Aero-Vibro Acoustics For Wind Noise

Application
David Roche and Ashok Khondge
ANSYS, Inc.

Outline
1. Wind Noise
2. Problem Description
3. Simulation Methodology
4. Results
5. Summary

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

Aerodynamics Noise Generation

A-Pillar Vortex
Cavity Resonance

Flow separation/
Vortex shading
Thursday, October 02, 2014

Cavity Resonance

Flow separation/
vortex shading

2014 Automotive Simulation World Congress

Flow separation/Vortex
shading
3

Wind Noise
High Frequency (> 500 Hz) Noise generated by head wind and
perceived inside automotive cabin @ highway driving speeds
It is cost beneficial to address wind noise UPFRONT in Design
Process
1. Highest degree of freedom to change exterior design causing wind
noise
2. Avoids expensive late countermeasures
[1]

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

Problem Description
Demonstrate Aero-vibro-acoustics coupling to predict noise at the
interior of the Hyundai simplified model [2]
HSM Model Simplified model released by Hyundai Kia Motors for
2013 KSNVE Open Benchmark[2]
Sound Source
Transient Separated flow at
A-pillar

Thursday, October 02, 2014

Transfer Path
[Side glass, windshield]

2014 Automotive Simulation World Congress

Receiver
Ear of a driver

Simulation Methodology [1]

Connection between Vibrating
walls and Rigid walls
A-pillar Mirror

Turbulence

Glass
Inflow
External CFD Model
Transient Flow

CFD modeling
Thursday, October 02, 2014

Outer Walls (Rigid)

Interior Walls
Mic.

Vibrating Surfaces
(Side Glass, Windshield)

Acoustics Model
(Car Interior)

Vibroacoustics Modeling
2014 Automotive Simulation World Congress

Simulation Methodology [2]

Solve
Transient
CFD

Time Freq.
domain
transform

Mapping
Freq. Domain
Pressure Loading

Solve VibroAcoustics
Model

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

Workflow Studied
Strong Vibroacoustic Coupling

Pressure
Mapping after
FFT

ANSYS Fluent

Harmonic Strongly
Coupled Vibro-acoustic

One Way Vibroacoustic Coupling

Pressure
Mapping after
FFT

ANSYS Fluent

Thursday, October 02, 2014

Velocity
Mapping

Harmonic
Structural

2014 Automotive Simulation World Congress

Harmonic
Acoustic
8

Test Measurement Points

90mm

200mm

1000mm

650mm

Interior Microphone
Locations

Accelerometers
mounted on LH Side
Glass

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

Transient CFD Modeling

CFD Domain consists of External HSM surfaces,
side glasses and windshield & wind tunnel
boundaries
Configuration Studied : HSM 0 deg. Yaw
Nozzle Inlet : Velocity Inlet : 130 kmph [Profile]
Tunnel Outlet : Pressure Outlet
(Gauge Pressure = 0 Pa)
Tunnel Inlet : Pressure Inlet
(Gauge Tot. Pressure = 0 Pa)
Tunnel Top, floor, side, wall BC
(No-Slip)

Inlet Vel. Profile

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

CFD Domain

Boundary Conditions
10

Mesh Details

Thursday, October 02, 2014

Total Cell Count = 45 Million

Prims Cell Count = 23 Million
No of Prism Layers = 12
First Prism Layer Height = 0.05 mm
Surface Mesh Size : A-pillar 1.5 to 2.0 mm,
Side glasses, windshield = 2.0 to 3.0 mm

2014 Automotive Simulation World Congress

11

Solver Settings : Transient CFD Simulation

1.

Solver : ANSYS Fluent, Pressure Based, Double Precision, Transient ,

Gradient Green Gauss Node Based
Transient Formulation : 2nd Order Implicit, Time Step Size = 2e-5 s
Material - Air as Ideal Gas
Turbulence Model Steady State : SST K-Omega
Turbulence Model Transient : DDES SST K-Omega
Pressure Velocity Coupling SIMPLEC
Spatial Discretization

2.
3.
4.
5.
6.
7.

Pressure : Second Order, Density : Second Order Upwind

Momentum : Bounded Central Differencing
TKE & Specific Dissipation Rate : Second Order Upwind
Energy : Second Order Upwind

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

12

Solution Procedure
1.

Run Steady State Simulation using SST K-Omega Turbulence Model

2.

Steady State Simulation Solver Settings Pressure Based Coupled Solver

3.

Switch to Transient Simulation, Use Second Order Temporal Discretization

4.

Switch to DDES SST K-Omega Turbulence Model

5.

Run initial transient simulation to achieve dynamic steady state

6.

Run Final transient simulation [time step size 2e-5, no. of iterations per
time step = 8]

7.

Export the ASD Data on Wind-shield, side-glass surfaces at every time step

8.

Perform Surface Acoustics FFT to transform source data into Frequency

Domain

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

13

Transient Flow Field

Velocity Contours at Z = 0.5 m

Pressure Contours at Z = 0.5 m

Iso-surface of Q-Criterion colored by velocity magnitude

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

14

Source Data : Transformation

Time Frequency Domain
Acoustic Source FFT is a Beta Feature
in R 16.0

3
1

1. Set Modes
(Real /Img.)

2. Octave (SPL)
3. 1/3rd Octave
(SPL)

4. Constant Band
(SPL)
Thursday, October 02, 2014

2014 Automotive Simulation World Congress

15

Surface dB Map
1/3rd Octave 100 Hz

1/3rd Octave 1000 Hz

1/3rd Octave 500 Hz

Thursday, October 02, 2014

1/3rd Octave 1600 Hz

2014 Automotive Simulation World Congress

16

Acoustics Pressure Loading in

Freq. Domain
Freq. 455 Hz

Freq. 455 Hz

Freq. 1575 Hz

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

Freq. 1575 Hz

17

Acoustics Source Mapping

ANSYS Fluent

Mapping for 100 Hz

ANSYS Mechanical

Mapping for 1000 Hz

Thursday, October 02, 2014

18

Vibroacoustics Modeling
Structural Material Properties
PROPERTIES

GLASS

AL 6061

HEAVY
LAYER

Thickness (mm)

12

Density (kg/m3)

2500

2700

2000

70

69

0.04

0.22

0.33

0.45

Youngs Modulus (GPa)

Poisson's ratio

PROPERTIES

Air

Foam

Mass Density (kg/m3)

1.2

1.2

Sound Speed (m/s)

343

343

Fluid Resistivity (N s /m4)

Porosity
Tortuosity

6.83E+16
0.879
3.31

Viscous Length (m)

9.483e-10

Thermal Length (m)

1.2174e-10

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

19

Vibroacoustics Modeling
Strong Coupling:
Full Vibroacoustics harmonic analysis
from 50 to 1000 Hz (117 frequencies)
Weak Coupling:
Full structural harmonic analysis from
50 to 1000 Hz (117 frequencies)
Full acoustic harmonic analysis from
50 to 1000 Hz (117 frequencies)

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

20

Results : Acceleration vs Frequency

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

21

Results : SPL(dB) vs 1/3rd Octave Freq.

@ Interior Microphone

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

22

Summary
1.

Aero and Vibroacoustics coupling is demonstrated using transient CFD

and Vibroacoustics modeling
ANSYS Fluent solver is used for transient aeroacoustics simulation
A Vibroacoustics simulation is done using ANSYS Mechanical using two
approaches

2.
3.

4.
5.

Strong Vibroacoustics coupling approach

Weak Vibroacoustics coupling approach

Simulation Results are fairly in good agreement with Test Data

Differences between strong and weak Vibroacoustics coupling are
observed
It doesnt seem possible to neglected the effects of the acoustics cavity on the
deformation of the structure

Thursday, October 02, 2014

2014 Automotive Simulation World Congress

23