TY - JOUR
T1 - Vibration Characteristics Analysis and Anti-rattle Optimization of Vehicle Suspension Damper based on the Combination of Test-simulation Approach
AU - Chen, Xiaokai
AU - Wen, Hansheng
AU - Liu, Xiang
N1 - Publisher Copyright:
© Springer Nature Singapore Pte Ltd. 2025.
PY - 2025/6
Y1 - 2025/6
N2 - Purpose: A combined method of vehicle road test, damper rig test, and simulation is proposed. Vehicle road test provides subjective and objective data on rattle noise for the rig test, which is performed to develop the evaluation metrics. Methods: The damper rig test provides validation data for the simulation model and defines the rattle noise level. In addition, a modeling method of combining parametric and localized finite element simulation is proposed, which applies computational fluid dynamics to calculate the relationship between flow rate and pressure drop of the irregular orifices inside the damper. The proposed methods are applied to analyze the rattle noise generation mechanism and optimize the rattle noise. Results and Conclusion: The damper rig test can reproduce the damper rattle noise characteristics by imposing the road excitation acquired from the vehicle road test. The evaluation metrics of damper rattle noise are developed based on the RMS of the rod-end vibration acceleration in the 100–200 Hz frequency band, which can identify different levels of rattle noise. The proposed simulation method can accurately represent the damping and vibration characteristics of the damper, with a maximum error of less than 10%. In vibration characteristics sensitivity analysis, the piston and rod diameter, gas pressure, bushing stiffness, and properties of the valve system have a large impact. The valve systems assembled on the piston (flow and rebound valves) exhibit the same impact pattern and the valve system on the base valve (compensation and compression valves) exhibit the same impact pattern. For the same valve system, the stiffness property and preload have the same impact tendency, while the flow property is the opposite. Notably, the tendency of the difference between the peak and trough values of the vibration acceleration time-domain curves for disc valves is positively correlated with the RMS of the rod-end vibration acceleration in the 100–200 Hz frequency band. The anti-rattle design scheme is presented by design of experiments, which uses damping force as the constraint. The stiffness property of disc valves and the flow property of orifices are optimized. The RMS of the optimized damper decreases from 3.102 m/s2 (2.417 m/s2) to 1.131 m/s2 (0.904 m/s2) in vehicle road test (damper rig test), which is in no rattle condition.
AB - Purpose: A combined method of vehicle road test, damper rig test, and simulation is proposed. Vehicle road test provides subjective and objective data on rattle noise for the rig test, which is performed to develop the evaluation metrics. Methods: The damper rig test provides validation data for the simulation model and defines the rattle noise level. In addition, a modeling method of combining parametric and localized finite element simulation is proposed, which applies computational fluid dynamics to calculate the relationship between flow rate and pressure drop of the irregular orifices inside the damper. The proposed methods are applied to analyze the rattle noise generation mechanism and optimize the rattle noise. Results and Conclusion: The damper rig test can reproduce the damper rattle noise characteristics by imposing the road excitation acquired from the vehicle road test. The evaluation metrics of damper rattle noise are developed based on the RMS of the rod-end vibration acceleration in the 100–200 Hz frequency band, which can identify different levels of rattle noise. The proposed simulation method can accurately represent the damping and vibration characteristics of the damper, with a maximum error of less than 10%. In vibration characteristics sensitivity analysis, the piston and rod diameter, gas pressure, bushing stiffness, and properties of the valve system have a large impact. The valve systems assembled on the piston (flow and rebound valves) exhibit the same impact pattern and the valve system on the base valve (compensation and compression valves) exhibit the same impact pattern. For the same valve system, the stiffness property and preload have the same impact tendency, while the flow property is the opposite. Notably, the tendency of the difference between the peak and trough values of the vibration acceleration time-domain curves for disc valves is positively correlated with the RMS of the rod-end vibration acceleration in the 100–200 Hz frequency band. The anti-rattle design scheme is presented by design of experiments, which uses damping force as the constraint. The stiffness property of disc valves and the flow property of orifices are optimized. The RMS of the optimized damper decreases from 3.102 m/s2 (2.417 m/s2) to 1.131 m/s2 (0.904 m/s2) in vehicle road test (damper rig test), which is in no rattle condition.
KW - Anti-rattle optimization
KW - Computational fluid dynamics
KW - Damper rig test
KW - Hydraulic damper
KW - Parametric simulation
KW - Sensitivity analysis
KW - Vehicle road test
KW - Vibration characteristics
UR - http://www.scopus.com/inward/record.url?scp=105004845433&partnerID=8YFLogxK
U2 - 10.1007/s42417-025-01853-2
DO - 10.1007/s42417-025-01853-2
M3 - Article
AN - SCOPUS:105004845433
SN - 2523-3920
VL - 13
JO - Journal of Vibration Engineering and Technologies
JF - Journal of Vibration Engineering and Technologies
IS - 5
M1 - 295
ER -