Konzernforschung

Simulation of Exhaust System Noise

using 1D-CFD / 3D-BEM Methods
for the VW EcoRacer Concept Car
L. Miranda, Dr.Henry-Paul Bensler
LMS Conference Europe Stuttgart, 17.-18.April, 2007
Konzernforschung
VW EcoRacer 2005
Motivation: Sound Tuning of Eco-Racer
Konzernforschung
Driving performance
0-100 at 6.3s
v
max
230 km/h
Driving
pleasure
without regret
Variability
Lightweight design and
low consumption
Roofwings for a better boarding
removable roof
removable rear roofpart
removable windscreen
850 kg
3.4 l/100km
Diesel, DSG
CFK, Al
EcoRacer Attributes
Konzernforschung
c
W
-optimised for 3L Stripping as an additional
feature!
Optical driving pleasure
Fascination Fascination
Low Low consumption consumption
Affordable Affordable lightweight lightweight design design
Driving Driving pleasure pleasure with with Diesel-Power Diesel-Power
Extreme Sportiness
Driving behaviour
like
Lotus Elise
Cost potential of
production concepts
for low volumes
Economy at sporty
driving performance
<4 L/100km at
<7s Accel. 0-100 km/h
Variability of
bodyshell
(Roof, windscreen, rear
roofpart removable)
Konzernforschung
Completely closed
Roof parts removed
Rear roof part removed
Windscreen removed
Variability of the bodyshell
Konzernforschung
_ Improvement of the sound emision in low frequency [250 300 Hz] range
_ Reduction of flow noise
_ Calculation of the transmission loss
_ Engine noise simulation 3 Cylinder TDI 85 KW with
Gas dynamics simulation:
_ Simulation TDI Engine on test chamber (Performance)
_ Simulation TDI Engine + Exhaust system (Sound Tuning)
_ Audible sound files generation with WNoise for subjective evaluation
_ Optimisation of exhaust pipe location
Exhaust System Noise Goals
Konzernforschung
Input Models
CAD Model
Virtual Lab BEM Model
WAVE Modell
Ansaugung
Luftfilter
ESD (4 Lang)
KAT
LLK
Turbine
Verdichter
Motor
Methodology
Konzernforschung
Airfilter
Muffler
Catalisator
LLK
Turbine Verdichter
Engine
intake
Engine Model 1D-CFD
Konzernforschung
0
50
100
150
200
250
300
350
1000 1500 2000 2500 3000 3500 4000 4500
Drehzahl [1/min]
D
r
e
h
m
o
m
e
n
t

[
N
m
]
Messung M7
Simulation M7
0
10
20
30
40
50
60
70
80
90
100
1000 1500 2000 2500 3000 3500 4000 4500
Drehzahl [1/min]
L
e
i
s
t
u
n
g

[
K
W
]
Messung M7
Simulation M7
0
50
100
150
200
250
300
350
400
450
1000 1500 2000 2500 3000 3500 4000 4500
Drehzahl [1/min]
L
u
f
t
d
u
r
c
h
s
a
t
z

[
K
g
/
h
]
Messung M7
Simulation M7
0
20
40
60
80
100
120
140
160
180
200
1000 1500 2000 2500 3000 3500 4000 4500
Drehzahl [1/min]
P

m
a
x

Z
y
l
.
1

[
b
a
r
]
Messung M7
Simulation M7
1-D CFD Performance
Konzernforschung
6
2
0
4
3
1
5
Fiberglass /Advantex
Perforation
serie
Muffler Designs
Konzernforschung
standard with flow noise
Initial Case 0:
Areas of low Sound Intensity
Engine Orders: 1.5 3.0 4.5 6.0 7.5
Konzernforschung
Best in class 3 und 4
T=900 K
Simulation of Transmission Loss Analysis for Muffler only
Prototypes
Konzernforschung
150 mm 150 mm 50 mm
75 mm 75 mm
75 mm 75 mm
55 mm
55 mm
100 mm
350 mm
100 mm
350 mm
55 mm 55 mm
20 mm
20 mm
20 mm
41 mm
3
4
Variante
41mm
20 mm
20 mm
41 mm
41 mm
45 %
20% 20 %
20 % 45 %
3.5 mm
Lchern
41 mm
41 mm
3 Chamber Muffler
Mufflers Models for 3-D BEM Analysis:
Konzernforschung
3-D BEM Simulation: Sound Energy of Muffler
Optimisation of Inner Muffler Design (initial 3 Chamber Prototype shown)
220 Hz
315 Hz
Modal Response of Excitation
455 Hz 545 Hz
Konzernforschung
Komponente wirksame Lnge Gastemperatur
n =1 n =2 n =3 n =4
[mm] [K] [Hz] [Hz] [Hz] [Hz]
v. Turbine Strecke Zyl.1 432 900 335 1005 1676 2346
Gesamtstrecke Zyl. 1 Lang 2450 770 56 169 282 395
Gesamtstrecke Zyl. 1 Kurz 2229.4 770 62 186 310 433
Gesamtstrecke Zyl. 1 Center 1985 770 69 208 347 486
vor Kat 568 780 461 923 1384 1846
KAT - ESD 255.3 770 935 1870 2806 3741
Endrohr Lang 655 720 390 780 1170 1559
Endrohr Kurz 434.4 720 573 1146 1719 2292
Endrohr Center 190 720 1196 2392 3588 4784
Resonanzfrequenzen
1-D CFD Resonance Frequencies in different Exhaust System
Locations for different Exhaust Pipe Lengths:
Konzernforschung
Left Right
30
40
50
60
70
80
90
100
1000 1500 2000 2500 3000 3500 4000 4500
Drehzahl [U/min]
S
P
L

d
B

(
A
)
Overall
1.5 MO
3.0 MO
4.5 MO
6.0 MO
7.5 MO
30
40
50
60
70
80
90
100
1000 1500 2000 2500 3000 3500 4000 4500
Drehzahl [U/min]
S
P
L

d
B

(
A
)
Overall
1.5 MO
3.0 MO
4.5 MO
6.0 MO
7.5 MO
1-D CFD Sound Pressure Level of Prototype 4 with long Dual
Exhaust Pipes (left and right ):
Konzernforschung
Production Muffler
Prototype 4
1-D CFD Results: Prototype 4
Engine Orders: 1.5 3.0 4.5 6.0 7.5
Konzernforschung
_ Good correlation between simulation and test
of engine performance required
_ Significant improvement of exhaust system
sound was achieved
_ Combined usage of 1D-CFD and 3-D BEM
methods very effective for exhaust system
engineering
_ Very good method to quantify and evaluate
exhaust system sound
Conclusions
Konzernforschung
Konzernforschung
|
|
|
|
|
|
|
|
j
)

|
\
[
A
~
~
+
~ =
1
0
1
m
a
b
e x
0
0 0
Wiebe Function represents the burning rate
b
x
=mass fraction burned
0
=crankangle
0
0
=crankangle of the initial combustion
A0
=duration of combustion
1-CFD Combustion Model
Konzernforschung
Methodology: Transmission Loss Analysis of Muffler only