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Squeak and rattle (S&R) problems in body structure and trim parts have become serious issues for automakers because of their influence on the initial quality perception of consumers. In this study, various CAE and experimental methods developed by Hyundai Motors for squeak and rattle analysis of door systems are reported. Friction-induced vibration and noise generation mechanisms of a door system are studied by an intelligent combination of experimental and numerical methods. It is shown that the effect of degradation of plastics used in door trims can be estimated by a numerical model using the properties obtained experimentally. Effects of changes in material properties such as Young's modulus and loss factor due to the material degradation as well as statistical variations are predicted for several door system configurations. As a new concept, the rattle and squeak index is proposed, which can be used to guide the design.

With the recent development of technologies for interpreting vibration and noise of vehicles, it has become possible for carmakers to reduce idle vibration and driving noise in the phase of preceding development. Thus, the issue of noise generation is drawing keen attention from production of prototype car through mass-production development. J. D. Power has surveyed the levels of customer satisfaction with all vehicles sold in the U.S. market and released the Initial Quality Study (IQS) index. As a growing number of emotional quality-related items are added to the IQS evaluation index, it is necessary to secure a sufficiently high quality level of low-frequency speaker sound against rattle noise. It is required to make a preceding review on the package tray panel, which is located at the bottom of the rear glass where the woofer speakers of a passenger sedan are installed, the door module panel in which the door speakers are built.

Two potential applications of a dynamic stiffness matrix (DSM) based direct damping matrix identification method are presented in this paper. The method was proposed to identify both the mechanism and spatial distribution of damping as a matrix of general function of frequency. First potential application is the analytical-experimental hybrid structural dynamics modeling, in which the model is constructed by combining analytically formulated mass and stiffness matrices with the experimentally identified damping matrix. Second application is the direct measurement of complex shear modulus of viscoleastic materials. The real and imaginary parts of the dynamic stiffness measured on a test setup that resembles a single degree of freedom system is used to compute the shear modulus and the loss factor of viscoelastic materials.

Theoretical development of a dynamic stiffness matrix (DSM) based direct damping matrix identification method is revisited in this paper. This method was proposed to identify both the mechanism and spatial distribution of damping in dynamic structures as a matrix of general function of frequency. The objective of this paper, in addition to the review of the theoretical development, is to investigate some major issues regarding the feasibility of this method. The first issue investigated is how the errors in measured frequency response functions (FRF) affect the accuracy of the DSM. It was already known that the DSM is highly sensitive to errors that are present in the FRF. A detailed analytical and computational study is conducted, which finally leads to a sound physical explanation of the high sensitivity of the DSM to measurement errors. A new and also important conclusion is that the leakage error drastically affects the accuracy of the computed DSM.

An air-conditioner compressor-mounting bracket is a structural component of an engine, on which bolts attach an air-conditioner compressor. In this paper, the shape of the air-conditioner compressor-mounting bracket of a passenger car is optimized using a finite element software, and the optimized bracket is manufactured and verified by tests. An objective function for the shape optimization of the bracket is the weight of the bracket. Two design constraints on the bracket are the first resonant frequency of the compressor assembly and the need not to fracture during the workbench durability test. The compressor assembly, which consists of a compressor, a bracket and connection bolts, is modeled using finite elements. The bracket is modeled by solid elements and the swash-plate-type compressor is represented by rigid masses and beam elements in order to consider the elastic effects of the compressor.

Despite tremendous advances in modern computational technology, there still remain many engineering problems that do not allow numerical solutions of reasonable accuracy. In many of these problems the main difficulty stems from lack of our ability to accurately model damping. Such examples are simulation of structure-borne noise, stability analysis of dynamic systems and numerical prediction of fatigue failure. In these problems small difference in damping description results in a completely different solution, while the current state of the art of damping modeling cannot provide such accuracy. A new concept proposed by one of the authors [1,2], which uses the dynamic stiffness matrix (DSM-the inverse of a frequency response function matrix), is studied in this two-part paper. Advantages of the method and practical issues to overcome are discussed in both papers. The method obtains the damping model directly from measured data; and is independent of classical damping models.