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An integrated approach to simulating interior acoustics in the low to mid frequency domain

Introduction

The main objective of any interior acoustic simulation is to determine the sound pressure levels (SPL) inside the vehicle and if it meets to the deciding specifications or not. Another objective is not only to thoroughly analyze the situation, to diagnose problems, but to adapt the design parameters and ultimately to optimize the design.

Depending on your application needs, Virtual.Lab interior acoustics provides three solutions to perform an interior acoustic simulation. The first and standard solution takes you straight to the SPL in the vehicle cavity giving a clear indication if you have met your targets. It will also provide you with the contributions of the different radiating panels in the car body.

Interior Acoustics_PIC1.gifThe second and more premium solution offers extra detailed analysis capabilities. It will provide the additional information needed to better pin point the problem areas and to more efficiently fine tune the design. This is done using acoustic boundary elements or acoustic finite elements based on acoustic transfer vectors (ATV’s).

A third and complementary solution is a more advanced acoustic simulation where the acoustic trim is more accurately represented. As your frequency range increases then so does the importance of accurately modeling the trim. This can be costly if a full Biot analysis method is used, using 3D solid FEM elements for which many thousands of additional DOFs will be added to the analysis. Virtual.Lab uses a fast substructuring technology of the acoustic multilayer without introducing additional DOFs to the model. The acoustic performance of multilayer that are applied to a base structure can be evaluated at a marginal extra cost.

The integration of all aspects of the analysis within the LMS Virtual.Lab product enables engineers to quickly and accurately determine interior sound levels, but more importantly it provides valuable insight regarding the sources of noise, the main structural contributors to the noise and the paths by which the vibrations are transferred. In addition it allows easy assessment of different design options from which valid and timely recommendations can be made.

First approach: sound pressure level analysis using a direct coupled

The first and standard solution is designed to be fast and easy to setup using a Nastran solver as the computational engine. This can be any Nastran solver that is currently on the market. To make it a bit easier to understand a process showing the steps that are taken is shown on the left.

The total setup time for this is very fast, about 20 minutes in total. This is due to the automation of the Assembly process. The Assembly process couples two incompatible meshes together allowing you to directly use the vibroacoustic solutions integrated in the Nastran Solver.

Structural Mesh

The detail of the structural mesh greatly depends on the frequency range you are interested in. If the frequency range of interest is at the low side, i.e. below 100Hz, then there is no need to model all the interior trim panels in detail. A lumped mass representation is fine.

Cavity Mesh

interior-acoustics-simulation-low-mid-frequency-domain-1In order to analyze interior noise, the acoustic cavity of the vehicle needs to be both defined and meshed. As for any FE analysis it is important to create an accurate, realistic model. In order to analyze the interior noise, the interior should be meshed such that the vibration from the structure can be transferred to the cavity across the outer envelope of the cavity mesh. LMS Virtual.Lab provides tools, which enable the cavity mesh to be generated directly from the structural model, thus ensuring the close proximity between the two. A mechanism for detecting and repairing holes and thus defining the cavity is employed first, before a high quality mesh is created automatically. The level of automation required can be determined by the user; a flexibility that allows either the entire vehicle cavity or just volumes of specific interior-acoustics-simulation-low-mid-frequency-domain-3interest to be meshed. The meshing algorithm can competently handle sharp and smooth features, seats and footprints. The envelope mesh is detected automatically. These dedicated tools mean that anaccurate and effective mesh is generated in hours.

The frequency dependent characteristics of interior components can be modeled in various ways. Seats can be modeled as 3D elements through their volume absorption characteristics. Alternatively they can be modeled as 2D surfaces to which panel absorbent properties can be applied. The difference being the 3D element volume absorption will affect the modes while the 2D surface for the seats will be treated as a rigid wall.

Structural – Acoustic assembly

Once both the cavity mesh and structural mesh are available you need to identify which is the structural mesh and which is the acoustic cavity mesh. If needed at this point you can also provide the necessary material characteristics, i.e. air properties, for the cavity mesh. The next step is to define how the two meshes will be linked together. Assuming that they are not compatible meshes you need to use a mesh mapping tool.

Mesh Mapping

The mesh mapping is an automatic process to link the incompatible structural and cavity mesh together. This method is also flexible in that you can modify any of the parameters. To do that it is better to understand what is happening. The method used in Virtual.Lab starts by creating automatically the envelope of the main cavity. You can then tell the software that for every node on the envelope you would like to link it to X nodes on the structural mesh. Default parameters are provide and are typically fine. You then give it a distance ‘Y mm’, from which to search and the software will generate a mesh mapping matrix on one node of the envelop to max X nodes on the structural mesh within a distance of Y mm. The nodes of the structural mesh that are linked to an acoustic node are called the wetted surface nodes. Virtual.Lab as default takes 4 nodes and 10mm. This is normally enough to have a good coupling. Within Virtual. Lab you can generate an image of the min or max distance between the cavity envelope and the structural mesh.

Nastran Forced Response Case

With Nastran, one can calculate the coupled modes (Nastran 103) or do a forced response. When performing a Nastran Forced Response in Virtual.Lab you have to define that you want to perform a vibro acoustic analysis. If you have also defined your acoustic and structural mesh the software will automatically define the Mesh Mapping and link your two meshes together. So all you are left with is defining your input load and output points. The loads can be taken directly from test or from an excel sheet, the points at which you will apply your loads can be based on node ID’s or coordinates with a search tolerance to the nearest node. Virtual.Lab is very flexible in its approach to loading a structure. At this point you will also have to define what Nastran Solution sequency you would like. Virtual.Lab supports NASTRAN SOL103, 107, etc.

Second approach: design iteration approach using ATV technology


The premium solution is tailored to the needs of the engineer who wants to make a more detailed analysis of the situation, to diagnose problems, to refine and improve the structural design. It provides extensive analysis data, and due to a particular methodology employed, that allows rapid and efficient re-runs to realize the optimum design. It will incorporate both the use of an FE solver to generate the structural modes and the Sysnoise solver for the generation of the acoustic internal radiation. The process involved in setting up this simulation is shown in the image interior-acoustics-simulation-low-mid-frequency-domain-4on the left.

The total setup time for this simulation is a little longer than the Standard solution, but the computation time is a lot shorter, including the possibility to optimally apply automatic substructuring technologies on the structural model using for example AMLS. For multiple runs, the computation time is significantly faster again. When using predefined Virtual.Lab templates, the setup time can be reduced again. The data transfer analysis in the process will also involve coupling two incompatible meshes together, this is again done using the mesh mapping tool.


Structural Modes

The structural modes can be computed using any of the major FE packages such as Nastran, Ansys, Abaqus, etc. Virtual.Lab will then read directly the results files from your FE code and allow you to still add viscous damping to the modes after you have imported them. Another possibility Virtual.Lab offers is to reduce down the large FE result files. Virtual.Lab helps you in setting this up quickly and effectively by using the mesh mapping technology to define your output for the FE result to only be computed on the wetted surface. The result is a significant reduction in FE results file (i.e. from severl GB’s to 100MB).

Modal based forced response case

At this point in the process you want to use the forced response solvers to generate the vibration information. This can be in the form of modal participation factors or can be in the form of real panel vibration. The panel vibration method can be used to perform panel contribution analysis. The forced response analysis requires input and output points to be defined; once the input points are defined you can link the structural load to them. The applied loading is either test or CAE based.

Data transfer analysis case


The Data transfer analysis is a key process in the setup of your analysis. This allows you to transfer the detailed structural modes over to the cavity mesh. The software first makes a bridge between the structural mesh and acoustic cavity mesh using the Mesh Mapping tool. It then allows you to select the structural modes and transfer them over. After the transfer you will have a reduced set of structural modes on the acoustic mesh. These modes will then be used in your Modal ATV response analysis.

Generate field point mesh

The generation of the field point mesh is to define whereyou would like to visualize results. This is done to reduce the amount of responses generated. Normally your entire Finite Element cavity mesh will deliver results. Storing these results takes time and a good way to reduce that is to define a smaller set, such as the drivers and passengers ear locations. These field points can then be used to generate your Acoustic Transfer Vectors (ATV’s).

ATV Database - Modal ATV response analysis case


The traditional BE and FE approaches used the structural vibrations directly to define the boundary interior-acoustics-simulation-low-mid-frequency-domain-5conditions for the acoustic radiation problem. The draw back of this approach is that these boundary conditions vary with loading conditions and so a different solution must be found for each loading condition. The LMS Virtual.Lab implementation uses Acoustic Transfer Vector (ATV) technology. ATVs are transfer functions that link the input of the structural velocity of the radiating surfaces and the Sound Pressure Levels at the desired output field points. They are dependent only on the geometry and media characteristics of the acoustic domain, the acoustic surface characteristics (impedances and admittances), the frequency and the location of the field points. They are independent of the loading, which means that they are especially well suited for multi-case forced responses and optimization of the structure. This represents an enormous advantage in that loading and design parameters can be varied without having to run original solvers again. Depending on your need, you can apply the ATV technology to either a boundary element mesh or a finite element mesh. For the FEM one can model 3D volume absorbers more in detail while in the BEM approach one only takes surface impedances. 

Looking at the formulas we know that; {Sound Pressure} = [Acoustic Transfer Matrix] . {Surface Velocities}

We also know that the surface velocities are normal component of the structural velocities since only this normal component plays a role in the generation of sound waves. We can then rewrite the formula to look like this
interior-acoustics-simulation-low-mid-frequency-domain-6


Therefore the Acoustic transfer vector concept is nothing more than an assembly of Acoustic transfer functions relating to the normal vibrations on the surface of a mesh to the sound pressure at a single microphone location, as illustrated below.

interior-acoustics-simulation-low-mid-frequency-domain-7So we know that
interior-acoustics-simulation-low-mid-frequency-domain-6


We also know that

interior-acoustics-simulation-low-mid-frequency-domain-9



{velocity boundary conditions} = [modes] . {modal participation factors}

Also the structural displacements {u} can be represented by:

interior-acoustics-simulation-low-mid-frequency-domain-10


If you then combine both equations, we obtain:

interior-acoustics-simulation-low-mid-frequency-domain-11


If we want to obtain a direct input-output relation between the structural model response vector and the microphone point (field point) sound pressure we use 
P = {Modal Acoustic Transfer Vector}T . {MRSP(w)}
Where the Modal Acoustic Transfer Vector (abbreviated to MATV) is defined as:

interior-acoustics-simulation-low-mid-frequency-domain-12


This is then interpreted as an assembly of acoustic transfer functions relating the contribution of the individual structural modes to the sound pressure at a single microphone location.

In contrast to ATV’s, Modal ATV’s cannot be computed purely from acoustic parameters but in addition require knowledge of the dynamic behavior of the vibrating structure in the form of structural mode shapes. The entire process is illustrated in the figure below:
interior-acoustics-simulation-low-mid-frequency-domain-13









This entire process has a huge advantage in that you can store the ATV database and reuse it again as long as you don’t make any changes to the acoustic model. The structural model can be modified with some degree, and after the modification you simple perform the data transfer analysis case again and re-compute your acoustic response, which is just a multiplication.

Third approach: Fast Trim modeling using modal coupling

The third complementary solution is using the Synoise solver in a fully coupled approach to generate the acoustic pressure. That being a modal structure coupled to a modal acoustic using a wave reduction technique for modeling the connecting trim panel properties. This method also incorporates mesh reduction techniques to reduce the computation time considerably without affecting the accuracy of your model. It is a full finite element approach and also takes advantage of our acoustic trim modeling techniques which is based on wave reduction. By using the modal coupling method to compute, the computation time is greatly reduced from 40 minutes per frequency to 40 seconds on a full automotive model.

The process for this simulation looks like this:

interior-acoustics-simulation-low-mid-frequency-domain-14









Reduced Modal Model

The main objective of this method is to generate the coupling between incompatible meshes without loosing accuracy. The reason for this is the vibro acoustic fully coupled simulation.This sounds like a very difficult thing to do, but in fact Virtual.Lab makes it quite simple with its mesh reduction techniques. What the software can do is take the envelope of the cavity mesh and use that as the main body for the re-duced structural mesh. What you then do is include all the input and output locations and with the mesh mapping tool transfer your modes from the detailed structural mesh to the new reduced mesh. This reduced mesh and the cavity mesh will have the exact same correspon-ding nodes for the wetted surface. Virtual.Lab can then handle all the node numbering issues that might generate due to using the same mesh.

Trim panel property definition

As the frequencies for which the analysis results are required increases then so does the importance of accurately modeling the trim. This can be costly however and if the full Biot analysis method is implemented based on 3D solid FEM then thousands of additional dofs will be added to the analysis. This is prohibitive from a practical point of view. 
The LMS Virtual.Lab Fast Trim module allows for the evaluation of the acoustic performance of multi-layers that are applied to the base structure. It employs a new methodology based on wave-reacting transfer admittances, representing the relation between the pressure and the velocity on both sides of the multilayer, i.e. the structural base and the acoustic cavity. Transfer admittance coefficients are determined using transfer matrix method, and results show an exceedingly good correlation with measurement data at the higher frequencies where the effects are critical. When applying Trim panel properties there is no need to define the wetted surface in the model. The wetted surface is the surface that links both the cavity and structural mesh together. Normally this is the envelope of the cavity mesh.

Creating engineers insights from acoustic simulation

interior-acoustics-simulation-low-mid-frequency-domain-15Post Processing - Visualization of data

The standard solution allows you to animate the structural modes as well as listing of modal characteristics that can greatly improve the understanding of the behavior of the modes. Acoustic modes too can be visualized and the presentation of acoustic responses as frequency functions means that problem frequencies are easily identified.




interior-acoustics-simulation-low-mid-frequency-domain-16Panel Acoustic Contribution Analysis

The surface can be defined as a number of panels that represent different structural features of the radiating surface, and they can be easily defined using a number of identification criteria, such as feature angle, position, or material characteristics. Panel contribution analysis enables you to identify the contribution of each of these panels indicating which physical parts are radiating the most.



interior-acoustics-simulation-low-mid-frequency-domain-17Grid Contribution

The LMS Virtual.Lab premium solution takes this analysis to a more detailed level allowing you to identify ‘hotspots’; particular locations where the acoustic radiation is high, and which require special attention or where modifications will be most effective.





interior-acoustics-simulation-low-mid-frequency-domain-18Modal Acoustic Contribution Analysis

When assessing the effect of different structural modes, to the overall sound pressure level, the modal participation factor is not sufficient. The contribution to the global noise level is a combination of the modal participation factor, the vibration levels and the radiation factors. For a specific field point, the premium solution provides a dedicated view on the modes in a frequency range where high responses are obtained meaning that the relative contribution of different structural modes can be assessed.

Understanding the critical modes is crucial; the insight gained into the structural behavior of the vehicle leads to the most effective solutions. The use of such a distinct tool is essential due to large number of modes and the higher modal bandwidth.

Path Contribution Analysis

High levels of acoustic radiation are due not only to high loads (vibrations) but to easy transfer paths. So in addition to the panel contribution one has the ability to identify critical paths whereby the source of the noise is transferred to the acoustic radiation provides crucially important information. Only by understanding both the levels and the paths can a truly effective optimization of the design be accomplished.

Refinement and optimization

Whether there are distinct problems with target levels, or whether the objective is to improve the design, the goal is to use the analysis data to close the design loop. This can be done through scalable solutions, which involve increasing degrees of modification to the analysis data, the mesh or the structural model.

Fast Modification Prediction

Modification of the analysis data represents the tightest loop in the design process associated with trouble shooting and problem solving, which would be performed when the design of the vehicle is fixed and it is necessary to make small adjustments. Fast modification prediction allows you to adjust the behavior of the structural modes by the placement of physical characteristics at key locations on the structure. Such physical modifications can be the addition of a lumped mass, the effect of increasing stiffness or damping. Due to the integrated approach within LMS Virtual.Lab, these modifications can be made and the analysis results re-computed to determine the effect. Graphical representation of the modified locations and a graphical comparison of the ‘before and after’ response functions provide the information you need. This is a fast and efficient means to assess the effects that does not require any re-computation of modes by the original Finite Element solvers, this is available as part of the premium solution.

Mesh based modifications

More significant modifications can be applied to the original FE mesh defining the structure. These modifications can include changing the properties of the existing mesh, by adjusting physical dimensions such as panel thicknesses, material properties or beam stiffness. The nature of the mesh can also be changed by the addition of elements, by changing the shape or by morphing the mesh. In both cases the FE solvers need to be re-run, butLMS Virtual.Lab provides drivers to run these external processes allowing you to remain within its integrated environment. The capture of the complete process means that mesh modifications are then carried through the entire analysis process.

Wave Based Substructuring

When a full acoustic analysis has been performed refinements of specific parts of the structure can be performed using a reduction technique termed Wave Based Substructuring. This provides an extremely rapid way of optimizing the design. A reduced and efficient assembly formulation is obtained by writing the interface displacements as a series of interface basis functions (waves). This drastically reduces the number of interface dofs involved and thus allowing faster assembly predictions.

The technique can be applied to optimization in areas such as rib stiffening, cowltops, glues, bead and seals by concentrating the optimization in a defined discrete area of interest.

As a comparison, after a full run up to 200Hz, taking around 19hours of computations, a WBS analysis can take just 20 minutes. {Automated Multilevel Substructuring 9 hours.}

This technique takes even greater importance as the frequency range of interest is increasing and the subsequent analysis costs associated with this augment in consequence.

Optimization

In today’s highly competitive environments, the optimum design is one that is close to the design limits. The LMS Virtual.Lab Optimization package offers an integrated set of powerful capabilities, tools, techniques that give engineers rapid insight into all possible design options that meet their requirements.

All the capabilities are integrated into a module that allows users to specify the design objective, set design parameters and their distribution, automates, controls and monitors the optimization routines.

The Design of Experiments (DOE), technique can be used to carry out virtual experiments, the results of which can be viewed using various Response Surface Modeling (RSM) techniques giving critical insight into design parameters and the tradeoffs involved.

Once an optimum is achieved it is important to investigate the robustness of the optimum, due to tolerances on the design parameters, input design parameters must be considered as distributions rather than single deterministic values. Variation of the design around its optimum values can be evaluated to meet robustness reliability and quality criteria.

Conclusion

LMS Virtual.Lab Interior Acoustics meets the needs of all engineers involved in achieving vibro-acoustic targets. The standard solution operates within the familiar FE environment and offers a simple and easy management of the analysis and yields direct information about whether targets are met.

For the engineer who needs to improve and optimize the design based in the vibro-acoustic criteria, the premium and complementary solution offers all the analysis data required, plus the effective, efficient techniques and methodologies to adjust the design parameters and accurately and efficiently assess design changes. Our trim paneling modeling technique using wave reduction offers a fast alternative to the traditional Biot approach (using 3D SOLID elements), reducing computation time even further without affecting the accuracy of your model.

The integrated LMS Virtual.Lab environment provides an effective and efficient means of managing the data and the process. Data from a variety of sources; meshes, loading functions, design parameters are incorporated into the one analysis. The process itself is captured in a tree structure which defines and controls the entire process including executing external procedures. Input data, analysis conditions and results are clearly defined, and easy to reference thus enabling a convenient and well managed process.



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