2019-06-12 MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR) 1

Multidisciplinary OPTIMZATION OF GEOMETRIC VARIATIONS &

MODAL BEHAVIOUR FOR SQUEAK & RATTLE PREVENTION

MSc Thesis Students

SAIPRASAD KULKARNI, chalmers university of technology

DHARUN VELMANI THANGA RATNAM , chalmers university of technology

Supervisor

MOHSEN BAYANI, Volvo cars corporation

Sandeep shetty, volvo cars corporation

Examiner

Prof. LARS LINDQVIST, CHALMERS UNIVERSITY OF TECHNOLOGY

MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR) 2

Agenda

- Thesis statement

- METHODOLOGY

- Geometric variation analysis

- Modal Behavior analysis

- Multidisciplinary optimization

- Results

- feedback

2019-06-12

THESIS statement

3

➢ To minimize the occurrence of Squeak & Rattle in the Interior

assemblies of premium segments of Volvo Cars.

➢ To perform Multidisciplinary Optimization for Geometric

variation analysis & Modal Behaviour analysis to find the

optimal position in an interior assembly.

MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)2019-06-12

MDO METHODOLOGY

Geometric

Variation

Modal

Behaviour

RD&T

Pre processor-ANSA

Post processor- Meta

Solver- NASTRAN

MDO Techniques

modeFrontier

MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)2019-06-12 4

INTERIOR ASSEMBLIES SUBJECTED TO SQUEAK & RATTLE

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SR.NO. CATEGORIES MATERIAL COMBINATION ASSEMBLY NAME

1 Panel - Panel Plastic - Steel Side Door

2 Panel - Structure Steel - Steel Tailgate

3 Panel Beam Metal - Metal Door outer panel - Crash Beam

4 Bracket - Panel Metal - Metal A-Pillar - IP Bracket

5Panel - Complex

Geometry (Structure)Plastic - Plastic IP Top cover - IP Deco Panel

6 Panel - Structure Plastic - Metal Glovebox - IP (dampers,latches,hinges)

MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)2019-06-12

Geometric variation analysis

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Measures

Weld PointsRD&T Model – Deco Panel & IP AssemblyMDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)2019-06-12

Variation Analysis outputs following results:-

➢ Measure details

➢ Range

➢ 6 Sigma

➢ 8 Sigma

➢ Nominal values

➢ Mean

➢ Mean shift

Geometric variation analysis

2019-06-12 7MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

Modal behavior analysis

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C-Bush Elements

ANSA Model - Deco Panel & IP Assembly MeasuresMDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)2019-06-12

Eigen Mode ANALYSIS

2019-06-12 9MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

Dynamic stiffness (magnitude) plots – Normal

2019-06-12 10MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

Modefrontier setup

2019-06-12 11MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

DESIGN OF EXPERIMENTS

2019-06-12 12MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

FULL FACTORIAL SETUP

For k factors, each at 2 levels, a full factorial design has 2k runs.

i.e. 28 runs (since input variables =8)

No.of Design Samples = 256

Feasible designs = 70

Unfeasible designs = 186

For combination of 4 input

variables as design sample

nCr =n !

r ! (n − r)!,

RESULTS

2019-06-12 13MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

PARALLEL COORDINATE CHART

70 Feasible soltuions

8 input variables & 2 objectives

2 Feasible soltuions

8 input variables & 2 objectives

results

2019-06-12 14MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

feedback

2019-06-12 15MDO OF GEOMETRIC VARIATION & MODAL ANALYSIS FOR SQUEAK & RATTLE PREVENTION (SKULKAR6,DTHANGAR)

Thank you !