic wavelength is small compared with the overall dimensions of the vibrating surface, in which case the second integral in Eq. (3) becomes insignicant [36], however, a better alternative to the Rayleigh formulation is considered for computation of acoustic characteristics by using an asymptotic formulation where the boundary pressure is related to the acoustic normal velocity through the C impedance.

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By substituting Eq. (2) into Eq. (6) and evaluating the Rayleigh integral for all combinations of r0 and R, for all grids dening the surface, the radiated acoustic pressure at the nite element grids of the surface becomes {p} = [RI ]{Vn }; (7) where [RI ] is an acoustic radiation impedance matrix [9]. For a harmonically vibrating structure, the surface average mean-square vibration velocity is expressed as follows: (Vn2 )A = (1=A)
A

Vn Vn dA ;

(8)

where Vn is the complex conjugate of the surface normal velocity Vn at each grid determined by Eq. (2). The acoustic power radiated normal to the vibrating surface is the real part of the surface integral expressed as PW = (1=2)Re
A

pVn dA ;

(9)

where p is the surface acoustic pressure at the grid determined by Eq. (6). The surface acoustic intensity is the spatial distribution of the acoustic power and is dened as I (x; y) = (1=2)Re{pVn }: The radiation e ciency can be dened as = PW =PO ; cA[(V 2 ) (11) where PO = n A ] is the acoustic power that a piston would radiate into the same half space if all parts of the piston were vibrating in phase. Studies [9,15] show the radiation e ciency of a structure depends on its natural frequencies and mode shapes. The odd modes of vibration (causing volume displacement) have higher radiation e ciency than the even modes. Therefore, the odd modes contribute more signicantly to the radiated noise due to vibration. Calculations of radiation e ciency at the resonant frequencies of concern are useful. If energy is conserved in the acoustic medium, the acoustic power and the radiation e ciency obtained at the surface of a vibrating plate set in an innite rigid plane ba e should be equal to that obtained at a control surface in the far-eld of the acoustic medium. Base on the fundamental principles described above, a computer program PGA was developed and used to read results from a nite element frequency response analysis and evaluate the Rayleigh integral to compute the mean-square vibration velocity, the surface acoustic intensity and the radiated sound power of the snorkel in response to the internal acoustic pressure pulsations. 3. Numerical results and discussion The original design of the air cleaner snorkel associated with the type X induction system had two small longitudinal ribs. For understanding the e ects on modied structures caused by sti ening ribs, a baseline nite element model (Fig. 1) of the snorkel with no rib was rst created to study its structural and acoustic characteristics. In order to study the structural frequency responses of the snorkel due to uniform internal acoustic pressure pulsation, the snorkel was clamped at the end (10)

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Fig. 1. The baseline nite element model of the air cleaner snorkel with clamped end at the air cleaner side: (a) upper surface, (b) lower surface.

connecting to the air cleaner. The amplitude of the pressure pulsation loading was determined by enveloping the fast Fourier transforms of the pressure frequency spectra at the inlet and the outlet of the snorkel. The pressure frequency spectra, as shown in Fig. 2, were generated by enveloping results from running a computer program PGB, which was developed for noise and volumetric e ciency

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Fig. 2. The pressure spectra (envelop of pressure spectra at di erent engine rpm) at the inlet and the outlet of the snorkel: (a) pressure spectra at snorkel inlet, (b) pressure spectra at snorkel outlet.

analysis for an engine intake system model, at di erent engine speeds. However, generation of pressure spectra is proprietary to the sponsor of this project. Detailed information is not presented here. The FEM structural frequency response results of the baseline model were post-processed with the program PGA to calculate the surface average mean-square vibration velocity, the sound intensity, the radiation e ciency and the radiated sound power. As an example, the sound intensity levels on the top and the bottom surfaces of the snorkel at 383 Hz, which is the third natural frequency of the baseline model, are shown in Figs. 3 and 4, respectively. Sti ness modications were implemented through adding ribs to the high sound intensity areas to minimize the radiated noise. Since the Rayleigh integral is especially valid for at or slightly curved surface, a simplied approach by adding the beam elements as sti ening ribs to the baseline model was rst used to

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Fig. 3. Sound intensity contours on the top surface of the baseline model of the snorkel at 383 Hz (third mode).

Fig. 4. Sound intensity contours on the bottom surface of the baseline model of the snorkel at 383 Hz (third mode).

evaluate various designs to determine the optimal modication. Both small ribs (6:8 mm wide, 2:9 mm deep) and big ribs (10 mm wide, 4 mm deep) were represented by the beam elements in the modied models. Three major trends of modications were considered. The natural frequencies of these modications are shown in Table 1. As expected, the resonant frequencies of the

D.T. Huang / Finite Elements in Analysis and Design 41 (2004) 31 47 Table 1 Natural frequency of beam sti ened models (simplied approach) of the snorkel Case Case I: baseline model (not sti ened) Case II: sti ened with longitud. beams Small (orig. design) 272 355 383 466 510 285 383 428 542 600 Big 288 390 439 556 617 Case III: sti ened with lateral beams Small 309 519 595 601 703 Big 317 538 612 665 723 Case IV: sti ened with small longitud. beams and big lateral beams Location 1 322 547 625 726 733 Location 2 316 505 595 719 736

39

Freq (Hz) 1 2 3 4 5

baseline model are the lowest among all design cases for all orders. The resonant frequencies of the beam-sti ened models were higher. The local sti ness of the snorkel was changed due to the structural sti ening e ect; so was the sound intensity distribution. From the analysis based on the simplied beam approach, it was concluded the lateral ribs are more e ective in sti ness modication than the longitudinal ribs. In order to estimate more precise structural resonant frequencies, detailed nite element models with real ribs built in were created for a few cases with favorable results obtained from the simplied approach. These models can be classied into three categories: the design with small longitudinal ribs (with or without bolts, shown in Fig. 5), the design with big lateral ribs (with or without central longitudinal rib), and the design with small longitudinal ribs plus big lateral ribs (Fig. 6). The natural frequencies of these modied models are listed in Table 2. It is noted that the lowest three resonant frequencies of the bolted snorkel were lower than those of the snorkel with no bolt, namely, the original design. It is due to the lumped masses of the two bolts, which totally amounts 114 g. Similar to Table 1, Table 2 also shows the resonant frequencies, except the rst one, of the original design of snorkel were shifted above 500 Hz level by adding big lateral ribs. The internal pressure pulsation loading was applied to these models to evaluate their sound intensity and radiated noise levels. Fig. 7 shows the sound intensity contours at 364 Hz (second mode) on the top surface of the snorkel with small longitudinal ribs (the original design). Fig. 8 shows the sound intensity contours at 404 Hz (third mode), on the bottom surface of the same model. Because the top and the bottom surfaces are not symmetrical to each other, and the local sti ness is di erent, the sound intensity plots show di erent contours even at the same frequency. It helps to determine where to add sti ness. The area of highest sound intensity shifts due to sti ness modication. As a comparison, the sound intensity contours at 524 Hz (second mode) on the top surface of the modied design with the small longitudinal ribs and the big lateral ribs are shown in Fig. 9; while those at 548 Hz (third mode) on the bottom surface of the same modied design are shown in Fig. 10. It is noticed the top surface of this modied design with the small longitudinal ribs and the big lateral ribs excites more in the second mode and results in higher sound intensity, while the bottom surface generates higher sound intensity at the third mode. Because of the pressure pulsation loading, the breathing mode was excited and can be recognized from the sound intensity contours.

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Fig. 5. A detailed nite element model of the air cleaner snorkel with small longitudinal ribs and bolts built in: (a) upper surface, (b) lower surface.

Fig. 11 shows the surface average mean-square vibration velocity for the original and two modied designs in the frequency domain up to 700 Hz. At high frequency, the radiation e ciency approaches unity, and the surface average mean-square vibration velocity is a measure of the radiated sound power. At low frequency, the surface average mean-square vibration velocity provides only a trend-estimate of the radiated noise. Based on an assumption that the radiation e ciency is 1.0, the surface average mean-square velocity was converted to sound power in db units. Fig. 12 shows the relative radiated sound power for the snorkel sti ened with small longitudinal ribs (either without or with bolts) and the one sti ened with both small longitudinal ribs and big lateral ribs. The latter is seen to be with the lowest sound power level. After taking into account the e ect of the radiation e ciency, the true sound power at certain resonant frequencies was computed and listed in Table 3. It indicates that the sti ness modications shift the resonant frequencies and avoid high intensity radiated noise in the lower frequency region.

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Fig. 6. A detailed nite element model of the air cleaner snorkel with small longitudinal ribs and big lateral ribs built in: (a) upper surface, (b) lower surface.

The pressure proles along the centerline of the snorkel were calculated, using the program PGB, for di erent harmonics at di erent engine speeds. Some of the pressure proles show sizable variation along the centerline. Since most of the harmonics are not at the structural resonant frequencies of the original or the modied designs of the snorkel, those pressure proles were ignored. Also, for some pressure proles at the 200 Hz levels, the pressure at either the inlet or the outlet of the snorkel is the highest, so the uniform pressure used in the analysis is conservative. The pressure distributions in the 500 Hz range are half sine wave and of special concern. The worst case, which occurred

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Table 2 Natural frequency of rib sti ened models (detailed approach) of the snorkel Case Case I: sti ened with small longitud. ribs No bolts (orig. design) 267 364 404 481 544 With bolts 252 304 327 586 651 Case II: sti ened with big lateral ribs No central longitud. rib 229 519 574 649 680 With central longitud. rib 233 552 591 701 738 Case III: sti ened with small longitud. ribs and big lateral ribs No inter. lateral rib 241 525 549 643 683 With inter. lateral rib 243 555 587 691 719

Freq. (Hz) 1 2 3 4 5

Fig. 7. Sound intensity contours on the top surface of the snorkel (with small longitudinal ribs only) at 364 Hz (second mode).

at 4000 rpm, was applied to the modied models. The overall sound power levels did not show signicant change. Since the snorkel surface is highly curved in certain regions and the rst several resonant frequencies are all in the low frequency range, the Rayleigh integral used in the program PGA does not provide an accurate absolute magnitude of the sound power at a specic frequency. However, the Rayleigh integral formulation still gives a trend of relative magnitude of sound power among di erent designs for determining the most e ective modication. Since the clamped boundary condition is applied in the analysis, the calculated resonant frequencies of the snorkel are approximate. The pressure spectra generated by program PGB may also involve some approximation. Therefore, experiment is necessary to determine the true radiated sound power

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Fig. 8. Sound intensity contours on the bottom surface of the snorkel (with small longitudinal ribs only) at 404 Hz (third mode).

Fig. 9. Sound intensity contours on the top surface of the snorkel (with small longitudinal ribs and big lateral ribs) at 525 Hz (second mode).

level for each design. This analysis has considered the frequency response and radiated noise of the air cleaner snorkel due only to pressure pulsation inside the induction system. It is worthwhile to study the snorkel noise generated by engine vibrations as well.

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Fig. 10. Sound intensity contours on the bottom surface of the snorkel (with small longitudinal ribs and big lateral ribs) at 549 Hz (third mode).

Fig. 11. Surface average mean-square vibration velocities vs. frequencies for the modied designs.

4. Conclusions In industries, the design engineers are more familiar with the nite element method than other methods. Besides, commercialized general-purpose FEM codes are readily available to the engineers. Therefore, this report proposes a simulation approach by using FEM as a tool for evaluating the design alternatives of a snorkel for the purpose of noise reduction. Initial alternatives are quickly evaluated using a simplied nite element model. The detailed models are used for nal evaluation.

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Fig. 12. Sound power levels vs. frequencies for the modied designs. The radiation e ciency is assumed to be one. Table 3 Radiation e ciency adjusted sound powers of various designs Cases Original design with small longitud. ribs Resonant freq. (Hz) 267 364 404 Adjusted sound power (Db) 89.7 77.8 85.4 Modied design with small longitud. ribs and big lateral ribs Resonant freq. (Hz) 241 525 549 Adjusted sound power (Db) 75.2 83.9 86.5

Peaks 1 2 3

The surface normal vibration velocity, surface acoustic intensity and radiated acoustic power are calculated for the vibrating snorkel due to internal acoustic pressure pulsations. Although various simplications were made in the analysis, this study still provides a trend of relative magnitude of parameters of concern among di erent designs for determining the most e ective modication. The following conclusions are drawn from the results of this study: 1. The two small longitudinal ribs on the modied design I provide no signicant improvement over the no-rib baseline design. However, the bolted design shows improvement over the original design, in agreement with experimental observation. 2. Lateral ribs are more e ective than the longitudinal ribs. 3. A practical, near-optimum design, superior to the bolted design, was developed which e ectively reduce breakout noise across the frequency range below 400 Hz. It does have higher noise in the range of 500600 Hz, where there are two signicant resonant frequencies located. However, this is judged to be of no concern by the testing engineers. The design requires the addition of two large lateral ribs on both the top and bottom halves of the snorkel.

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