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Splitter Box Analysis Methodology

Pascal Pelloquin, Liebherr Machines Bulle


Forum ANSYS, 2014-09-10

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9/9/2014
Liebherr Group

 Workforce: 39’500

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 Companies worldwide > 130
 Turnover: 9 billion €

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2014-09-10 PEL Splitter box analysis methodology @ LMB
Liebherr Machines Bulle
Diesel engine

Splitter box

Hydraulic
motors

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3 2014-09-10 PEL Splitter box analysis methodology @ LMB
Overview
Static model

CAD Static Fatigue


Design Simplifications Analysis Analysis

Dynamic model

CAD Modal Harmonic


Simplifications Analysis Analysis

Acoustic model

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Acoustic
CAD Modelling
Analysis

4 2014-09-10 PEL Splitter box analysis methodology @ LMB


Overview
Static model

CAD Static Fatigue


Design Simplifications Analysis Analysis

Dynamic model

CAD Modal Harmonic


Simplifications Analysis Analysis

Acoustic model

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Acoustic
CAD Modelling
Analysis

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LMB designs & applications
Design

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Static and fatigue CAD
Simplifications
 Model preparation for static analysis
 Splitter box
 Minor simplifications in Pro/E
 Diesel engine
 Simplified model of flywheel housing
 Mock-up for the block
 Hydraulic pumps (housing)
 Cast filets removed in Pro/E
 Most machining features removed in Pro/E
 Final simplifications with Design Modeler
 Engine feet

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 Important for moment balance on splitter box

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Static and fatigue Static
Analysis
 Model setup
 Mass balance
 Point mass for fluids in the engine and in the
pumps
 Point mass for hydraulic pipes

 Components idealized as Ansys bushing linear


elements:
 Bearings (stiffness obtained from Bearinx)
 Engine mount (stiffness obtained from supplier)
 Part liaison:

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 Non-linear contacts
 Bolt pretension considered

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Static and fatigue Static
Analysis
 Static loading
 All 8 possible load case combinations considered
 Static results Accelerations

Von Mises
Equivalent
Stress

1g +/-Vertical

+/- Axial
+/- Lateral
Bolt check according to

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VDI2230

No plastic deformation,
→ design acceptable

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Static and fatigue Fatigue
Analysis
 Fatigue loading
 All 8 possible load case combinations, load cycles
following specs, surface roughness, 99.99%
Accelerations
survival probability considered into FEMFat
 Fatigue results
Safety
Factors

1g +/-Vertical

+/- Axial
+/- Lateral
Bolt check according to

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VDI2230
Critical positions
Minor design
improvements mandatory

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Overview
Static model

CAD Static Fatigue


Design Simplifications Analysis Analysis

Dynamic model

CAD Modal Harmonic


Simplifications Analysis Analysis

Acoustic model

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Acoustic
CAD Modelling
Analysis

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Dynamic Analysis CAD
Simplifications
 Model preparation for dynamic analysis
 Model assembly into Design Modeler
 Reduced size of function tree
 Bolts replaced by bonded contact surfaces

Ød

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ØD

Bonded surfaces
ØD = Ød + 2h

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Dynamic Analysis Modal
Analysis
 Engine unbalanced forces and moments
 Based on inertia of cranktrain and cylinder pressure
curves
 For example, avoid a certain frequency range for
moment along Z-Axis
Frequencies [Hz]

𝒏 𝑶 (𝟏 ± 𝑴𝒔 )
Flow Avoid this range Fhigh 𝒇=
𝟔𝟎

Fmode 𝒇: 𝒇𝒓𝒆𝒒𝒖𝒆𝒏𝒄𝒚 𝒐𝒇 𝒆𝒙𝒄𝒊𝒕𝒂𝒕𝒊𝒐𝒏 𝑯𝒛

𝒏: 𝒆𝒏𝒈𝒊𝒏𝒆 𝒔𝒑𝒆𝒆𝒅 𝑹𝑷𝑴

𝑶: 𝒆𝒙𝒄𝒊𝒕𝒂𝒕𝒊𝒐𝒏 𝒐𝒓𝒅𝒆𝒓 −

𝑴𝒔 : 𝒎𝒂𝒓𝒈𝒊𝒏 𝒐𝒇 𝒔𝒂𝒇𝒆𝒕𝒚 −

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Above critical freq. range
→ acceptable design

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Dynamic Analysis Harmonic
Analysis
 Procedure
 Accelerations obtained from measurements on
existing products
 Maximal moment on whole frequency range
 If needed, fatigue analysis with FEMFat
(99.99% survival probability, infinite life)
Orders

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Design acceptable if
safety factor >1

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Overview
Static model

CAD Static Fatigue


Design Simplifications Analysis Analysis

Dynamic model

CAD Modal Harmonic


Simplifications Analysis Analysis

Acoustic model

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Acoustic
CAD Modelling
Analysis

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Acoustic Analysis Acoustic
Analysis
 Typical measurement
𝒏𝒊𝑶𝒑
 Frequencies for pumps 𝒇𝒑 =
𝟔𝟎 Pumps Gears
1st order 1st order
𝒇𝒑 : 𝒑𝒖𝒎𝒑𝒔 𝒆𝒙𝒄𝒊𝒕𝒂𝒕𝒊𝒐𝒏 𝒇𝒓𝒆𝒒𝒖𝒆𝒏𝒄𝒚 𝑯𝒛 nd
2 order 2nd order
rd
(3 order)
𝒏: 𝒆𝒏𝒈𝒊𝒏𝒆 𝒔𝒑𝒆𝒆𝒅 𝑹𝑷𝑴 (4th order)
5th order
𝒊: 𝒕𝒓𝒂𝒏𝒔𝒎𝒊𝒔𝒔𝒊𝒐𝒏 𝒓𝒂𝒕𝒊𝒐 𝒔𝒑𝒍𝒊𝒕𝒕𝒆𝒓 𝒃𝒐𝒙 − 6th order

𝑶: 𝒆𝒙𝒄𝒊𝒕𝒂𝒕𝒊𝒐𝒏 𝒐𝒓𝒅𝒆𝒓 −

𝒑: 𝒉𝒚𝒅𝒓𝒂𝒖𝒍𝒊𝒄 𝒑𝒊𝒔𝒕𝒐𝒏 𝒄𝒐𝒖𝒏𝒕 − (𝟗)

Sound Pressure Level [dB(A)]


𝒏𝑶𝒛
 Frequencies for gears 𝒇𝒈 =
𝟔𝟎

𝒇𝒑 : 𝒑𝒖𝒎𝒑𝒔 𝒆𝒙𝒄𝒊𝒕𝒂𝒕𝒊𝒐𝒏 𝒇𝒓𝒆𝒒𝒖𝒆𝒏𝒄𝒚 𝑯𝒛

𝒏: 𝒆𝒏𝒈𝒊𝒏𝒆 𝒔𝒑𝒆𝒆𝒅 𝑹𝑷𝑴

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𝑶: 𝒆𝒙𝒄𝒊𝒕𝒂𝒕𝒊𝒐𝒏 𝒐𝒓𝒅𝒆𝒓 −

𝒛: 𝒕𝒆𝒆𝒕𝒉 𝒄𝒐𝒖𝒏𝒕 𝒐𝒏 𝒇𝒊𝒓𝒔𝒕 𝒈𝒆𝒂𝒓 −

Frequency [Hz]

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Acoustic Analysis Acoustic
Analysis
 Excitation for acoustic analysis
 Pumps
 Axial forces obtained from
hydraulic simulation group
 Fast Fourier Transformation
 0th Order: constant force
 9th / 18th / 27th / 36th orders
dominate

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Acoustic Analysis Acoustic
Analysis
 Excitation for acoustic analysis
 Gears
 Bearing reaction forces from
Kisssoft
 Fast Fourier Transformation
 1st / 2nd / 3rd orders dominate

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Acoustic Analysis
CAD Modelling
 Mock-up instead of engine
 Air volume around splitter box corresponds to
microphones’ position
 Wave absorbing elements (Perfectly Matched Layer PML)
 Air as simple volumes

1000

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500
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Acoustic Analysis Acoustic
Analysis
 Mesh
 6 elements per wavelength
𝒎𝒎
𝑺𝒑𝒆𝒆𝒅 𝒐𝒇 𝒔𝒐𝒖𝒏𝒅
𝑾𝒂𝒗𝒆𝒍𝒆𝒏𝒈𝒕𝒉 𝒎𝒎 = 𝒔
𝑭𝒓𝒆𝒒𝒖𝒆𝒏𝒄𝒚 [𝑯𝒛]

 High frequencies lair≈ 10mm

 PML size at least ¼ of wavelength,


at least 4 element over PML
thickness

 Typical mesh size on interface,

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12mm

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Acoustic Analysis Acoustic
Analysis
 Harmonic setup
Usum [mm]
 Calculation point every 50 RPM
over engine speed range
 1 analysis per excitation order
 Constant damping 0.02

1. 2-way coupled acoustic analysis


ANSYS Acoustic ACT
APDL

with structural part and oil (splitter


box, pumps) SPL [dB(A)],
Low frequency

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2. 1 way coupled acoustic analysis
(velocities applied to air domain)

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Acoustic Analysis Velocitysum [mm/s] Acoustic
Analysis
 Results
 Surface velocities
 Sound Pressure Levels dB(A)
 Sound Power Level dB(A)
 Sum over orders SPL [dB(A)]
𝐿𝑆𝑃𝐿𝑛
𝐿𝑆𝑃𝐿 = 10 log 10 10
𝑛

 Comparison with measurement on


other splitter box :

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 <2 dB(A)

22 2014-09-10 PEL Splitter box analysis methodology @ LMB


Overview
Static model

CAD Static Fatigue


Design Simplifications Analysis Analysis

Dynamic model

CAD Modal Harmonic


Simplifications Analysis Analysis

Acoustic model

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Thanks for your attention !
Acoustic
CAD Modelling
Analysis

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