11 Automotive ACTRAN在汽车工业的应用

Actran for Automotive NVH
Ze Zhou,
Application Engineer, FFT
ze.zhou@fft.be
Copyright Free Field Technologies

Outline
 Introduction: 2 levels of usage of ACTRAN
 Simulating isolated components (up to a few kHz)
 Tire, wheel arch
 Powertrain & cover design
 Carpet, dashboard, etc: multilayered trim design
 Intake, Exhaust systems
 Diesel injection ducts
 Sealing problems
 HVAC duct (aeroacoustics)
 HVAC blower, EC fan
 Side windows (aero-vibro-acoustics)
 Simulating the complete vehicle
 Trim Body Analysis (up to 500Hz)
 How to feed other tools with Actran inputs?
2 Copyright Free Field Technologies

Introduction
 There are two possible types of computations
 Predictive computation
 Objective: compare results to experiments
 A correct source description + correct boundary conditions are
mandatory
 Very often, this means that the complete system must be modeled
 Exceptions: isolated problems (ex HVAC) or small contact
(superelement)
ACTRAN TEST
 Comparative computation
 Objective: compare different designs, absolute levels are not needed
 Approximate sources & BCs can be sufficient
 Then it is much smarter to focus on the component
 This is usually much easier thus preferable
Intake, Exhaust Simulation
From low frequencies up to several kHz

Intake, Exhaust
 Ex: exhaust line Out
Out
(shell)
 Pipe noise: propagation of acoustic waves (pipe)
is ducts subject to heterogeneous flows &
temperature, with perforations, foams… In
 Shell noise: radiation of the vibrating skin

of the mufflers; the vibration is fully coupled
with the interior acoustics
 ACTRAN can model both phenomena
 Boundary conditions for ducts
 Support of heterogeneous fluid media
 Foams, perforated sheets, …
 Fully coupled vibro-acoustic solver
 TMM strategy to cut the problem in subproblems
 Coupling with 1D tools
 And account for the presence of the car (rigid or vibrating)

Problem Description
 Characterization of a component of the line (example: muffler)
Incident
Transmitted
power
power (pipe
from the
noise)
engine
Not reflective
BC
 The Transmission Loss (TL) is calculated
 TL: difference between the incident power (from the engine) and transmitted
power (pipe noise) going through a component
TL =10.log10(Wincident/Wtransmitted)
 Using the Transfer Matrix Method, the transmission through the entire
line can be deduced a posteriori

Take the Temperature into Account
 The effect of temperature / flow on the local sound speed and density is
computed by Actran
 The temperature field must be computed at each node location. This
can be done by an external CFD code or using Actran (simplified
assumptions)
600°
K
300°
K

Effects of the Temperature – Transmission Loss
Transmission Loss
With temperature
 Strong effect of the temperature !!

Transfer Matrix Method (TMM) with Actran
 Analytical TMM methods are limited
TMM analytic codes are limited to the
 Simple shapes lowest cut-on frequency of all the
elements (inlet/outlet/internal duct).
 Only plane modes (see )
Ex:
 No shell noise , no structure dissipation
 Homogenous medium Finlet = 8000Hz
Foutlet 6000Hz
Finternal = 2000Hz
TMM analytic codes can perform the TL

computation only until 2000Hz.
 For more complex modeling, TMM can be
used within Actran Mix-method (ACTRAN+TMM) can compute
 Complex geometries the TL until the lowest cut on frequency of
the inlet/outlet duct.
 Up to the cut-on frequency related to the
Ex:
connecting ducts
 Shell noise + structure dissipation possible Finlet = 8000Hz Finternal = 2000Hz
 Flow or temperature gradients possible In this case, ACTRAN can perform the TL
computation until 6000Hz

TMM: Process
Task 1: Geometry – Division into subsystems

 Process
 A specific GUI menu
activates this behavior
Task 2a: ACTRAN Model creation To be
 Automation is possible performed
through the scripting for each
 The coupling with 1D Task 2b: ACTRAN computations component
tools is straightforward
Task 3: Results recombination using TMM

MITSUBISHI Application of Exhaust Noise:
Transmission Loss
A real example from Mitsubishi

Introduction
 Objective: model real exhaust systems efficiently Complete Line
and accurately E
D
 Strategy C
 The source is well known (expertise of Mitsubishi) B

A
 Each part of the line is modeled individually in
ACTRAN
 Porous parts: Biot model
Subsystems
 Perforated plates: Mechels technique
 Boundary conditions: duct modes
 The parts are assembled using the TMM
 Validation
 Comparison with the complete exhaust line modeled in
one simulation
 Results match perfectly
 Exploitation: influence of the presence of the car
 More details in the proceeding of the FFT Users
Meeting 2010
Example of a typical muffler
 The perforations are modeled

using the Mechels’ formula
 The foam (porous) is modeled

using porous UP elements

Simulation case result
 Up to 2KHz the simulation result have good matching
 Need to check their accuracy for those value above 3KHz

Add the car
 Set exterior sound field around exhaust exit
 Re-build body structure and simulate the sound propagation
Taking the presence of the car into account

Effective to validate
•The position of the
partition plate
•The insulation material

 Predict body exterior noise

Aero-Vibro-Acoustics: Side windows and
Windshield
ISNVH 2012 Conference ( Paper 2012-01-1521 )

Introduction - Objectives
 Objective:
 Compute the sound pressure level inside the car cavity induced by
aerodynamic pressure fluctuation applied on both the side windows
and the front windshield.
 Analyses:
 Contributions from side windows and windshield
 Influence of yaw angle (flow angle with car)
 Dissipation mechanism

Computation strategy
 Compressible CFD transient simulation around the car
 Mapping and Fourier transform of the CFD pressure results (time domain) on
structure surface mesh (frequency domain)
 Vibro-acoustic computation of the coupled structure and cavity
Actran Actran/VI
Vibro-acoustic model Post-processing

Acoustic Source and Surface Pressure Source
Acoustic source from turbulence:
Turbulences Actran Aero-Acoustics Actran VibroAcoustics

Vortex structures shed Turbulence noise from the Noise transmission
downstream the side mirror vortex structures through the window
generates turbulences
Surface pressure source

from turbulence:
Actran VibroAcoustics
Turbulences
Pressure fluctuation on the Noise transmission
surface of the side window through the window

Aerodynamic excitation
 Flow : cruising speed ~ 130km/h
 Compressible Unsteady CFD results with PowerFlow™
 CFD results in the time domain . T: 0.6s, t: 4e-5s
 Outputs: the wall pressure fluctuation loaded on the windows at each CFD
time steps
 Results are available for 2 flow conditions (Yaw angle)
 0° orientation (symmetric)
 10° orientation

Vibro-Acoustic Model (1)
 The Windshield is made of three  Side windows are made of a single
layers (Glass - PVB - Glass). layer of glass.
 They are connected to the car
 Mechanical properties of PVB is (assumed perfectly rigid) through
frequency dependant, including a rubber seals
damping loss factor.
Windshield mesh

Vibro-Acoustic Model (2)
 The acoustic cavity is meshed to

reach 2000Hz based on 4
quadratic element per wavelength
 In order to represent the damping

of the cavity, the speed of sound
Imaginary Part of C
is provided as a complex value
deduced from the 60dB
reverberation time (T60).
[m/s]
frequency
[Hz]

Comparison with Measurements
 SPL at driver’s ear position
10dB

Contributions from the Windows (0°)
 With 0o yaw angle, the contributions of each side window and windshield are
evaluated
 The contribution from the windshield is negligible above 500Hz. The high
damping of PVB is important
10dB
Mean Square Pressure in Car Cavity

0° flow configuration

 With a 10° yaw angle, more turbulent flow (vortices) is produced by the
flow separation close to the left A-pillar. On the right side, the static
pressure is higher but the fluctuations are less important.
10dB
10dB
Mean Square Pressure in Car Cavity


 The pressure field is much more intense on the left side than on the
right side.
Integrated Wall Pressure Fluctuation
- on the left side window (a)

- on the right side window (b)
at 1000Hz for the 10°yaw angle

Dissipation in Different Components
 Below 500Hz, more power is dissipated in the windshield
 Above 500Hz, the windows are dissipating more energy than the
windshield
 The dissipation occurring in the cavity due to the trim (modeled using a
complex speed of sound) is low
10dB

Transmission mechanism of flow-induced noise from the
forward facing step through the glass plate

Actran for Trim Component Analysis

Carpet, Dashboard, etc: Trim design
 ACTRAN can model multi-layered trim components
 Foams are modeled using the BIOT theory (state of the art)
 The solver can accommodate any number of material
layers
 Even thin air layers can be modeled (viscothermal losses)
 And composites (eg for textiles)
 Ex. of use of ACTRAN: optimize a multilayered trim
 in-built model of Diffuse Sound Field (RTC III)
 Access to the energy balance
Frame
Heavy Layer
Porous Layer
Damping Layer
Metal Layer
Picture courtesy of Rieter Automotive

Problem Description - 1
 RTC-III (from French, Rayonnement des Tôles de Carrosserie)
 simplified representation of a floor panel of a passenger car body
 measure of the efficiency of damping materials and treatments
 The system comprises essentially three parts:
• An upper cabin which serves

as a reception chamber.
• The excitation part: a very

stiff frame excited by a shaker,
• The lower cabin, on which

the excitation assembly is
placed

Problem Description - 2
 The experimental set-up is modeled in Actran
 The three layers of the trim component are modeled
Modes of the
cavities
Trim component description
 aluminum
 foam
 heavy layer (carpet)

Results - Average Acceleration
Measurement vs. Actran Measurement vs. Actran

Steel only Trimmed panel

Results – Average Acoustic Pressure
Average SPL Average SPL

Measurement vs Actran Measurement vs Actran
Steel only Trimmed panel

Automatic Power Balance Statement
 ACTRAN allows for the evaluation of dissipated powers in all materials
 dissipation by structural damping within the skeleton
 dissipation by thermal effects within the fluid phase
 dissipation by viscous effects within the porous mat. (fluid/skeleton friction)
W
 Dissipated power (W) and stored energy (E)  loss factor : 
2E

Case Study 2:
Vibro-acoustic FEA Modeling of Two Layer Trim
Systems
Christian Y. Glandier and Ralf Lehmann

DaimlerChrysler AG
Takashi Yamamoto and Yoshinobu Kamada
Mitsubishi Motors Corporation
2005 SAE International

Model Description
 Each layer as well as the frame
and the air are modeled with finite
elements
 The following properties are used

Measurement Set-Up
 The experimental set-up is
described in the picture beside.
A shaker excites a frame
which is connected to the trim
component
Excitation system
 2 radiating conditions are set-up

 Radiation in free field
 Radiation in closed-box
Free field radiation / closed box

radiation
Results
 Acoustic Results
SPL at 1m (foam SPL at 1m (fibrous

trim) trim)
 Very good agreement between simulations and measurements

Floor Transmission Analysis
 Structure & airborne transmission through rear floor
 Airborne: diffuse sound field
 Structure borne: mechanical load

Carpet, dashboard, etc: trim design
 Application example: optimize the treatment on a dashboard
 The dashboard is modeled in ACTRAN
 The presence of the car is modeled with a NASTRAN superelement
Multilayered trims
+ dashboard shell
In ACTRAN
Boundary Condition: The performance of the treatment

a NASTRAN superelement can be quantified

ACTRAN for
Large Trimmed Body Modeling

ACTRAN for NASTRAN: Large Trimmed Body Modeling
 Problem being addressed to: Evaluate the vibro- Trims

acoustic behavior structure
of full-trimmed body (vehicle for example): cavity
 Car body : complex geometry, lightly damped structure;
including the non-acoustic trims (ex: oil tank)
 Car compartment : irregular acoustic cavity
 Acoustic Trim components : visco-elastic and porous
materials
trim components have important vibro-acoustic
damping effect
(ex: carpets, headliner, dash insulator, dashboard "IP")
 ACTRAN offers an innovated strategy to solve the

above problem

Large Trimmed Body Modeling with ACTRAN
Process
Dynamic FEA Code ACTRAN
Modal extraction of Modal results

the structure
Computation of Trim Reduces

Modal extraction of Impedance  Trim database
the cavity
Computation of Fluid /
Structure coupling for a
given Trim configuration
FRF solution for the complete

Process
model (cavity + structure + trim)

Computation: Step 1 – Modal Extraction
Structural Modes
Modal extraction of Modal results

the body (Φs ) - SOL103
Modal extraction of
the cavity (Φa ) - SOL103
Acoustic Modes
Performed is in NASTRAN

Computation: Step 2 –Impedance of Trim
Model the trim component in Actran and calculate its impedance
Structure
uT ,s uT ,inner
Trim: T
pT ,inner
pT ,F
Cavity
Trims are modeled with multi-layer components, including damping

layers, porous material foams, etc.

Computation: Step 3 – Projection of Trim Impedance
Project the trim impedance into modal coupling of BIW and cavity
Structure
uT ,s uT ,inner
Trim: T
pT ,inner
pT ,F
Z red   Cavity
Projection of trim’s Reduced
Impedance into modal space Structure / Cavity coupled system
 Ts 0    s 0    TS  FS   
      Z   
 F   SF    s   
 0 TF  red  0   
 T  F   
SS
    
FF    F   
T F
 SF  F 
 2 
modal modes ×
impedance factor excitation
Injection of modal space

impedance into system equation
Configuration Studies
 The impedance matrices of different trims are stored in different files
 Configuration studies can be easily performed
Config: headliner
Trims
structure
cavity Config: dash
Config: floor

Validations :
Exhaust Noise Transmission to the Interior of a
Trimmed Vehicle
Reference :
Numerical Prediction of the Exhaust Noise Transmission to the Interior of a Trimmed Vehicle by using the
Finite/Infinite Element Method
Diego d’Udekem et al. (FFT), Takashi Yamamoto (Nissan Motor Co Ltd),
SAE International 2011 Noise and Vibration Conference and Exhibition, 2011, Michigan, USA

Background and purpose
 Predict exhaust contribution to interior noise in acceleration phases
 Focus on the prediction of the efficiency of the insulation package
 Estimate the acoustic field into the cabin
Engine revolutions per minute [rpm]
Transfer
function Transfer function
for air-borne for structure-borne
noise noise
Frequency [Hz]
Boomin Sound Exhaus Input force

g noise qualit t noise from Engine
y

Modeling Strategy
 Two-step approach:
Exterior Acoustic Model Interior Vibro-Acoustic model
From the plane wave source in the exhaust From the distributed pressure on the exterior of
pipe, get the distributed pressure on the the car structure, get the pressure fluctuations
exterior of the car structure in the car cavity (modal approach with trims)
ACTRAN Acoustic FE/IE model ACTRAN for Nastran model

Computational Sequence: Two Years Ago

Computational Sequence: Now
ACTRIM ACLOAD
New cards in MSC.Nastran 2012:
ACTRIM: import Actran frequency dependant trim impedance

ACLOAD: import Actran frequency dependant pressure load

Validation - Exterior Acoustic Analysis
 The distributed pressure on the exterior of the car structure is compared with
experimental data :
Measurement
4 Calculation
Experimental setup : Spherical source set at the exhaust,
Measure on right side of vehicle with 100 mm resolution 2 3
1
5
Measurement
Calculation
100Hz 300Hz
Measurement Measurement
Calculation Calculation
Dash insulator and floor carpet
Experiment Simulation
Dash insulator and floor

carpet
W/o insulator W/o insulator
W/ insulator W/ insulator
Acoustic transfer function Acoustic transfer function
Structure transfer function Structure transfer function

Sound Pressure Response in Cabin
 The Transfer function from speaker source to ears position is displayed
with and without insulator

Powertrain Acoustic Radiation

Powertrain & Cover Design
ANSYS Computation ACTRAN Model
ANSYS Computation
MORE… ACTRAN Results

Powertrain: Experimental Validation
 Acoustic measurements have been done to assess the accuracy of both
the structural computation and acoustic radiation.
 For the complete set of frequency, regimes and microphones, a
maximum of 2dB difference has been detected.
(Normalised results)
Magnus Gustafsson (VolvoTrucks) et. All. : Experimental Validation of an Efficient Procedure for Large
Acoustic Radiation Problems, ISMA 2010 Copyright Free Field Technologies
64
Actran AeroAcoustics for HVAC ducts, Air conditioning
Application examples
17
16
15
14
Theta = 180°
13
Phi = 0°
12
11
10
9
Phi = 180°
8
Theta = 0° 7
6
5
4
1 2 3

Simplified HVAC duct
Benchmark validation study proposed by Daimler, Audi, VW, BMW, Porsche

Results published at the AIAA Aeroacoustics conference
17
16
15
14
Theta = 180°
13
Phi = 0°
12
11
10
9
Phi = 180°
8
Theta = 0° 7
6
5
4
3
1 2 Copyright Free Field Technologies
German Aeroacoustics Consortium
 Daimler, Audi, VW, BMW, Porsche have
defined a test case: duct + elbow + flap
17
16
15
14
Theta = 180°
13
Phi = 0°
12
11
 Measurements (@Dornier) in anechoic room 10
 CFD input: star-CD results, LES-type Phi = 180°

8
Theta = 0° 7
 Acoustic computations with ACTRAN 5

6
4
3
67 Copyright Free Field Technologies 1 2
Results
 Several investigations have been conducted to gain expertise on this
type of problems (ex: modeling the complete windtunnel is very
important)
 Published result:
The green envelope corresponds to the

min, max and averaged levels measured;
The numerical curve show only the averaged
CFD from star-CCM+
AIAA 2009-3352: Validation of a New Hybrid CAA strategy and Application to the Noise Generated by a Flap in a
Simplified HVAC Duct- S. Caro, Y. Detandt, J. Manera, R.Toppinga, F.Mendonça
Aero-Acoustic Predictions of Automotive
Instrument Panel Ducts with ACTRAN
Case Study Description

Context
 These results have been obtained within a joint effort of FFT and VISTEON Interior
Systems France
 The main goal of this study is to show the ability of ACTRAN to predict accurately the
noise generated by a steady turbulent flow inside a instrument panel duct
 2 representatives cases of ventilation duct are investigated
 The CFD computations have been performed with ANSYS FLUENT and the
measurements have been done by VISTEON
 These results are included in a scientific paper presented at the 2009 NVH SAE
Conference (Aero-Acoustic predictions of automotive instrument panel ducts; Detry, Manera, Detandt, d’Udekem;
SAE NVH 2009)

Process Overview
 Easy to use procedure - CFD

and acoustic computational
chains are decoupled
 Efficient procedure - mapping
strategy (integration
technique). A pure acoustic
meshing criterion is sufficient:
there is no need for a
refinement of the mesh in the
sources zone
 Robust procedure ACTRAN
directly reads native CFD files

Test Cases
Central Duct
Lateral Duct
43
cm

Central Duct
Experimental Set-Up ACTRAN Results
CFD Results - Fluent

TEST
ACTRAN

Aircondition Aeroacoustics

HVAC duct (aeroacoustics)
 Objective: post-process complex, unsteady CFD results and compute
the flow noise of a HVAC duct system
 Example: Fluent + ACTRAN
 Another example: true register

 CFD: 15h
 CAA: 6h
 Target: 3kHz
 Our unique strategy
ensures excellent results
HVAC blower, EC fan
 Objective: compute the noise from a rotor
 ACTRAN can handle rotating devices
 There is no need to assume free field or far field conditions!
 Target application: HVAC blower, EC fan…
 (please ask for details)

Conclusions
 ACTRAN can model lots of components
 Tire, wheel arch
 Powertrain & cover design
 Carpet, dashboard, …: multilayered trim design
 Intake, Exhaust
 Diesel injection ducts, Sealing problems
 HVAC duct (aeroacoustics), HVAC blower, EC fan
 Side windows (aero-vibro-acoustics)
 ACTRAN can simulate complete vehicles

 Trim Body Analysis (below 500Hz)
 How to feed other tools with ACTRAN inputs?

11 Automotive ACTRAN在汽车工业的应用

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Actran for Automotive NVH

Copyright Free Field Technologies

2 Copyright Free Field Technologies

From low frequencies up to several kHz

Copyright Free Field Technologies

 Shell noise: radiation of the vibrating skin

5 Copyright Free Field Technologies

6 Copyright Free Field Technologies

7 Copyright Free Field Technologies

 Strong effect of the temperature !!

TMM analytic codes can perform the TL

9 Copyright Free Field Technologies

Task 1: Geometry – Division into subsystems

Task 3: Results recombination using TMM

A real example from Mitsubishi

Copyright Free Field Technologies

 The source is well known (expertise of Mitsubishi) B

 The perforations are modeled

 The foam (porous) is modeled

13 Copyright Free Field Technologies

 Up to 2KHz the simulation result have good matching

 Need to check their accuracy for those value above 3KHz

14 Copyright Free Field Technologies

15 Copyright Free Field Technologies

16 Copyright Free Field Technologies

17 Copyright Free Field Technologies

ISNVH 2012 Conference ( Paper 2012-01-1521 )

Copyright Free Field Technologies

 Contributions from side windows and windshield

 Influence of yaw angle (flow angle with car)

19 Copyright Free Field Technologies

20 Copyright Free Field Technologies

Turbulences Actran Aero-Acoustics Actran VibroAcoustics

Surface pressure source

21 Copyright Free Field Technologies

22 Copyright Free Field Technologies

23 Copyright Free Field Technologies

 The acoustic cavity is meshed to

 In order to represent the damping

24 Copyright Free Field Technologies

25 Copyright Free Field Technologies

Mean Square Pressure in Car Cavity

26 Copyright Free Field Technologies

Mean Square Pressure in Car Cavity

27 Copyright Free Field Technologies

Integrated Wall Pressure Fluctuation

- on the left side window (a)

at 1000Hz for the 10°yaw angle

28 Copyright Free Field Technologies

10° flow configuration

29 Copyright Free Field Technologies

Copyright Free Field Technologies

Copyright Free Field Technologies

32 Copyright Free Field Technologies

• An upper cabin which serves

• The excitation part: a very

• The lower cabin, on which

33 Copyright Free Field Technologies

34 Copyright Free Field Technologies

Measurement vs. Actran Measurement vs. Actran

35 Copyright Free Field Technologies

Average SPL Average SPL

36 Copyright Free Field Technologies

37 Copyright Free Field Technologies