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Roles of Rear Subframe Dynamics and Right-Left Spindle Phasing in the Variability of Structure-Borne Road Noise and Vibration TH

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Roles of Rear Subframe Dynamics and Right-Left Spindle Phasing in the Variability of Structure-Borne Road Noise and Vibration TH Roles of Rear Subframe Dynamics and Right-Left Spindle Phasing In the Variability of Structure-Borne Road Noise and Vibration THESIS Presented in Partial Fulfillment of the Requirements for the Degree Master of Science in the Graduate School of The Ohio State University By Revathi Rengarajan Graduate Program in Mechanical Engineering The Ohio State University 2016 Master's Examination Committee: Dr. Rajendra Singh, Advisor Dr. Jason Dreyer Dr. Scott Noll Copyright by Revathi Rengarajan 2016 ABSTRACT New experiments and minimal order analytical and computational models are developed and analyzed to investigate the variability of structure-borne noise and vibration due to tire/road interactions in the lower to mid-frequency regimes. The investigation focuses on a class of rear suspension systems that contain both direct and intersecting structural paths from the tire contact patches to the vehicle body. The structural paths intersect through a dynamically active rear subframe structure. Controlled operational experiments are conducted with a mass production minivan on a chassis dynamometer equipped with rough road shells. Unlike prior literature, the controlled experiments are analyzed for run-run variations in the structure borne noise up to 300 Hz in a single vehicle to evaluate the nature of excitations at the spindle as the key source of variation in the absence of significant manufacturing, assembly and instrumentation errors. Further, a deterministic, modal expansion approach is used to examine these variations. Accordingly, an eleven-degree- of-freedom reduced order lumped parameter half vehicle model is developed and is analytically utilized to demonstrate that left-right spindle excitation phasing dictates the participation of the subsystem vibrational modes in the system forced response. The findings are confirmed through the analysis of a reduced finite element model of the vehicle system with a high fidelity, modally dense suspension model, where the left-right rolling excitation phasing at the spindle alone is found to affect the component dynamic vibration amplitudes up to 30 dB depending upon the component location and frequency ii range. These results are in qualitative agreement with the type of variations observed in the experiments. iii DEDICATION To my beloved family iv ACKNOWLEDGMENTS I would like to thank my advisor, Prof. Rajendra Singh for providing me with the wonderful opportunity to work under him and for his knowledge, guidance and support throughout my master’s program and research project. I would also like to express my immense gratitude to Dr. Scott Noll for mentoring me through the course of my research and encouraging many technical discussions to enhance this work. I would also like to thank my committee member Dr. Jason Dreyer for taking the time to critically review my work, and also for being ever ready to extend a helping hand at various stages of my research work. I would also like to thank all the members of the Acoustics and Dynamics Lab for their thoughtful feedback on the numerous research presentations over the past two years. I would like to thank the member organizations such as F.Tech R&D and Honda R&D of the Smart Vehicle Concepts Center (www.SmartVehicleCenter.org) and the National Science Foundation Industry/University Cooperative Research Centers program (www.nsf.gov/eng/iip/iucrc) for supporting this work. I am extremely grateful to my parents and my brother for their endless support and encouragement. v VITA 2014................................................................B.Tech Mechanical Engineering, Amrita School of Engineering Coimbatore, India 2014 to present ..............................................Graduate Research Associate, Department of Mechanical Engineering, The Ohio State University Fields of Study Major Field: Mechanical Engineering Concentration: Automotive Noise, Vibration, and Harshness; System Dynamics vi TABLE OF CONTENTS ABSTRACT ........................................................................................................................ ii DEDICATION ................................................................................................................... iv ACKNOWLEDGMENTS .................................................................................................. v VITA .................................................................................................................................. vi Fields of Study ............................................................................................................... vi TABLE OF CONTENTS .................................................................................................. vii LIST OF TABLES .............................................................................................................. x LIST OF FIGURES ........................................................................................................... xi LIST OF SYMBOLS……………………………………………………………………xiv Symbols ........................................................................................................................ xiv Subscripts ...................................................................................................................... xv Superscripts ................................................................................................................... xv Abbreviations ................................................................................................................ xv CHAPTER 1: INTRODUCTION ...................................................................................... 1 1.1. Background .......................................................................................................... 1 1.2. Literature Review ................................................................................................. 2 vii 1.3. Problem formulation ............................................................................................ 3 CHAPTER 2: OPERATIONAL VEHICLE EXPERIMENTS AND DEVELOPMENT OF HIGH FIDELITY FINITE ELEMENT MODEL ......................................................... 7 2.1. Operational Vehicle Experiments ........................................................................ 7 2.1.1. Test Setup ......................................................................................................... 7 2.1.2. Operational measurements ............................................................................... 8 2.2. Development of high fidelity finite element model ........................................... 15 CHAPTER 3: MINIMAL ORDER LUMPED PARAMETER MODEL OF THE REAR- HALF VEHICLE .............................................................................................................. 17 3.1. Development of a minimal order lumped model ................................................... 17 ....................................................................................................................................... 17 3.2. Real eigensolution of the lumped vehicle model ................................................... 21 3.3. Forced response analysis using real eigensolutions ............................................... 23 3.4. Forced response analysis using complex eigensolutions ....................................... 31 CHAPTER 4: FORCED RESPONSE FROM FINITE ELEMENT MODEL ................. 35 4.1. Forced response from finite element model under harmonic excitation ............ 35 4.2. Comparison of predicted and measured results.................................................. 38 CHAPTER 5: CONCLUSION ......................................................................................... 43 5.1. Summary ................................................................................................................ 43 viii 5.2. Contributions and future work ............................................................................... 44 REFERENCES ................................................................................................................. 46 ix LIST OF TABLES Table 1: Parameters for the lumped vehicle model of Fig. 7 ............................................ 22 Table 2: Real and complex eigenvectors for left and right spindles ................................. 30 Table 3: Modal force vectors for in-phase and out-of-phase cases .................................. 31 x LIST OF FIGURES Figure 1: Schematic of rear suspension (a) top view; (b) side view; key- A, subframe; B, suspension spring; C, damper; D, trailing arm; E, spindle center; locations for accelerometers on the subframe are given by 1– 6. ............................................................ 4 Figure 2: Measured sound pressure level spectra (Lp, dBA re 20 μPa) at the driver’s left ear (DLE) on a narrow band basis from 30-300 Hz (a) run-run variations: ―, Run 1; ----, Run 2; …, Run 3; (b) range plot representation of the run-run variations; (c) difference between maximum and minimum sound pressure levels (ΔLp, dBA) at each frequency. ................ 9 Figure 3: Measured acceleration spectra (푳풛, dB re 1.0 g rms) on the rear subframe (at location 1 as shown in Fig. 1), on a narrow band basis from 30-300 Hz (a) run-run variations: ―, Run 1; ----, Run 2; …, Run 3; (b) range plot representation of the run-run variations; (c) difference between maximum and minimum acceleration response (횫푳풛, dB) at each frequency. .....................................................................................................
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