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Abstract
The aim of the present work is to set up an integrated approach for an automobile vibro-acoustic analysis, useful to assess, visualise
and compare vibro-acoustic performance to pre-determined design targets, while identifying and quantifying the forces and sound
sources responsible for the current behaviour. Such design approach, based on experimental and numerical procedures, enables the
prediction of noise emissions and the correlation with the structural vibration source.
Vibro-acoustic prediction in the low- to mid-frequency range is generally performed through finite element method (FEM) or
boundary element method (BEM) but in this work a combined usage of the two methodologies is adopted: FEM is used for the structural
dynamics and BEM for the acoustic problem resolution. The BE methodology adopted is based on an indirect formulation and on a
variational solution scheme.
The adopted FEM–BEM approach takes advantage of the Modal Acoustic Transfer Vector algorithm that is particularly useful
when big problems are to be analysed. The comparison between numerical and experimental results enables an assessment of the
accuracy level.
r 2006 Elsevier Ltd. All rights reserved.
Keywords: Integrated FEM–BEM; Vibro-acoustic; BEM indirect formulation; BEM variational solution scheme; MATV
0955-7997/$ - see front matter r 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.enganabound.2006.09.004
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methodologies [6–10]. In both FEM and BEM methodol- and the level of the structural excitation f(o) that generated
ogies acoustic models can be developed using general- it (applied on the point j), expressed in dB:
purpose modellers through the link to CAD provided, but !
with BEM the boundary mesh generation is very simple pðoÞi
BASðoÞi;j ¼ 20Log10 .
compared with volume mesh generation and can be f ðoÞj
completed automatically with little user interaction.
Such combined approach provides results that are useful It is an intrinsic property of the system under linearity
to plan active [3] and passive [4] design adjustments to hypothesis and expresses the attitude of the system to
minimise the structural born noise that is transmitted inside transform structural excitations into noise inside the cabin.
the car body, so as to avoid very costly experimental In particular such transfer function, also called fre-
campaigns. quency response function (FRF), was evaluated for each
Virtual troubleshooting by contribution analysis helps to frequency and in specific points inside the cabin, the
identify the root causes of the problem; whether they are driver’s hearing point and the rear passenger hearing point
structural-born or air-born [11]. (Figs. 2a–b).
In particular, starting from experimentally obtained The structural excitation was applied in the X, Y and Z
levels of sound field and knowing the transfer functions direction (Figs. 2a and b) on the engine attachment point
between the structural forces and the receivers, the B, rear (11) and forward (M) suspension attachment points
FEM–BEM numerical simulations determines which is (Figs. 3a and b). Such points constitute the major path
the ‘‘path’’ that mostly contributes to the problem. It will through which energy comes into the car interior (vibration
also show whether this is due to excessive internal force or and interior noise in vehicles are mainly caused by power
response amplification in the structural transfer. train and road input).
The maximum analysed frequency was 300 Hz, because
2. Problem description the structural noise of interest is predominant below such
frequency: as a matter of fact the powertrain and tyre
In the present work a numerical model was created for components of these automobiles have predominant
the simulation of the vibro-acoustic behaviour of the structural excitation levels up to this frequency. Moreover,
FIAT car Punto (ver. 188—3 doors, 16 V, 1242 cc.) shown in the upper frequency range the dynamic behaviour is
in Fig. 1. In parallel an experimental measurement directly affected by the high modal-density and damping
campaign was performed at the ELASIS S.C.p.A. labora- provided by the body structure, which are extremely
tories in order to allow the validation of the implemented difficult to model explicitly.
procedure by comparison of numerical and experimental
vibro-acoustic transfer functions, called Body Acoustic
Sensitivities (BASs). 3. Experimental activity
The BAS is defined as the ratio between the sound
pressure level p(o) inside the car body (in a specific point i) The experimental activity was realized at the ELASIS
laboratories and all the acquisitions were done in a
semianechoic chamber in order to simulate the car
environment that is generally reflectionless but from the
road surface.
The internal absorbing parts, even if in reality have a
non-negligible positive effect on the vibro-acoustic beha-
viour of the car, were removed from the car body (Figs. 4a
and b), leaving only the metallic surfaces (body in white):
this choice made easier the acoustic characterization of the
internal surfaces for the numerical simulation [12]. More-
over, the engine was disconnected from the car body
(Fig. 1) because not modelled in the numerical analysis.
The realized impact test is of the type ‘‘Roving Hammer’’:
the structure was excited by an instrumented hammer (with
a Brüel & Kjær type 8200 force transducer) and the
resulting sound field measured at the aforementioned
hearing points (as indicated by the FIAT procedure).
The process of acquisition and elaboration of the
excitation force signal and resulting sound signal was
realized by the software LMS CADA-X running under
Fig. 1. FIAT Punto in semianechoic chamber (the engine is disconnected Windows environment. For each X, Y and Z acquisition
from the car body). direction the hammer structure excitement was repeated
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Fig. 3. (a and b) Engine attachment (B), forward (M) and rear suspension attachment (11).
three times in order to average on the three corresponding chamber that has an inferior threshold frequency equal to
results and consequently reducing the systematic errors. 50 Hz (under this frequency the camera sound absorbing
The main results to be visualised and analysed by capacity is progressively vanishing). Consequently, in the
CADA-X consist of the coherence functions (COH) that following the transfer functions are considered only for
provides the level of external measurement contamination frequencies higher than such threshold.
and of system non-linearity, and the FRF. The aforemen-
tioned excitation process was repeated until satisfactory 4. FEM and BEM numerical models
values (close to unity) of the COH were obtained.
As visible from Fig. 5 the experimental outcome is not To create the car body FE model the Altair HYPER-
much reliable at low frequencies (lower than 50 Hz): this is MESH software was adopted. In order to reduce the
due to an intrinsic limit of the adopted semi anechoic problem dimension, some components were not discretized
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but represented as a rigid body with given inertia (mass and Then, in order to obtain the BE cavity model it was
moment of inertia) or not modelled at all (Table 1). necessary to import such FE cavity model into HYPER-
Starting from the car body structural FE model (Figs. 6a MESH, select the ‘‘skin’’ (Figs. 8a and b) and export it
and b) and using the code SFE AKUSMOD, a coarsened in a NASTRAN format (.bdf). Using for the BE
interior cabin FE mesh was obtained (Figs. 7a and b). cavity model the NASTRAN format allowed a straightfor-
ward model manipulation within the SYSNOISE environ-
ment. The FEM and BEM mesh details are illustrated in
Table 2.
1.0
5.1. Introduction
0.4
If we consider the cavity enclosed inside a car body, the
0.2 boundary structural vibrations generate pressure variations
0.0
in the fluid mass, causing the internal noise phenomena.
0 100 200 300 The dynamic response of a fluid mass inside a cavity is
Frequency (Hz) activated by the car body structural modes but at the same
time fluid resonance can influence the structure dynamic
Fig. 5. Example of COH function correspondingly to the engine behaviour, so as to require in general a fluid-structure
attachment point, excitement along Z direction and measurement point
in MIC2 (rear passenger ear).
coupled analysis (structural-borne noise such as booming is
due to the coupling between the structural vibration and
the interior sound pressure fluctuations). When the fluid is
Table 1 air and its acoustic modes are not coincident with the
Car body FE model assumptions structural modes, it is possible, in a first approximation, to
neglect such interactions.
Elements modelled with Rear lateral windows, radiator,
concentrated mass and moment of rear and anterior bumper, fender,
In this work, only a ‘‘weak coupling’’ between the fluid
inertia anterior and rear headlights and the structure was considered (the structure dynamics is
not influenced by the fluid), so as to separately calculate by
Non modelled components Rear and anterior suspensions,
exhaust group
FEM the problem dynamics while using BEM in a later
phase for the fluid acoustic assessment.
Fig. 7. (a and b) FE interior cavity model (on the right the inferior view).
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The fluid (air) is supposed to be conservative so that its ATVs can be interpreted as an ensemble of Acoustic
physical properties are real and consequently the solution Transfer Functions from the surface nodes to a single field
is real. For the acoustic analysis, the modelled fluid point and they only depend on the configuration of the
properties are the following: acoustic domain, i.e. geometry and properties (speed of
sound and density), on the acoustic surface treatment, on
density: 1.22 kg/m3; the frequency, and on the field point; they do not depend
sound speed: 344 m/s; on the loading condition and structural response.
reference pressure: 2E-0.5 N/m2. In the classical approach, the acoustic response is
calculated by solving the system of equations for each
loading conditions, preferably in a multi-load case solution
5.3.2. Acoustic transfer vectors sequence. In general, this is time consuming, since the BEM
The acoustic analysis
is based
on the concept of acoustic system of equations needs to be assembled and solved at
transfer vector ATV ðoÞ : this provides input–output
each frequency and load case.
relations between the node normal velocities vn ðoÞ of The idea in the ATV approach is quite different: first the
the radiating surface and the sound pressure level pðoÞ at a acoustic transfer function is evaluated from the radiating
specific field point (Eq. 7) surface to the specific field point for the range of involved
frequencies, without taking into account the actual loading
pðoÞ ¼ ATV ðoÞ vn ðoÞ , (7)
condition; in a second step, the acoustic response is
where o is the angular frequency. If, like in this case, more calculated for all loading conditions by combining the
than one microphone/field point is present, then for each of ATV with the normal structural velocity boundary condi-
them an ATV is calculated so as to obtain (Eq. 8) tion vector. This ‘‘forward’’ ATV-response calculation is a
vector–vector product and involves negligible computation
pðoÞ ¼ ½ATMðoÞ vn ðoÞ , (8)
time. An important advantage is that this frequency
where ½ATMðoÞ is the matrix of ATVs. The generic dependent ATVs can be used for contribution analysis at
element of such matrix ðATMðoÞi;j Þ represents the con- any excitation frequency.
tribution at the angular frequency o, of the jth element The normal velocity boundary conditions are generated
(belonging to the acoustic mesh) vibration to the pressure from the structural displacements calculated in the FE
in the ith field point. package NASTRAN, through the SYSNOISE Generate
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Procedure, which supports incompatible meshes. In this ing in modal coordinates results in an important data
way, the displacements calculated on the structural model reduction. However, MATVs are no longer independent
are automatically interpolated and transferred to the from the structural model as they are linked to the
acoustic model where an ATV response is evaluated.
structural modal basis. Whenever the structural modal
More in detail, the structural velocities vðoÞ are basis changes, e.g. due to structural modifications, the set
transferred from the FE nodes to the BE nodes by of MATVs need to be re-evaluated.
interpolation algorithms and projected along the normal In more detail,
rather than importing the structural
to the fluid boundary. Indicating as [T] the overall transfer velocities vðoÞ , the modal eigenvectors
[f] and the
matrix providing the interpolation
and projection, the related modal coordinates xðoÞ of the structural model
relation between vðoÞ e vn ðoÞ is given by: are imported. This is possible considering that:
vn ðoÞ ¼ ½T vðoÞ . (9) vn ðoÞ ¼ jo½T ½f xðoÞ ¼ jo fn xðoÞ , (10)
The aforementioned procedure is graphically described in in which fn ¼ ½T ½f represents the modal matrix of the
Fig. 11 where a comparison between the classical BEM structural model, transferred to the BE
acoustic
model (as
approach and ATV approach is highlighted. The main previously described for the vector vðoÞ ) and projected
difference is that with the classical approach there is in
thenormal direction. Substituting Eq. (10) in Eq. (8),
dependence from the structural response whilst with the pðoÞ can be alternatively expressed as
ATV approach the dependence is on the field points. In our
pðoÞ ¼ ½MATMðoÞ xðoÞ , (11)
case this is an advantage because the microphone positions
are in general fixed by the normative whilst the structural where
response is varying with the different excitations and
½MATMðoÞ ¼ jo½ATMðoÞ fn . (12)
influenced by structural optimisations (even those not
affecting the cavity shape). The matrix ½MATMðoÞ represents the contribution, at the
Another efficient use of the ATV concept can be seen in angular frequency o, of the structural modes to the sound
a structural design evaluation and optimisation loop for pressure in the microphonic points and its calculation
structural design parameters. As the ATVs are completely proceeds through the following steps:
independent from these design parameters, the acoustic
response can be easily evaluated at each design cycle at Calculation of the acoustic transfer matrix;
virtually no cost. Calculation by NASTRAN (SOL 103) of the structural
model eigenvectors;
5.3.3. Modal acoustic transfer vectors (MATVs) Transfer of such eigenvectors to the acoustic model.
In alternative to the ATVs approach also another, more
efficient, acoustic response calculation has been put in In addition, to proceed with the calculus of the sound
place, the so-called MATV-response. The modal acoustic pressure vector it is needed:
transfer vectors (MATVs) are the modal counter part of
the ATVs: they express the acoustic transfer function in to calculate by NASTRAN (SOL 111) the vector of
modal coordinates from a radiating structure to a field modal coordinates;
point, and, therefore, list the acoustic contribution from to apply on it the modal acoustic transfer matrix.
each individual structural mode. The acoustic response in
the field point is obtained by recombination of the MATV
In Fig. 12 a comparison between ATV and MATV
with the corresponding structural modal responses. Work-
technique is shown.
Velocity B.C. Microphones (a) Generation of the file cavity_model.bdf by the software
BE Solution ATV Computation
AKUSMOD, through the ‘‘skinning’’ of the cavity
Can be stored
FEM model;
BE Potentials ATVs (b) ATV computation by SYSNOISE;
Can be changed (c) Acquisition of the NASTRAN output, eigenvectors
Microphones Velocity B.C.
and modal coordinates, and conversion of the acoustic
Postprocessing ATV Solution
transfer matrix;
Pressure Pressure (d) MATV solve, to obtain the pressure levels by multi-
plying the modal acoustic transfer matrix and the
Fig. 11. Comparison between classical approach and ATV technique. vector of modal coordinates.
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Table 3
ATV Technique MATV Technique Data transfer evaluation
BE Geometry BE Geometry ATV technique vn ðoÞ / FEnodes Frequency Range Subcases
8.75E8 3.5E5 2.5E2 1.0E1
Microphones Microphones
MATV technique 3.5E8 3.5E5 1.0E3
ATV Computation ATV Computation ½fðoÞ / FEnodes Modes
2.5E6 1.0E3 2.5E2 1.0E1
ATVs ATVs MPFðoÞ / Modes Frequency Range Subcases
Modal Base
Experimental
FEM-FEM
FEM-BEM
B.A.S. [dB]
50 100 150 200 250 300 50 100 150 200 250 300
Frequency [Hz] Frequency [Hz]
B.A.S. [dB]
B.A.S. [dB]
50 100 150 200 250 300 50 100 150 200 250 300
Frequency [Hz] Frequency [Hz]
B.A.S. [dB]
50 100 150 200 250 300 50 100 150 200 250 300
Frequency [Hz] Frequency [Hz]
Fig. 13. Body acoustic sensitivities (the ordinate grid step is 10 dB).
and rear passenger ear (MIC 8). Consequently a number of FRSFo1 - the numerical curve is on average at a
3 3 2 2 ¼ 36 sound pressure graphs are available: higher level than the experimental one;
such pressure values divided by the magnitude of the FRSF41 - the numerical curve is on average at a
excitation provide the vibro-acoustic transfer functions lower level than the experimental one.
named BASs. Acceptable values of such index are included in the range
In order to assess the correlation between numerical and 0.95–1.05.
experimental results, the literature recommends the adop- The FRAC is defined as the ratio:
tion of the following indexes: the Frequency Response Scale
Factor (FRSF) and the Frequency Response Assurance FRACðj; kÞ
Criterion (FRAC). T 2
The FRSF is defined as the ratio: num H jk ðf Þ exp H jk ðf Þ
¼ T T .
T
num H jk ðf Þ num H jk ðf Þ exp H jk ðf Þ exp H jk ðf Þ
exp H jk ðf Þ num H jk ðf Þ
FRSF ðj; kÞ ¼ T ,
num H jk ðf Þ num H jk ðf Þ The values of such index are included in the interval (0C1)
and highlight the correlation level between experimental
where the terms exp H jk ðf Þ and num H jk ðf Þ , respectively and numerical results.
represent the experimental and numerical transfer func- FRAC ¼ 1 shows a perfect correlation and values higher
tions at the frequency f, in correspondence to the jth than 0.95 are considered satisfactory.
hearing point, for an excitation on the kth point. The In Fig. 13 some values of experimental and numerical
FRSF index point out how much the experimental results (both FEM–FEM and FEM–BEM) BASs are shown, in
overestimate or underestimate the numerical ones and in particular with reference to the microphonic points MIC 2
particular: and MIC 8, for an harmonic excitation of constant
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amplitude in X direction. As previously said, for the RAM usage, I/O data transfer, and disc space occupation;
FEM–BEM approach the MATV technique was adopted. in particular the differences between the two approaches
Each graph analyses a different excitation point and FEM–FEM and FEM–BEM are analysed. All the FEM
shows the dB values of the BASs versus frequencies (the calculus were carried out with an MSC NASTRAN version
absolute BASs values are omitted for confidentiality dating back to 2001, with web access on e-HPC server.
reasons but each interval on the grid corresponds to 10 dB). The peculiarities of the reference Host (Dirac) are: model
In Figs. 14 and 15 the numerical values of the index SGIR 12400, operative system IRIX 6.5, frequency
FRSF and FRAC are shown (these are calculated 400 MHz, number of processors 28, physical memory
considering the BASs values expressed in dB). 22528 Mb, swap file 32000 Mb.
It is clear from the above that both approaches All the BEM analysis were instead carried on with the
(FEM–FEM and FEM–BEM) provide satisfactory values release 5.6 of LMS SYSNOISE on a SUN workstation
of the index FRAC (the threshold value of 0.95 is always whose characteristics were: SUN Ultra 60 model, operative
overcome), whilst for that concern the index FRSF, 13 of system SOLARIS 5.7, frequency 384 MHz, RAM 640 Mb,
the 36 combinations considered provide values outside the Disc 10,000 Mb.
optimal range 0.95C1.05. In Table 5 a synthesis of computational times, I/O data
More specifically, the FEM–FEM approach provides transfer and memory usage is shown with reference to the
higher values for the FRSF index than the FEM–BEM simulations:
approach and in general the FEM–BEM results are judged
closer to the experimental results than the FEM–FEM NASTRAN (SOL 111) for the FEM–FEM analysis;
results. NASTRAN (SOL 103+SOL 111) and SYSNOISE
(MATV analysis) with reference to FEM–BEM analy-
8. The impact on computational times and memory usage sis.
The aim of this paragraph is to highlight how demanding From Table 5 it is possible to conclude that the
are the aforementioned FEM and BEM analysis in terms of FEM–BEM approach is more demanding with respect to
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