Structural optimization of an asymmetric automotive brake disc with cooling channels to avoid squeal

Brake squeal is still a major issue in the automotive industry due to comfort complaints of passengers and resulting high warranty costs. Many measures to avoid squeal have been discussed in the engineering community reaching from purely passive measures like the increase of damping, e.g. by the application of shims, to the active or semiactive suppression of squeal. While active measures can be effective but are elaborate and therefore more expensive, passive measure are less complex in most cases. This leads to the necessity to develop passive, economic and robust measures to avoid squeal. Asymmetry of the brake rotor has been proposed to achieve this goal and the resulting split of all double eigenfrequencies of the brake rotor has lately been shown to stabilize the system.     

Reduced-order models for parameter dependent geometries based on shape sensitivity analysis

The proper orthogonal decomposition (POD) is widely used to derive low-dimensional models of large and complex systems. One of the main drawback of this method, however, is that it is based on reference data. When they are obtained for one single set of parameter values, the resulting model can reproduce the reference dynamics very accurately but generally lack of robustness away from the reference state. It is therefore crucial to enlarge the validity range of these models beyond the parameter values for which they were derived. This paper presents two strategies based on shape sensitivity analysis to partially address this limitation of the POD for parameters that define the geometry of the problem at hand (design or shape parameters.) We first detail the methodology to compute both the POD modes and their Lagrangian sensitivities with respect to shape parameters. From them, we derive improved reduced-order bases to approximate a class of solutions over a range of parameter values. Secondly, we demonstrate the efficiency and limitations of these approaches on two typical flow problems: (1) the one-dimensional Burgers’ equation; (2) the two-dimensional flows past a square cylinder over a range of incidence angles.     

Fringe analysis for automotive applications

The capabilities of Ford USA's Computer Aided Holometry (CAH) system for stepped phase interferometry are presented. Holographic test equipment and facilities are briefly reviewed. Fringe analysis algorithms and procedures for practical semi-automated processing of stepped phase interferograms of complex real life structures for quantitative measurement of deformation and shape are discussed. Several automative applications illustrating the fringe analysis technique are presented, including: (1) the use of CAH combined with Finite Element Analysis (FEA) methods to study frictional effects of the thermal insertion of a wrist pin into a connecting rod; (2) a study of engine deformation due to hydraulic loading of the cylinders; and (3) the computation of sound pressure from CAH measured vibration amplitude/phase and shape using the Rayleigh integral and SYSNOISE methods. In the past, holometry methods have been used primarily for problem solving in structures that were already in production, often where limited opportunities existed to make expensive modifications to existing tooling. Infrequently holometry was used by knowledgeable engineers to develop optimized components in the prototype stage even without the current CAE methods. The opportunity and challenge of our day is to closely couple CAE (FEM, EFA) methods and experimental methods (CAH, modal, etc.) to optimize structural performance in the upstream product development process where necessary tooling modifications can and will be made.     

Enhancement in sensitivity of a blood perfusion parameter for frame-rate analysis of bio-speckle image

We have previously presented a blood perfusion parameter by means of the spatial contrast of speckle patterns observed for blood perfusion in skin tissue and a blood vessel. This parameter permits us to visualize a relative blood perfusion distribution from a single speckle pattern. Therefore, it can estimate the blood perfusion with a frame rate of an imaging device employed. This parameter is, however, dependent on the speckle size and the condition of image processing of speckle patterns. In the present study, we estimated this condition with relation to the speckle size for obtaining high sensitivity and good linearity of the parameter to the blood perfusion. Experiments were conducted for ground-glass model, flow model and human wrist to investigate perfusion sensing characteristics of the present parameter.

     

拓展傅里叶幅度敏感性检验(EFAST)在陆面过程模式中参数敏感性分析的应用探索

本文旨在探讨拓展傅里叶幅度敏感性检验(EFAST)在陆面参数敏感性分析中的应用. 基于2008年吉林通榆观测值站的退化草地观测资料,针对通用陆面过程模式(CoLM)的关键陆面参数, 使用地表感热通量、潜热通量作为检验变量,尝试将EFAST方法运用到陆面过程模式参数敏感性试验中. 在充分考虑单个参数敏感性的基础上,将参数间的耦合作用考虑进来, 研究了相互影响制约下的多参数变化对非线性系统的影响,并且对这种非线性影响进行了定量分析. 敏感性分析结果表明:土壤砂土比例、最小水分透过孔隙度为影响地表感热通量与潜热通量的关键参数, 验证了EFAST方法在陆面过程模式参数敏感性分析方面的可行性.本项研究对于外场观测试验的设计 和发展陆面模式物理过程参数化方案具有积极的指导意义. 关键词： 陆面过程模式 陆面参数 EFAST方法 参数敏感性     

随机平衡设计傅里叶振幅敏感性分析方法和拓展傅里叶振幅敏感性分析方法在陆面过程模式敏感性分析中的应用探索

探讨了随机平衡傅里叶振幅敏感性分析方法(RBD-FAST)和扩展傅里叶振幅敏感性分析方法(EFAST)在陆面过程模式参数敏感性研究中的应用. 试验中使用通用陆面过程模式(CoLM)和通榆退化草地2008年夏季观测资料, 针对陆气相互作用中重要的要素: 感热通量(SH)、潜热通量(LH)、地表温度(ST), 2 m气温(T2m)和2 m湿度(Q2m), 分析了11 个参数(土深、1–5层黏土比率、孔隙度、最大露水厚度、50%植物根深、地表空气粗糙度和冠层下土壤拖曳系数)的敏感性大小. 结果表明, RBD-FAST和EFAST对参数的一阶敏感性检验结果较为一致且与之前的研究结果类似, EFAST方法还可以得到考虑了参数间相互作用的整体敏感性. RBD-FAST的优势主要表现为在极大地减少了计算消耗机的同时, 一次取样即可计算所有参数的一阶敏感性, 而EFAST的优势则在于通盘考虑了参数之间的相互影响, 可以得到更为合理的整体敏感性序列. 针对不同需求, 选择使用这两种敏感性分析方法, 有助于提高陆面过程模式参数化方案的改进效率.     

Experimental and numerical analysis of automotive gearbox rattle noise

The aim of this work is to characterize the rattle noise of automotive gearboxes, resulting from impacts between toothed wheels of unselected gear ratios. These stereo-mechanical impacts are modeled by a coefficient of restitution which describes damping during the squeezing of the lubricant film for approaching surfaces, and the elastic deformation of impacting bodies. The dynamic response of the loose gear first depends on the design parameters and the engine operating conditions. The unknown parameters are the drag torque and the coefficient of restitution. They are identified experimentally through implementation of two optical encoders in an actual automotive gearbox and the operation of a specific test bench which replicates the automotive power train. Models of the different drag torque sources are validated from analysis of the free damped response of the driveline. The coefficient of restitution and its probability density function are measured from experiments under stationary operating conditions. A nonlinear model is built. The dynamic response of the loose gear depends on the dimensionless backlash, the coefficient of restitution and a dimensionless parameter proposed to describe the rattle excitation level. Experiments under controlled excitation are performed to validate the assumptions, to confirm the ability of the parameter proposed to describe the rattle noise threshold, and to characterize the dynamic response. The nonlinear model predictions are fitted with the drag torque and coefficient of restitution previously identified. They are compared with measurements to demonstrate the ability of the model to predict gear rattle for any loose gear, any gearbox and any operating condition.     

Whole-field optical diagnostics for structural analysis in the automotive industry

This paper reviews the whole-field optical diagnostic methods developed by the Applied Optics Laboratory (AOL) of the Rover Group for structural analysis. The techniques discussed provide measurements of a range of parameters, specifically: deformation, vibration amplitude and phase, shear stress, surface form, and flow velocity. The paper describes the philosophy used to develop the techniques and the overall business issues and applications which have driven their development. Each measurement system is then discussed in turn with emphasis on the novelty of the optical device or data analysis procedure used, and their relevance to automotive engineering applications. Illustrative examples are presented for each technique.     

Using sensitivity derivatives for design and parameter estimation in an atmospheric plasma discharge simulation

The problem of applying sensitivity analysis to a one-dimensional atmospheric radio frequency plasma discharge simulation is considered. A fluid simulation is used to model an atmospheric pressure radio frequency helium discharge with a small nitrogen impurity. Sensitivity derivatives are computed for the peak electron density with respect to physical inputs to the simulation. These derivatives are verified using several different methods to compute sensitivity derivatives. It is then demonstrated how sensitivity derivatives can be used within a design cycle to change these physical inputs so as to increase the peak electron density. It is also shown how sensitivity analysis can be used in conjunction with experimental data to obtain better estimates for rate and transport parameters. Finally, it is described how sensitivity analysis could be used to compute an upper bound on the uncertainty for results from a simulation.     

Stability assessment and operating parameter optimization on experimental results in very small plasma focus,using sensitivity analysis

Regarding the importance of stability in small-scale plasma focus devices for producing the repeatable and strength pinching, a sensitivity analysis approach has been used for applicability in design parameters optimization of an actually very low energy device (84 nF, 48 nH, 8–9.5 kV, ～2.7–3.7 J). To optimize the devices functional specification, four different coaxial electrode configurations have been studied, scanning an argon gas pressure range from 0.6 to 1.5 mbar via the charging voltage variation study from 8.3 to 9.3 kV. The strength and efficient pinching was observed for the tapered anode configuration, over an expanded operating pressure range of 0.6 to 1.5 mbar. The analysis results showed that the most sensitive of the pinch voltage was associated with $0.88\pm 0.8\text{mbar}$ argon gas pressure and 8.3–8.5 kV charging voltage, respectively, as the optimum operating parameters. From the viewpoint of stability assessment of the device, it was observed that the least variation in stable operation of the device was for a charging voltage range of 8.3 to 8.7 kV in an operating pressure range from 0.6 to 1.1 mbar.     

Forensic analysis of automotive paints by Raman spectroscopy

In this work, the possible contribution of Raman spectroscopy in forensic science is evaluated, more specifically for the analysis of automotive paint samples. Spectra from paint flakes as well as from cross sections were examined, in order to identify not only the pigments but also binders and extenders in all paint layers. Moreover, the possibility of distinguishing paint samples from different cars was evaluated to assess the use of vibrational spectroscopic techniques in the investigation of a hit-and-run accident. The presence of rutile and extenders, such as calcite and barium sulphate, could be demonstrated by their characteristic Raman bands. However, the identification of the binder by Raman spectroscopy was hampered: only with additional information from IR analysis could most of the bands in the spectrum be assigned to molecular vibrations of the binders. In contrast, organic pigments, having very distinctive and well-resolved characteristic bands, could easily be identified by comparing the spectra from the basecoat of the sample with spectra from a reference database. Because of these characteristic bands, the basecoat seems to provide the best spectra to distinguish paint samples. Moreover, some paints can also be distinguished by the absence or presence of the bands from calcium carbonate and barium sulphate in the primer surfacer. When recording spectra from paint flakes, Raman bands from the spectra of the clearcoat as well as from the basecoat are obtained. Copyright © 2005 John Wiley & Sons, Ltd.     

Improvement in the predictivity of squeal simulations: Uncertainty and robustness

The objective of this paper is to improve the predictivity of squeal simulations by introducing uncertainty and robustness concepts during simulations. Complex eigenvalue analysis is a traditional way to detect numerically the unstable modes that can be associated with extensive vibration and noise pollution. This simulation, for which associated computational times are compatible with the design phase, is known to be insufficiently predictive. We first propose a complete strategy that relies on the integration of random fields into the contact interface, complex eigenvalue calculations, probabilistic analysis and a robustness criterion. Next, this strategy is applied to study the instabilities of a complete industrial brake system. Experimental comparisons highlight the efficiency of the improved squeal detection methodology.     

Modeling and analysis for the image mapping spectrometer

The snapshot image mapping spectrometer(IMS) has advantages such as high temporal resolution,high throughput,compact structure and simple reconstructed algorithm.In recent years,it has been utilized in biomedicine,remote sensing,etc.However,the system errors and various factors can cause cross talk,image degradation and spectral distortion in the system.In this research,a theoretical model is presented along with the point response function(PRF) for the IMS,and the influence of the mirror tilt angle error of the image mapper and the prism apex angle error are analyzed based on the model.The results indicate that the tilt angle error causes loss of light throughput and the prism apex angle error causes spectral mixing between adjacent sub-images.The light intensity on the image plane is reduced to 95%when the mirror tilt angle error is increased to ±100 "(≈ 0.028°).The prism apex error should be controlled within the range of 0-36"(0.01°)to ensure the designed number of spectral bands,and avoid spectral mixing between adjacent images.     

Design sensitivity analysis for sequential structural-acoustic problems

A design sensitivity analysis of a sequential structural-acoustic problem is presented in which structural and acoustic behaviors are de-coupled. A frequency-response analysis is used to obtain the dynamic behavior of an automotive structure, while the boundary element method is used to solve the pressure response of an interior, acoustic domain. For the purposes of design sensitivity analysis, a direct differentiation method and an adjoint variable method are presented. In the adjoint variable method, an adjoint load is obtained from the acoustic boundary element re-analysis, while the adjoint solution is calculated from the structural dynamic re-analysis. The evaluation of pressure sensitivity only involves a numerical integration process for the structural part. The proposed sensitivity results are compared to finite difference sensitivity results with excellent agreement.     

采用连续/不连续单元边界元法的声学灵敏度分析

采用连续单元与不连续单元混合离散建模的方法,将源点与场点分别划分为连续单元与不连续单元,由于两种网格节点互不重合,从而可以有效避免边界元法中奇异积分的问题。该方法简单易执行,利于工程应用。将该边界元公式应用于声学灵敏度分析中,所得的公式可以用来计算设计参数的改变而导致的场点声压改变量,为验证这一方法的正确性,以脉动球为例进行声灵敏度计算,并与常单元方法比较,证实了该方法的准确性。     

Method for sensitivity analysis of photonic crystal devices

We present a new method for sensitivity analysis of photonic crystal devices. The algorithm is based on a finite-difference frequency-domain model and uses the adjoint variable method and perturbation theory techniques. We show that our method is highly efficient and accurate and can be applied to calculation of the sensitivity of transmission parameters of resonant nanophotonic devices.     

Finite element modelling for the investigation of in-plane modes and damping shims in disc brake squeal

Squeal propensity of the in-plane modes and the constrained-layer type damping shims for disc brake system is investigated by using the finite element method. Theoretical formulation is derived for a rotating disc in contact with two stationary vibrating pads attached to the damping shim components. By the conversion from the theoretical to FE brake model, the full equations of motion for the actual disc brake system describes the disc rotation, the in-plane friction characteristics and damping shims in association with squeal vibration. It is concluded from the results that the in-plane torsion modes can be generated by the negative friction slope, but they cannot be controlled by the damping shims. The in-plane radial mode is also investigated and found to be very insensitive in squeal generation.