Introduction To Automotive NVH

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VIT M. TECH.

(AUTO) COURSE (Noise, Vibration and Harshness )

INTRODUCTION TO AUTOMOTIVE NVH

NVH and CAE Laboratory

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Necessity of NVH Awareness

SOUND IS A PROPAGATING TYPE OF ENERGY.

NOISE IS A UNWANTED SOUND.

ƒ NOISE - AUDIBLE

ƒ VIBRATION - TACTILE

ƒ HARSHNESS - TACTILE AND AUDIBLE


(15Hz - 300Hz)

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Necessity of NVH

¾ Noise Pollution – CMVR, CPCB & NCNPC


¾ Customer Awareness Of Vehicle Ride Comfort
¾ Marketability
¾Trend Towards Higher Power And Smaller Size
Power trains.
¾ Sound Quality
¾ Design Optimization
¾ Consistency In Production

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PASS BY RIDE SPL


NOISE COMFORT OEL

EXTERIOR INTERIOR

NOISE NOISE

SOUND QUALITY

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Noise Contributions from Various Systems


Miscellaneous 3%
Other Structural
Components 10% Engine 21%

Fan & Radiator Assembly


6%

Drive Line 14%

Exhaust System 32%

Intake System 14%

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Automotive Noise Sources-Levels and Frequency Bands

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NVH Classification

„ By Noise Type „ By Vehicle Systems


„ Road NVH „ Body NVH

„ Wind noise „ Chassis NVH

„ Powertrain/Driveline „ Powertrain/Driveline

NVH NVH
„ Squeak and Rattle „ Vehicle components

„ Climate control
system
„ Wipers

„ Seat motors

„ Switches

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NVH Sources and their inter-relation

Power-train Sound
Ride Quality
Engine
Comfort
Transmission

Intake system
Cooling system Harshness
Others

Exhaust system Mount

Vibration Noise
Brake System

Road and Tyre Suspension

Wind Air

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Sound Quality

Sound quality (SQ) is the perceptual reaction to the sound of a


product that reflects the listener’s reaction to the acceptability of
that sound for that product; the more acceptable, the greater the
SQ
Both objective & subjective assessments need to be made

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Pass-by Noise of Automotive Vehicles

¾ Community Noise Pollution.(IS-3028/ISO-362)


¾ Maximum Sound Pressure level in “dB(A) measured
at a distance of 7.5m from the vehicle during vehicle
accelerated to full throttle

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Pass-by Noise of Automotive Vehicles


A’ B’

Microphone location point


1.2 ± 0.1 m above ground

7.5 ± 0.2 m

C C’

7.5 ± 0.2 m
Microphone location point
1.2 ± 0.1 m above ground
10 ± 0.2m 10 ± 0.2m

A B

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Pass-by Noise of Automotive Vehicles

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Legislative Noise Requirements


2 Wheelers
< 80 cc 75
80 cc & 175 cc 77
> 175 cc 80
3 Wheelers
< 175 cc 77
> 175 cc 77
4 w heelers
M1 74
M2/N1
GVW < 2 ton 76
2 – 3.5 ton 77
M2/M3
< 150 Kw 78
>= 150 kW 80
N2/N3
< 75 kW 77
75 – 150 kW 78
> 150 kW 80

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Interior Noise of Vehicle


¾ One of the most decisive selling points for passenger car
is the level and quality of interior noise.
¾ Like exterior noise engine is the main source of vehicle
interior noise.It gets transmitted inside the vehicle by,
¾ Direct infiltration:
Improper sealing , Holes in the lower dash panel
¾ Structural vibrations
¾ Engine mounts, loops in the exhaust system
¾ Drive shafts, support bearing ,rear axle drive shaft.

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Interior Noise Sources


Intake System
Surface Noise Radiation
Exhaust System
Surface Noise Radiation
Orifice Noise
Tailpipe Noise
System Vibrations
System Vibrations

Wind Noise Transfer Behaviour Wheel Suspension


Vehicle
Interior Noise
of Noise and Vibration
Drive Train Tyre

Power Train
Engine and Gearbox Surface
Global Power Train Mode
Local Mode (P/T Mode, P/T Mount Brackets
Accessories)

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Interior Noise of Vehicle

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Power Train –Engine Noise

Types of Engine Noise

¾ Airborne Noise : Exhaust and Intake

¾ Structure borne Noise : Vibrating


surfaces of engine structure and
connected covers

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Power Train –Engine Noise

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Power Train –Engine Noise

Main Excitation Forces and Structure borne Engine


Noise :

Combustion Noise: Unidirectional gas &


Inertia forces cause
combustion noise.
Mechanical Noise : Reversible forces created
due to crank mechanism
induce mechanical noise.

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Power Train –Engine Noise

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Intake Noise

Noise Generated due to


¾ Opening and closing of the valves.

¾ Inlet air column oscillation by sharp pressure


pulse from cylinder.

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Exhaust Noise

¾ Exhaust valve opens and releases gas at high pressure


into the exhaust system.
¾ The principal component of noise - Fundamental and
harmonics of firing frequency.

Exhaust system design is a compromise between


noise reduction and engine power loss due to
increase in back pressure.

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Clutch Noise
Clutch Judder is basically torsional vibration in the drive line
during starting of engagement. This results in rough starts
and affects the ride comfort.

The major causes are :


¾ Friction characteristics of the clutch i. e. relationship
between slip speed and the friction coefficient
¾ Torsional vibirations due to variation in axial load
resulting from misalignment of the driveline
¾ The clutch pedal vibrations can cause interior noise
problems

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Transmission Noise

Driveline noise and vibration sources results from transmission


of power from the engine to wheels.
Transmission gear noise:
¾ Bending dynamics of the individual gear tooth.
¾ Both bending and torsional dynamics of gear shafts.
¾ Type and precision of gears used.
¾ Fundamental and second harmonics of the gear mesh
frequency - most significant components of gear noise.

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Transmission Noise

Driveshaft and Propeller shaft :

¾ Excitation at rotational(fundamental) speed.


¾ Universal joint can provide excitation at second order
due to high angles of coupling.
¾ Rear wheel drive vehicles employ a constant velocity joint
in the center joint of two piece propeller shaft - provides axial
compliance in the driveline which decouples vibration from
rear axle.

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Driveline-Axle Noise

–Gear whine generated by gear mesh of the differential. See WHINE.


¾ Vibration excited by tooth meshing action of the axle gear set.

¾ Noise is narrow band and annoying even at low levels in the


passenger compartment of the vehicle.

¾ Noise due to resonance mode of the axle may be reduced by


altering axle mass and stiffness so that resonance lie outside
the normal operating range.

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Belt Noise

• Impact generated by collision of tooth of belts


against
bottomland of sprocket at the beginning of meshing
• Transverse and torsional vibration of the belt
• Airflow between belt and pulley at meshing
• Friction between belt and pulley and slip of the belt
• Vibration of the pulley

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Chain Noise

•impact of chain with sprocket and polygonal


effect
• Roller impacts of chain at higher speed
• Torsional vibration of camshaft causes
significant tension fluctuation in chains and
magnifies chain transverse vibrations
• Chain natural frequencies
• Cover frequencies

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Tyre Noise

Tyre noise is generated by,

¾ Rolling contact of the tyre ( a resonant system)with surface


of random roughness( the road).
¾ Tread vibration - Radial vibration of tread - primary contributor
noise.
¾ Tread squirm - Localized lateral vibration of tread - high
frequency part of noise spectrum.

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Tyre Noise

¾Air pumping - Air is expelled from tread or road cavities at


front end and sucked back at trailing edge
into tread or road cavities. Tread pattern is
significant in generating air pumping.

¾Aerodynamic noise -Generated by turbulent flow air around


the tyre. It contributes least to tyre noise

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Wind Noise

It is generated by ,

¾ Flow of air around the vehicle exterior - broad band in


characteristic - it may have pure tone due to vortex shedding
proturbulences such as rear view mirror.

¾ Air flow into or out of the cabin due to imperfect sealing around
the door frames and glass areas.

¾ Adequate window and door seals are fundamental to successful


wind noise control.

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Noise Sources and Corresponding Transfer Paths

Excitation Transfer Behaviour Interior Noise Share

• Noise Radiation of Airborne Interior


Air Borne Noise

P/T and Accessories • Vehicles Body Noise Noise


• Intake and Exhaust (Amplitude + Noise)
- Firewall
System Shell Noise Share 1
• Intake Orifice Noise -
- Under floor -
• Tailpipe Noise Share n Summation Interior
with Noise
correct
Structure-Borne phase Simulation
Structure- Borne

• Global Engine Vibration


Interior Noise
- Local Mode
• Engine Mounts (Amplitude + Noise)
Noise

- P/T Structure
- P/T Mount Brackets • Contact Points Share 1
-
• Accessory Vibration -
Share n

Measurement
Measurement Engine
Prototype Calculation
Test Bench
Series Vehicle

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NVH Glossary – Automotive Phenomena


„ Axle Noise:
„ Gear whine generated by gear mesh of
the differential.
„ Brake Squeal:
„ Very high-frequency sound generated by
braking
„ Brake Judder:
„ Low-frequency shaking of the vehicle
generated by braking. Usually due to
brake disk thickness variation

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NVH Glossary – Automotive Phenomena


„ Boom:
„ Low frequency sound

„ 20-100Hz,Power

train,Road/suspension,Impact
„ Buzz, Squeak and Rattle

„ Chuckle:
„ (shock absorber) Interior vehicle noise induced
by force variation of the shock absorber. Multiple
transient sounds.
„ Clunk:
„ Transient, low-frequency, broadband sound

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NVH Glossary – Automotive Phenomena


„ Drone:
„ A large-amplitude, single tone sound 100-

200Hz. A deep, sustained murmuring,


humming or buzzing sound
„ Gear rattle:
„ (usually manual transmissions only) A noise

resulting from torsional vibrations causing loss


of contact and impact of transmission gear
teeth. Often sounds very similar to engine
pre-ignition/knock

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NVH Glossary – Automotive Phenomena

„ Growl:
„ Broadband, 100-1000Hz, noticeable time
variation
„ Moan:
„ Low-amplitude, low frequency tone, 20-200Hz

„ Rattle:
„ Random Impact Noise. See “Gear Rattle”

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NVH Glossary – Automotive Phenomena

„ Road and Tire Noise:


„ Any noise perceived to be generated by the road
and tires
„ Roughness:
„ Sound with noticeable time variation –
modulation. Usually 100-500Hz tone with rapid
modulation.
„ Also, vibration from 2 -order wheel imbalance.
nd

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NVH Glossary – Automotive Phenomena

„ Rumble:
„ Low- to mid-frequency broadband noise, 150-500
Hz, with noticeable time variation
„ Shake:
„ A low-frequency vibration, 5-30Hz. Usually
steady-state (e.g. wheel imbalance at high-
speed)

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NVH Glossary – Automotive Phenomena

„ Shuffle/Bobble:
„ A fore/aft vehicle motion. Usually produced by
1st torsion mode of the powertrain.
„ Shudder:
„ A low frequency vibration; usually felt and not
heard. Sometimes defined as fore/aft lateral
movement. Usually somewhat transient event,
as in vehicle start-up.

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NVH Glossary – Automotive Phenomena


„ Tick & Hash:
„ Miscellaneous time varying noises

„ Whine:
„ Mid to high frequency, 200-5000Hz, tone,

sometimes with harmonics


„ Wow:
„ Low-frequency modulation of a tonal noise.

Usually caused by speed variation, as with an


electric motor

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Time and Frequency Domains


„ NVH must take into account both time domain and
frequency domain information

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Harmonics
„ Harmonic: Any of a series of musical tones whose frequencies
are integral multiples of the frequency of a fundamental tone.
Source: The American Heritage® Dictionary of the English
Language, Fourth Edition

Frequency

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Waterfall Plots and Order Analysis


Order

RPM
Overall Level

Frequency

Order Level

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Engineering Measures of Sound


„ Sound pressure – actual pressure change caused by
sound, usually measured in Pascals (Pa). 1 Pa = 1
N/m2
„ Sound intensity – average amount of acoustic power
passing through a unit area that is perpendicular to
the direction of sound propagation. A vector
quantity of sound. Can be used to indicate the
source of noise, or to calculate sound power.
Measured in Watts/square meter (W/m2)
„ Sound power – acoustic power of sound, measured
in Watts (W)

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Sound Weighting Schemes

„ dB(A), dB(B), dB(C)


„ Basic method of representing or approximating

how humans perceive sound level


„ Sound Quality Metrics:
„ More advanced methods of approximating human

perception of sound
„ Sones, speech intelligibility, roughness

„ Filters applied to sound signals to provide metrics

which correlate with human perceptions

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Source/Path/Receiver

Source X Path Sensitivity = Response


„ Source - causes disturbance
„ Path - may isolate or amplify disturbance
„ Receiver - responds to disturbance
„ NVH strategy

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NVH Tools and Methods


„ Source identification
„ Sound Intensity

„ Sound Acoustic Holography

„ Modal analysis
„ Experimental Modal Testing
„ Operating Deflection Shapes
„ Operational Modal Analysis
„ Operating Measurements
„ Order tracking

„ Noise Path Analysis


„ CAE
„ Sound Quality
„ Sound synthesis

„ Jury Evaluation

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Benchmarking Sources
„ Measurements on
„ Road tests

„ Lab tests

„ Equipment/components

„ CAE
„ Multi-body dynamics

„ Finite element analysis

„ Computational fluid dynamics

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Sound Source Identification


„ Sound Intensity
„ Obtain vector quantity of sound at various points/grid

locations around the test article using a 2-microphone


probe

„ Acoustical Holography/Beam Forming


„ Obtain a visual representation of the sound radiated from a

test article using a microphone array


y
microphone source

y focal point (level max)

o
x

antenna x z

focal point (level min)


Focusing plane = source plane

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Noise Contribution of Various Components


of Engine

Exhaust
system-35%

Intake system-
15%

Engine Block-
35%

Others-35%

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What is Modal Analysis?


F(t) X(t)
[ H(ω ) ]

Measurement Mode 1 Mode 3


H ij

Mode 2

Modal Parameter Estimation Frequency ω r

Damping Ratio ζ r

Mode Shape φ r

etc.

Modal Parameters

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ODS – Operating Deflection Shapes

„ Operating Deflection Shapes –


„ Measure motion transmissibility

functions relative to one fixed location,


( acci / accj ) at a lot of points, like
with Modal Analysis
„ It looks like a duck, but IT’S NOT A

DUCK (mathematically, these are forced


response shapes, not mode shapes -
it’s NOT modal analysis)
„ Can be time-domain or frequency domain

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Vibro-acoustic Prediction Technique

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Vibro-acoustic Prediction Technique

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Multi-body dynamics Software


„ Components modeled as rigid, lumped mass part
„ Connections through springs and dampers
„ Understand trajectory and time-response of system
„ As in suspension systems, steering systems, rigid-body
vibration modes of powertrain (bounce, pitch, roll)
„ Low frequency (below 100 HZ)
„ ADAMS is popular CAE software for this type of modeling
„ Used as support for Boundary Condition for FEM

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Noise Prediction by FEM Technique

FE Modal Analysis
Dynamic Response Analysis
Coupled Analysis

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BEM Technique

It is one of Numerical techniques


used to solve the acoustic
problems like Finite Element
Method(FEM).
• In BEM only the boundary of the
domain is dicsretized. For complex
Geometries the BEM modeling
leads to significant savings of
manpower and computational
time.

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Other CAE Techniques

„ Statistical Energy Analysis


„ Higher Frequency computational NVH

technique, usually used at frequencies


higher than 300 Hz in automotive
applications
„ Computational Fluid Dynamics
„ Applied to fluid-flow and air-flow (e.g.

wind noise)

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Correlation Between FE Technique and


Experimental Testing
Test
Initial FRFs
Model

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Correlation Between FE Technique and


Experimental Testing

VIBRATION VELOCITIES WITH


COMBUSTION FORCES MEASURED VIBRATION VELOCITIES
V-Loc 1 V-Loc 2
LOC 01 LOC 2 V-Loc 3 V-Loc 7
2.17E+02
LOC 03 LOC 07
1.97E+02
Vibration Veloc ity

Vibration Velocity_
1.77E+02

1.57E+02

1.37E+02

1.17E+02

9.70E+01
200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000
630 800 1000 1250 1600 2000 2500 3150
Centre Band Frequency (Hz)
Centre Band Frequency in " Hz "

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STRUCTURE BORNE ENGINE NOISE CONTROL.

Noise Reduction methods

• MECHANICAL NOISE :
METHODS SUGGESTED TO REDUCE
PISTON SLAP
-- Offsetting gudgeon pin

-- Reducing piston - liner clearance

-- Minimum r/l ratio

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STRUCTURE BORNE ENGINE NOISE CONTROL.

METHODS SUGGESTED TO REDUCE


PISTON SLAP

-- Lengthening piston skirt

-- Lubrication of skirt with oil film in


the liner to dampen piston slap

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STRUCTURE BORNE ENGINE NOISE CONTROL.

Noise Reduction methods

METHODS SUGGESTED TO REDUCE


PISTON SLAP

-- Low clearance in gudgeon pin and


Connecting rod bearings

-- Rigid liner with minimum


deformation and ovality.

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STRUCTURE BORNE ENGINE NOISE CONTROL.

Noise Reduction methods

• MECHANICAL NOISE :
METHODS SUGGESTED TO REDUCE
PISTON SLAP
-- Offsetting gudgeon pin

-- Reducing piston - liner clearance

-- Minimum r/l ratio

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STRUCTURE BORNE ENGINE NOISE CONTROL.


Noise Reduction methods

•TIMING GEAR NOISE :


-- Use of low inertia gears.

-- Replacement of standard timing gears


with double helix gears.
-- Gears with low pressure angle

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STRUCTURE BORNE ENGINE NOISE CONTROL.


Noise Reduction methods

•TIMING GEAR NOISE :

-- Isolating timing cover by using noise shield.

-- Reduce torsional vibrations of crankshaft

-- Design of camshaft for low impacts.

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STRUCTURE BORNE ENGINE NOISE CONTROL.


Noise Reduction methods
Engine Structure Modification :

Major Influencing Factors ::

• Design of lower crankcase

• Movement of Crankshaft journals during firing

• Design of engine covers

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STRUCTURE BORNE ENGINE NOISE CONTROL.


Noise Reduction methods

Engine structure modifications :


Cylinder Block :
• Stiffening of structural elements, connection
surfaces, and panels
• Close shielding of major noise radiating
surfaces

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STRUCTURE BORNE ENGINE NOISE CONTROL.


Noise Reduction methods
Engine structure modifications :
Engine Covers:
• Isolation from vibrating connection to the
engine structure surface
• Damping of cover material
• Addition of ribs to change the stiffness
for less response at critical frequencies
• Improvement in acoustical properties by
use of alternate materials

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STRUCTURE BORNE ENGINE NOISE CONTROL.


Noise Reduction methods
Engine structure modifications :

Fuel Injection Equipment:

• Reduced noise pump structure


• Low vibration transmission pump mountings
• Improved injector characteristics for
smoother combustion initiation

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STRUCTURE BORNE ENGINE NOISE CONTROL.


Noise Reduction methods

Engine structure modifications :


Cylinder head :
• Improved combustion features e.g. ports
and combustion bowl optimization for smoother
combustion initiation
Manifolds :
• Vibration isolation and damping added to the
manifolds

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

STRUCTURE BORNE ENGINE NOISE CONTROL.


Transmission gear noise Control:
Possible means for reduction of transmission error :
Shifting of resonances of each gear from gear meshing
freq.
Shifting of critical speed of shafts away from gear
meshing freq.
Shifting of freq. of housing away from gear mesh
frequency
Vibration Isolation
Tuned vibration absorbers
Constraint Layer Damping
Reduction of shaft deflection due to dynamic loading

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

STRUCTURE BORNE ENGINE NOISE CONTROL.

Belt Noise Control


• Vibration of the pulley
• By reducing the clearance,rattle can be reduced
• Covers of highly damped materials
• Profile with decreased tooth flank area which leads to
higher tooth tip width
• Modified sprocket profile with soft contact at bottom land
of belt and tooth tip of sprocket.

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

STRUCTURE BORNE ENGINE NOISE CONTROL.


Chain Noise Control

•Fine pitch and accurately matched pitches


• Damping of large sprockets
• Use of guide wheel and rubber ring to
driving sprockets
• Changing torsional behaviour of cam shaft

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

Acoustical
Treatment

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

Ride Comfort

Ride - Tactile And Visual Vibrations,


0 - 25 Hz
Ride Perception
Vibrations - Noise Aural (25 Hz - 20 kHz)

EXCITATION
SOURCES VEHICLE
Road roughness DYNAMIC VIBRATIONS
Tire/Wheel RESPONSE
Driveline Engine

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

Vehicle Ride Comfort

> Ride comfort in a vehicle is a subjective perception normally


associated with level of comfort experienced during travelling
in a vehicle.

> Perceived ride is cumulative effect of many factors.

> In the vibration spectrum,


Ride - 0 -25 Hz
Noise - 25Hz - 20KHz.
> Ride is a tactile and visual vibrations.

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

Vehicle Ride Comfort


> Vertical frequencies which feels most uncomfortable falls in the
range of 20Hz - 200Hz.

> Fatigue occurs most rapidly when subjected to vibrations in the


range of 4Hz to 8Hz or in the low band below 0.75 Hz where
dizziness and motion sickness can results

> Lateral or fore/aft frequencies in the same range are also


uncomfortable because it disturb balance of inner ear.

> ISO:2631 for exposure limits of whole body vibrations and


ISO:5349 for exposure to hand arm vibrations.

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VIT M. TECH. (AUTO) COURSE (Noise, Vibration and Harshness )

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