Powertrain induced NVH

Stephanos Theodossiades
email: S.Theodossiades@lboro.ac.uk

Wolfson School of Mechanical and Manufacturing Engineering
Loughborough University, Loughborough
United Kingdom
Any public or commercial use requires the agreement of the author.
- Overview


- Investigation Strategy


- Transmission Rattle


- Axle Whine


- Driveline Clonk
Any public or commercial use requires the agreement of the author.
Powertrain
All the components in a vehicle that contribute to the generation, transmission,
and distribution of drive torque to the wheels
Drivertrain
All the components required to deliver engine power to the road surface
Driveline
Assembly of the parts that transmit torque from the transmission to the wheels
How NVH issues initiate? The continuous trend for increased engine power,
reduced vehicle weight and lower costs have driven developments towards lighter,
thinner components -> increased vibration levels in powertrains
The significant advances in the reduction of engine/aerodynamic/tyre noises have
brought to the forefront other powertrain noise sources, previously masked
Any public or commercial use requires the agreement of the author.
Powertrain induced NVH Phenomena

Vehicle
shunt, boom
Clutch
whoop, judder
Axle Drive
whine
Drivetrain/Transmission
shuffle, clonk, rattle, whine
Any public or commercial use requires the agreement of the author.
Clutch
whoop (200-500Hz) knocking effect on clutch pedal during engagement/disengagement
and radiated noise in the driver foot area
judder (7-20Hz) torsional rigid body mode of powertrain at low engine speeds due to
stick-slip motion between flywheel/friction disk and friction disk/pressure plate

Gearbox
rattle (below 2000Hz) result of impacts between meshing gear teeth under various
loaded or unloaded conditions
whine (400-4000Hz) tonal noise excited by meshing gears in the gear meshing
frequency or/and its multiples

Differential
whine (200-800Hz) same mechanism as in gearbox

Drivetrain
shuffle/shunt (2-7Hz) coupled rigid body torsional and axial low frequency oscillations of
the drivetrain system,
clonk-thud (500-5000Hz) short duration transient response of metallic nature, usually
the result of a load reversal in the presence of backlash

Vehicle Cabin
boom (20-160Hz) drumming noise, excited by engine orders due to coincidence
between structural modes of vehicle body and its acoustic cavity modes
The Plethora of NVH Concerns
Any public or commercial use requires the agreement of the author.

Investigation Strategy
System testing
Any public or commercial use requires the agreement of the author.
Experimentation (Down-cascading)
Vehicle test in the semi-anechoic chamber Engine-transmission test bed
Electrically driven transmission-based rig
Single gear pair rig Any public or commercial use requires the agreement of the author.
Gear teeth impact-induced oscillations in manual
transmissions promoting Gear Rattle
Any public or commercial use requires the agreement of the author.
Problem definition - what is gear rattle?
Noise generated due to impacts between manual transmissions meshing gear
teeth in the presence of backlash and induced engine order vibrations

Mechanism of rattle
Types of rattle
- Idle rattle (clutch engaged, transmission in neutral, engine at idle rpm).
- Drive/Creep rattle (clutch engaged, any gear, 1200 - 2000 rpm).
- Coast/Over-run rattle (clutch engaged, high engine loads, 1500 - 4000 rpm).
Any public or commercial use requires the agreement of the author.
Experimentation:
High and low rattle measurements
High, medium and low measured rattle input conditions from vehicle tests
Spectral content:
Low rattle condition
High rattle condition
Any public or commercial use requires the agreement of the author.
Regime of Lubrication
Ra
h
=
Stribeck Curve
Boundary lubrication ( < 1)
Mixed (1 3)
Elastohydrodynamic (3 < 5)
Hydrodynamic (5 < 100)
N normal applied load [N]
F
f
friction force [N]
h film thickness
Ra RMS
surface roughness
N
F
f
=
1 3 5 10 100


Any public or commercial use requires the agreement of the author.
Mathematical Formulation of Conjunctions:
(a)- Loose gear pairs
( )
0
0
3
2 , 0
2
2 , 0
eq
eq
eq
L r
h h
W u
h t t
h
r
L r
h
W u
h t
| |
|
c c |
= <
|
c c
|
|
\ .
c
= >
c
b p p w w
h C r r =
0 1 os
v l r
F
C
=
0
2
s eq
f
L u r
F
h
=
Pinion
Loose Wheel
W
F
h
cp
r
cw
r
os
r
W
Shaft
Lubricant
Lubricant between
gear teeth surfaces
Pinion
Loose Wheel
W
F
h
cp
r
cw
r
os
r
W
Shaft
Lubricant
Lubricant between
gear teeth surfaces
Forcing elements for loose gears (analytical solution)
Petrov friction:
Flank friction:
Hydrodynamic impact load:
Lubricant film thickness:
Any public or commercial use requires the agreement of the author.
Mathematical Formulation of Conjunctions:
(b)- Engaged gear pair
Forcing elements for engaged gear (analytical solution)
Grubins relationship for load (W)
and lubricant film thickness (ho):
1
2
2
2 1
2 ln
2
*
*
2 1
2 ln
2
p
l
mv
b

LE
lE
W
l
b
( | | | |
+
( | |
\ . \ .
(
=
(
(
(

(
(
(
~
(
( | |
+
(
| (
\ . (
( )
8
1
11
11
*
2.076
x
o x
x
E lr u
h r
r W
| |
| |
=
|
|
\ .
\ .
Since there is no relative
speed between shaft and
gear, no Petrov friction
Visous friction
Adhesive fricion
f v a
v
a
F F F
F
F
= +
=
=
Pinion
Loose Wheel
W
F
h
cp
r
cw
r
os
r
W
Shaft
Lubricant
Lubricant between
gear teeth surfaces
Pinion
Loose Wheel
W
F
h
cp
r
cw
r
os
r
W
Shaft
Lubricant
Lubricant between
gear teeth surfaces
Any public or commercial use requires the agreement of the author.
Mathematical Formulation of Conjunctions:
(c)- Reynolds solution
Integrated pressure
from Reynolds' solution
W ~
Converged shape
from Reynolds' 1-D solution
h =
No Petrov friction for engaged
gear and analytical solution
for loose wheels
Visous friction
Adhesive fricion
f v a
v
a
F F F
F
F
= +
=
=
Pinion
Loose Wheel
W
F
h
cp
r
cw
r
os
r
W
Shaft
Lubricant
Lubricant between
gear teeth surfaces
Pinion
Loose Wheel
W
F
h
cp
r
cw
r
os
r
W
Shaft
Lubricant
Lubricant between
gear teeth surfaces
3 3
6 2
h p h p h h h
u v
x x y y x y t
| | | | c c c c c c c
+ = + +
`
| |
c c c c c c c
\ . \ . )
q q
Transient 1-D solution assumes no side leakage (terms in y-direction are disregarded)
Any public or commercial use requires the agreement of the author.
Mathematical Formulation of Conjunctions:
(d)- Energy equation
2
2
2
compressive heating convection cooling viscous heating
conduction cooling
x
e x x p c
v p
v v v C k
x z x z
| |
c c c c | | | | | |
+ =
|
| | |
c c c c
\ . \ . \ .
\ .
2
8
s
p
u b

h C
A =
2 *
2
entr
s
ku R

c Q
A =
2
max
max
2
'
'
i o
o
o
o
bu
u h p
h

bk
u h p
h
(
| |
+
( |
\ .
(
A =
( | |

|
(
\ .

EHL conjunction
In elastohydrodynamic films, the heat
is generated by compressive and
viscous heating
Due to thin film thickness and a low
Peclet number, convective cooling can
be neglected
Hydrodynamic conjunctions
In flank conjunctions, because of low
generated pressures, the effect of
compressive heating is neglected
Due to relatively high film thicknesses
and a high Peclet number, conduction is
assumed to be insignificant
Lubricant temperature rise in Petrov
bearings can be estimated as in
journal bearings
Any public or commercial use requires the agreement of the author.
Mathematical Formulation of Conjunctions:
(e)- Effective viscosity
273 , 273
bulk bulk contact contact
contact bulk contact
O = + AO = A +
O = O + AO
EHL conjunction
The effective temperature in the
contact is given by:
Hydrodynamic conjunctions
Low generated pressures in
hydrodynamic contacts (flank and
Petrov bearing) do not cause a change
in viscosity, hence:
The mean Hertizan pressure is:
1
2 *
'
4
m
x
P E
p
r
| |
=
|
\ .
t
t
The effective viscosity in the contact is
a function of pressure and temperature,
as proposed by Houpert:
( )
o
S
Z
m
o
o
p

p

(
| | O | |
( = + + (
` |
|
O
( \ .
\ .

)
*
8
1 138
ln 9.67 1 1
138 1.98 10
p
o
e =
*
1050.6
129
0.0001

e
| |
|
+
\ .
=
Any public or commercial use requires the agreement of the author.
Shaft and Bearing Dynamics Coupled to Gear Dynamics
Any public or commercial use requires the agreement of the author.
CAE Numerical Model
All the numerical models were created following Newton-Eulers formulation
The gear bodies are assumed to be rigid (except for local contact deformation)
The transmission casing is a deformable body
Input shaft
1
st
Output shaft
2
nd
Output shaft
D
i
f
f
e
r
e
n
t
i
a
l
1
st
2
nd
5
th
3
rd
4
th
6
th Rev.
1
F
2
F
3
F
4
F
6
F
5
F
rev
F
1 fd
F
2 fd
F
Input shaft
1
st
Output shaft
2
nd
Output shaft
D
i
f
f
e
r
e
n
t
i
a
l
1
st
2
nd
5
th
3
rd
4
th
6
th Rev.
1
F
2
F
3
F
4
F
6
F
5
F
rev
F
1 fd
F
2 fd
F
Diagrammatic view of the gearbox under investigation
Any public or commercial use requires the agreement of the author.
Natural Frequencies of the Torsional Linear System
Lubricant Stiffness
( ) ( ) ( )

=
+ + =
1
0
sin cos
p
i i sp i i cp i i
pn K pn K K K
( ) 0
6
1
0
= +

= i
i wi in pi pi i in in
r r r K I

( ) ( ) 0 ) (
, 1 ) ( 0 1 , 1 1 1 01 , 1 1
= + + +
wrev wrev prev prev prev rev in p prev w w prev prev
r r r K r r r K I I

( ) 0
2 2 2 2 02 2 2
= +
in p w w
r r r K I

( ) 0
3 3 3 3 03 3 3
= +
in p w w
r r r K I

( ) 0
4 4 4 4 04 4 4
= +
in p w w
r r r K I

( ) 0
5 5 5 5 05 5 5
= +
in p w w
r r r K I

( ) 0
6 6 6 6 06 6 6
= +
in p w w
r r r K I

( ) 0
, 1 0
= +
prev prev wrev wrev wrev rev wrev wrev
r r r K I

Linearised Equations of Motion
( )
2
1
~
h h
W
K
i
i
i
c
c
=
0
1 1 1 1 1
4
1
1 1 1 1 1
= + + + + +

=
y K x K K K K x M
y x x
i
in in x rev rev x i i x

0
1 1 1 1 1
4
1
1 1 1 1 1
= + + + + +

=
y K x K K K K y M
y x y
i
in in y rev rev y i i y

0
1 1 2 1 1 2
6
5
2 2 2 1 21 2 2
= + + + + + +

=
y K x K K K K K x M
y x x x
i
in in x rev rev x i i x x

0
1 1 2 1 1 2
6
5
2 2 2 1 21 2 2
= + + + + + +

=
y K x K K K K K y M
y y x y
i
in in y rev rev y i i y y

Any public or commercial use requires the agreement of the author.
Natural Frequencies and Mode Shapes of the Linearised System (1)
2 3 4 5 6 7
-40
-30
-20
-10
2 3 4 5 6 7
-35
-30
-25
-20
-15
-10
-5
2 3 4 5 6 7
-30
-20
-10
10

n
= 138Hz
1
st

Gear
Reverse
Gear
2
nd

Gear

n
= 193Hz

n
= 225Hz
1
st

Gear
4
th

Gear
Reverse
Gear
2 3 4 5 6 7
-50
-40
-30
-20
-10
2 3 4 5 6 7
-40
-30
-20
-10
2 3 4 5 6 7
-80
-60
-40
-20
4
th

Gear

n
= 258Hz
3
rd

Gear

n
= 359Hz
6
th

Gear

n
= 438Hz
Any public or commercial use requires the agreement of the author.
Natural Frequencies and Mode Shapes of the Linearised System (2)
2 3 4 5 6 7
-80
-60
-40
-20
5
th

Gear

n
= 1080Hz
1
X
Hz
n
1775 = e
1
X
Hz
n
1775 = e
1
Y
Hz
n
1800 = e
1
Y
Hz
n
1800 = e
2
X
Hz
n
1989 = e
2
X
Hz
n
1989 = e
2
Y
5
th
Gear
Hz
n
2146 = e
2
Y
5
th
Gear
Hz
n
2146 = e
Any public or commercial use requires the agreement of the author.
RMS Values of the Idle Gears Rotational Accelerations with respect to Temperature:
(a) 1st, (b) 2nd and (c) 6th gear
20 30 40 50 60
20
30
40
50
Rad/s
2
C
(a)
20 30 40 50 60
30
60
90
Rad/s
2
C
(b)
20 30 40 50 60
15
25
35
Rad/s
2
C
(c)
When the ratio (Rattle Ratio) Torque Drag Torque Inertia RR = exceeds unity, rattle occurs
Any public or commercial use requires the agreement of the author.
Model predictions creep rattle conditions
Engaged gear wheel: Loose gear wheel:
Meshing frequency dominates Improper meshing
Input energy converted to rattling at engine
order harmonics
Any public or commercial use requires the agreement of the author.

Transient at 60C
Transient at 50C
Grubin at 60C
Grubin at 50C


Analytical (Grubin)
Numerical transient

Fluctuations in film thickness in lightly loaded conjunctions of loose gear pair ( and ) 80 C
Comparison of load per EHL conjunction under
transient and analytical quasi-static conditions (60
o
C)
Transient history of central oil film thickness
of typical loaded gear teeth pair
Any public or commercial use requires the agreement of the author.
EHL of an engaged gear
Temperature variation for one meshing cycle (EHL - Hydrodynamic conditions)
EHL (inlet temperature of 20C)
Hydrodynamic (inlet
temperature of 60C)
Shaft/Gear Wheel conjunction
(inlet temperature of 60C)
Any public or commercial use requires the agreement of the author.
Impulsion ratio
Impulsion ratio ( )
If < 1 Decelerative motion of loose gears
If = 1 Uniform motion
If > 1 Accelerative motion

Three aspects may be controlled
Clearance between loose wheel and retaining shaft
Viscosity ratio (in the flank and Petrov bearing conjunctions)
Inertia is a controllable parameter (however it should not affect
torque transmission when engaged)
pet f
drive
m
drag pet
C
T
I
T h
=
q
q
m
I
Fluctuations in the impulsion ratio of lightly loaded loose gear pairs ( and ) 80 C
Any public or commercial use requires the agreement of the author.
Measured response with medium rattle input (DMF)
Wavelet response of accelerometer output from
transmission casing (lower shaft bearing cap)
Low-medium spectral content agrees with
numerical predictions
High spectral content is due to modal behaviour
of casing
Wavelet response of microphone output
positioned 1 metre from bearing cap
Structure-borne noise identified, commensurate
with wave propagation through solid and air
Noise response at point (B) in microphone signal
corresponds to structural vibration at point (A)
Any public or commercial use requires the agreement of the author.
Literature

- M. De la Cruz, W.W.F. Chong, M. Teodorescu, S. Theodossiades and H. Rahnejat. Transient mixed thermo-elastohydrodynamic lubrication
in multi-speed transmissions. Tribology International, 2012, 49, 17-29.
- M. De la Cruz, S. Theodossiades, P. King and H. Rahnejat. Transmission drive rattle with thermo-elastohydrodynamic impacts: Numerical
and experimental investigations. International Journal of Powertrains, 2011, 1(2), 137-161.
- De la Cruz, M., Theodossiades, S. and Rahnejat, H. An investigation of manual transmission drive rattle. Proceedings of the Institution of
Mechanical Engineers Part K: Journal of Multibody Dynamics, 2010, 224(2), 167-181.
- Tangasawi, O., Theodossiades, S., Rahnejat, H. and Kelly, P. Non-linear vibro-impact phenomenon belying transmission idle rattle.
Proceedings of the Institution of Mechanical Engineers, Part C, Journal of Mechanical Engineering Science, 2008, 222(10), 1909-1923.
- Tangasawi, O., Theodossiades, S. and Rahnejat, H. Lightly loaded lubricated impacts: idle gear rattle. Journal of Sound and Vibration, 2007,
308(3-5), 418-430.
- Theodossiades, S., Tangasawi, O. and Rahnejat, H. Gear teeth impacts in hydrodynamic conjunctions promoting idle gear rattle. Journal of
Sound and Vibration, 2007, 303(3-5), 632-658.
- Grubin, A. N. Contact stresses in toothed gears and worm gears. Book 30 CSRI for Technology and Mechanical Engineering, Moscow DSRI
Trans. 1949;337
- Snidle, R.W. and Evans, H.P. Elastohydrodynamics of gears. Trib. Series (Elsevier Sci.). 1997;32:271-280
- Evans, C. R. and Johnson, K. L. Regimes of traction in EHD lubrication. Proc. IMechE, Part C: J. Mech. Engng. Sci. 1986;200:313-324
- Gohar, R. and Rahnejat, H. Fundamentals of tribology, Imperial College Press, London. 2008
- Greenwood, J. A. and Tripp, J. The contact of two nominally flat rough surfaces. Proc. IMechE, J. Mech. Engng. Sci. 1970-71;185:625-633
- Li, S and Kahraman, A. A transient mixed elastohydrodynamic lubrication model for spur gear pairs. Trans. ASME, J. Trib. 2010;132
- Wang, K. L. and Cheng, H. S. A numerical solution to the dynamic load, film thickness and surface temperatures in spur gears, Part I
Analysis and Part II Results. ASME Journal of Mechanical Design. 1981a;103:177-187, 1981b;103:188-194
- Hua, D. Y. and Khonsari, M. Application of transient elastohydrodynamic lubrication analysis for gear transmissions. STLE Trib. Trans.
1995;38:905-913
- Brancati, R., Rocca, E. and Russo, R. A gear rattle model accounting for oil squeeze between the meshing gear teeth. Proc. IMechE , Part
D: J. Automobile Engng. 2005;219:1075-1083
- Houpert, L. New results of traction force calculations in elastohydrodynamic contacts. Tran. ASME, J. Trib. 1985;185:241-248
- Stribeck, R. Die Wesentliechen Eigenschaften der Gleit und Rollenlager. Z. Ver. Dt. Ing. 1902;46;38:1341-1348,1432-1438 and
1902;46;39:1463-1470.
- Rahnejat, H. Computational modelling of problems in contact dynamics. Engineering analysis. 1985;2:192-197
- Rahnejat, H. Multi-body Dynamics: Vehicles, Machines and Mechanisms, Professional Engng. Publ. (IMechE) and SAE (Joint publishers),
London, UK and Warrendale, PA, USA. 1998.
- Gohar, R. Elastohydrodynamics. Imperial College Press, London. 2001
- M. Perera, S. Theodossiades, H. Rahnejat and P. Kelly, Drive rattle elastodynamic response of manual automotive transmissions. SAE 2011
Noise and Vibration Conference and Exhibition, 2011, Grand Rapids, Michigan, USA.
- De la Cruz, M., Theodossiades, S., Rahnejat, H. and Kelly, P. Numerical and experimental analysis of manual transmissions - gear rattle.
SAE Proceedings, SAE 2009 World Congress, Detroit, USA. Any public or commercial use requires the agreement of the author.
Gear vibrations in automotive differentials promoting
Axle Whine
Any public or commercial use requires the agreement of the author.
Vehicle tests

front of Vehicle

Wheels
Z Nose
Acceleration

Y Nose
Acceleration
Mic1: Drivers ear
Mic2: Back of the cabin
Mic3: Underbody of vehicle
Y
X
Z

Mic 2

Mic 3

Mic 1
Any public or commercial use requires the agreement of the author.
Measurements
Wavelet of signal from the rear cabin microphone Wavelet of microphone data from differential nose
Vibration Intensity Znose - Temperature
0
0.5
1
1.5
2
2.5
3
3.5
0 200 400 600 800
Frequency (Hz)
I
n
t
e
g
r
a
t
e
d

P
o
w
e
r
Test 14 - 49C
Test 16 - 51C
Test 20 - 61C
Test 26 - 68C
Any public or commercial use requires the agreement of the author.
Methods of investigation
MDOF rear axle multibody model
(ADAMS) - Large Scale
Contact ellipse at mesh point of
gear pair - Micro Scale
Any public or commercial use requires the agreement of the author.
S-bend of leaf springs with twist
of the rear axle (at 356 Hz)
RWD Driveline Model
Butterfly mode with multiple
leaf spring bending (at 772 Hz)
Any public or commercial use requires the agreement of the author.
Gear pair model
Free body diagram
Equations of motion
) ( ) ( ) ( ) ( ) ( ) (
0 0
t e dt t R dt t R t x
t
t
g p g
t
t
p p p
=
} }
u u u u

s +
< <
>
=
b x b x
b x b
b x b x
x f
g
,
, 0
,
) (
or 1 DOF!
0 ~ = = =
g p g p
R R R R

( ) ( ) ( ) ( )
g g p m p g m p g g g
T x f k R x c R I = u u u u

( ) ( ) ( ) ( )
p g p m p p m p p p p
T x f k R x c R I = + + u u u u


p
u

g
u

( ) ( ) ) (x f k R
g p m p p
u u

( )
m p p
c R u x
( )
m p g
c R u
x

pinion
gear
p
T

g
T

( ) ( ) ) (x f k R
g p m p g
u u

Any public or commercial use requires the agreement of the author.
Contact Properties
Geometrical
Data
Numerical
Simulation of Gear
Mesh Tooth
Contact Analysis
(TCA)
Load distribution
Contact area
Rigid body
deflection
Any public or commercial use requires the agreement of the author.
Meshing properties (1)
Mesh Stiffness k
m

Static Transmission Error
Any public or commercial use requires the agreement of the author.
Pinion Contact Radius
Meshing properties (2)
Gear Contact Radius
Any public or commercial use requires the agreement of the author.
Gear pair dynamics
0 0.2 0.4 0.6 0.8 1 1.2
80
90
100
110
120
130
140
e
mesh
/e
n
m
a
x
i
m
u
m

d
i
s
p
l
a
c
e
m
e
n
t

(

m

)
single DOF - reduced order system
double dof system
Any public or commercial use requires the agreement of the author.
Effect of sliding frictional properties
Friction coefficient and corresponding Torque
Pinion speed 1800 RPM
(continuous contact)
Pinion speed 3600 RPM
(loss of contact)
Any public or commercial use requires the agreement of the author.
Thermal effects
Lubricant Temperature and viscosity variation
Pinion speed 1800 RPM
(continuous contact)
Pinion speed 3600 RPM
(loss of contact)
Any public or commercial use requires the agreement of the author.
Tooth Contact Analysis
(TCA)
Elastohydrodynamic Lubrication (EHL)
Tribo-dynamic
behaviour of
engaged gears
Flank data,
Machine setting
and assembly
parameters
Surface
velocities,
applied
load and
surface
radii
Film thickness, friction
force, efficiency,
extrapolated equation
Elasto-hydrodynamic lubrication
Any public or commercial use requires the agreement of the author.
Contact footprint and
direction of angled flow
Instantaneous contact footprint
orientation with respect to direction
of lubricant entrainment
Direction of lubricant flow and contact
Any public or commercial use requires the agreement of the author.
Pressure Distribution and Film Thickness
pinion angle Load [N]
Magnitude of
Velocity [m/s]
Velocity Along
Minor Axis
[m/s]
Velocity Along
Major Axis
[m/s]
Surface Radius
in Minor Axis [m]
Surface Radius
in Major Axis [m]
0.5027 744.5161 18.0398 7.9751 16.1813 0.0157 1.0067
pinion angle Load [N]
Magnitude of
Velocity [m/s]
Velocity Along
Minor Axis
[m/s]
Velocity Along
Major Axis
[m/s]
Surface Radius
in Minor Axis [m]
Surface Radius
in Major Axis [m]
0.9582 5764.1 15.7962 8.9823 12.9938 0.0180 1.2578
Any public or commercial use requires the agreement of the author.
Film thickness comparison to
other known methods
Friction coefficient variation
during the meshing cycle
Any public or commercial use requires the agreement of the author.
Literature

- Cheng, Y., Lim, T.C. (2001), Vibration analysis of hypoid transmission applying an exact geometry based gear mesh theory, Journal of Sound and
Vibration, 240(3), pp. 519-543
- Cheng, Y, Lim, T.C. (2003), Dynamics of hypoid gear transmission with non-linear time-varying mesh characteristics, Trans. ASME, Journal of
Mechanical Design 125, pp.373-382.
- Wang, J., Lim, T.C., Li, M. (2007), Dynamics of a hypoid gear pair considering the effects of time-varying mesh parameters and backlash
nonlinearity, Journal of Sound and Vibration, 229(2), pp.287-310.
- Vaishya, M., Singh, R. (2003), Strategies for modelling friction in gear dynamics, Trans. ASME, J of Mech Design, 125, pp. 383-393
- Kar, C. and Mohanty, A.R. (2007), An algorithm for determination of time-varying frictional force and torque in a helical gear system, Mechanism
and Machine Theory, 42, pp. 482-496
- Xu, H. and Kahraman, A. (2007), Prediction of friction-related power losses of hypoid gear pairs, Proc, IMechE, J. Multibody Dyn. 221, 387-400
- Vijayakar, S. 1998, Tooth Contact Analysis Software: CALYX, Advanced Numerical Solutions, Hilliard, OH
- Gosselin, G., Guertin T., Remond, D., and Jean, Y. 2000, Simulation and experimental measurement of the transmission error of real hypoid gears
under load, Journal of Mechanical Design, 122, pp.109-122
- Borner, J., Houser, D., 1996, Friction and Bending Moments as Gear Noise Excitations, SAE paper 961816
- M. Mohammadpour, S. Theodossiades and H. Rahnejat. Elastohydrodynamic lubrication of hypoid gear pairs at high loads. Proc. of the Inst. of
Mech. Eng. Part J: Journal of engineering Tribology, 2012, 226(3), 183-198.
- I. Karagiannis, S. Theodossiades and H. Rahnejat. On the dynamics of lubricated hypoid gears. Mech. and Mach. Theory, 2012, 48, 94-120.
- G. Koronias, S. Theodossiades, H. Rahnejat and T. Saunders. Axle whine phenomenon in light trucks: a combined numerical and experimental
investigation. Proc. of the Inst. of Mech. Eng. Part D: Journal of Automobile Engineering, 2011, 225 (7), 885-894.
- Rahnejat, H. (Ed.) Tribology and dynamics of engine and powertrain, Woodhead Publishing Ltd., Cambridge, UK, 2010
- Denny, C.M., Mesh friction in gearing, AGMA, Technical Paper No. 98FTM2, 1998
- Michlin, Y. and Myunster, V., Determination of power losses in gear transmissions with rolling and sliding friction incorporated, Mech.Mach.
Theory, 37, 2002, pp. 167-174
- Benedict, G.H. and Kelly, B.W., Instantaneous coefcients of gear tooth friction, Trans. ASLE, 4, 1960, pp. 5970
- Velex, P. and Cahouet, V.Experimental and numerical investigations on the influence of tooth friction in spur and helical gear dynamics, Trans.
ASME, J. Mechanical Design, 122, 2000, pp. 515522.
- Velex, P. and Sainsot, P. An analytical study of tooth friction excitations in errorless spur and helical gears, Mechanism and Machine Theory, 37,
2002, pp. 641658.
- Litvin, F. L., Fuentes, A., Fan, Q. and Handschuh, R. F. Computerized design, simulation of meshing, and contact and stress analysis of face-
milled formate generated spiral bevel gears, Mech. & Mach. Theory, 37, 2002, pp. 441459
- Kolivand, M., Li, S. and Kahraman, A. Prediction of mechanical gear mesh efciency of hypoid gear pairs, Mech. & Mach. Theory,45, 2010, pp.
15681582
- Simon, V., Inuence of machine tool setting parameters on EHD lubrication in hypoid gears, Mech. & Mach. Theory, 44, 2009, pp. 923937
- Vaishya, M. and Singh, R. Analysis of periodically varying gear mesh systems with Coulomb friction using Floquet theory, JSV., 243, 2001, pp.
525-545
- Akin, L. S., EHD lubricant film thickness formulae for power transmission gears, Trans. ASME, J. Lubn.Tech., 1974, pp.426-431
- Naruse, C., Haizuka, S., Nemoto, R., and Umezu, T.,Limiting loads for scoring and frictinal loss of hypoid gear, Bull. JSME, 29(253), 1986, pp.
2271-2280
- Xu, H., Kahraman, A. and Houser, D.R., A model to predict friction losses of hypoid gears, AGMA Tech. Pap.: 05FTM06, 2005
Any public or commercial use requires the agreement of the author.
Impact induced vibrations in vehicular drivelines promoting
Clonk (or Clunk!) Noise
Any public or commercial use requires the agreement of the author.
Shuffle and Shunt
Shuffle is the first rigid body torsional vibration mode of the entire powertrain system.
It is in the range 3-7 Hz.

It can be noted with sudden throttle tip-in from coast to drive condition, or conversely in
back-out by sudden release of throttle (tip-out) from drive to coast.

It is usually noted by the coupled fore and aft motion of the vehicle, referred to as
shunt (a translational motion at the same frequency as the shuffle response).

Shuffle can also be induced by sudden clutch engagement or release.

It also manifests itself when negotiating a speed breaking bump.

It is most prominent at low road speeds and in low gear.
Any public or commercial use requires the agreement of the author.
1st clonk
Time
Torque
2nd clonk
3rd clonk
shuffle
frequency 3-7 Hz
The shuffle action of the drivetrain leads to torque reversals as impact action takes
place in transmission and differential meshing teeth, as well as in the propshaft joints,
which in turn can lead to propagation of high frequency structural waves (clonk).
Clonk accompanies shuffle with sudden demands in throttle tip-in/tip out or with abrupt
clutch in low gear and at low engine speed actuation (1.5-5KHz).

Clonk is the high frequency elasto-acoustic coupling response of driveline system.
Any public or commercial use requires the agreement of the author.
Clonk is an audible and tactile response from the driveline, which may occur under
several different driving conditions, as follows:
Tip-in clonk, when the throttle is rapidly applied from coast.
Tip-out clonk, when the throttle is abruptly released from drive.
Clutch engagement clonk may occur after gear selection, if the clutch is rapidly
engaged. It is more noticeable during low speed creep manoeuvres and low gear.
Shift clonk may occur during a gear up-shift.

The resulting torsional impulse delivered to the driveline gives rise to a short duration
vehicle jerk and an accompanying metallic clonk or thud noise.

Important parameters affecting shuffle and clonk are:
- Lash zones in the drivetrain: transmission gear pairs, differential unit gears and
splined joints.
- Sources of compliance in the system, such as the dual mass flywheel torsional
stiffness, the torsional stiffness of the clutch, the presence of any clutch system pre-
damper, the stiffness of the rear-axle half-shafts and driveshafts in rear wheel drives,
the longitudinal stiffness of the tyre.
- The clonk response refers to coincidence of structural waves with modes of
acoustic cavities, such as in the transmission bell housing, the hollow driveshaft
tubes and the differential unit cavity.
Any public or commercial use requires the agreement of the author.
Driveline experimental rig (static)
Any public or commercial use requires the agreement of the author.
Experimental results
-150
-100
-50
0
50
100
Time
Accel erati on
Appl i ed
torque
Torque
1 - 2 ms impact
50 ms decay transient
Any public or commercial use requires the agreement of the author.
The three-piece
driveline
experimental rig
A: Accelerometer Location
L: Laser Location
M: Microphone Location
A
M M M
L L
L
A
A
A
Driveshaft(2) Transmission Driveshaft(3) Differential Motor
Driveshaft(1)
Clutch
Pedal
Centre
Bearing(1)
Centre
Bearing(2)
Positions of all
monitoring
equipment
Any public or commercial use requires the agreement of the author.
Solid flywheel configuration Wavelets of the clonk noise signal for the (a) front, (b) middle and (c) rear shafts
(a)
(b)
(c)
Clonk accelerative noise (impact)
Ringing noise
Clonk accelerative noise (impact)
Clonk accelerative noise (impact)
Any public or commercial use requires the agreement of the author.
DMF configuration Wavelets of the clonk noise signal for the (a) front, (b) middle and (c) rear shafts
(a)
(b)
(c)
Clonk accelerative noise (impact)
Ringing noise
Clonk accelerative noise (impact)
Clonk accelerative noise (impact)
Any public or commercial use requires the agreement of the author.
Driveline Tubes
Rear Wheel Axles
Input-Output Shafts
Flexible
Components
Introduced by FEA
Techniques and
applying the
component mode
synthesis method
Clonk Investigation in a light truck
Any public or commercial use requires the agreement of the author.
Transmission
(Helical Gears)
Differential
(Hypoid Gears)
Calculation of the developed forces between mating teeth pairs
during the meshing cycle through external code and introduction
in the model in real time (elastodynamics, elastohydrodynamics)
0 0.125 0.25
3.6E+008
3.9E+008
4.2E+008
k(t)

1
Any public or commercial use requires the agreement of the author.
(
1
t),
1
pinion
gear
( ,
2
t)
2
k t) (
R
1
R
2
pinion
gear
b b
Line of Action
0.05 0.1 0.15 0.2
440
442
444
446
448
450
452
Gear Meshing Stiffness (N/m) Variation with Respect to the Roll
Angle (rad) (Second Gear Set - One Cycle, Unmodified Gears).
0.05 0.1 0.15 0.2 0.25
420
425
430
435
440
445
Gear Meshing Stiffness (N/m) Variation with Respect to the Roll
Angle (rad) (Second Gear Set - One Cycle, Modified Gears).
Any public or commercial use requires the agreement of the author.
Any public or commercial use requires the agreement of the author.
Mode shapes of the main breathing modes observed in clonk noise measurements and numerical results
1830 Hz 1838 Hz
2312 Hz 2338 Hz
2454 Hz 2457 Hz
2502 Hz 2678 Hz
2871 Hz 3348 Hz
2718 Hz 2857 Hz

3540 Hz 3634 Hz
Any public or commercial use requires the agreement of the author.
Literature

- R. Krenz, Vehicle response to throttle tip-in/tip-out. SAE Technical Paper Series 850967 (1985).
- A. Laschet, Computer simulation of vibrations in vehicle powertrains considering nonlinear effects in clutches and manual transmissions.
SAE Technical Paper Series 941011 (1994).
- S. J. Hwang, J. L. Stout and C. C. Ling, Modeling and analysis of powertrain torsion response. SAE Technical Paper Series 980276 (1998).
- M. Menday, H. Rahnejat and M. Ebrahimi, Clonk: an onomatopoeic response in torsional impact of automotive drivelines. Proceedings of the
Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering 213 (1999) 349-357.
- S. Vafaei, M. Menday and H. Rahnejat, Transient high-frequency elasto-acoustic response of a vehicular drivetrain to sudden throttle
demand. Proceedings of the Institution of Mechanical Engineers, Part K: Journal of Multi-body Dynamics 215 (2001) 35-52.
- A. Farshindiafar, M. Ebrahimi, H. Rahnejat and M. Menday, High frequency torsional vibration of vehicular driveline systems in clonk.
International Journal of Vehicle Design 9 (2002) 127-149.
- J. W. Biermann and B. Hagerodt, Investigation into the clonk phenomenon in vehicle transmission-measurement, modelling and simulation.
Proceedings of the Institution of Mechanical Engineers, Part K: Journal of Multi-body Dynamics 213 (1999) 53-60.
- F. Petrone, G. Fichera and M. Lacagnina, A numerical model to analyze the dynamic response of a vehicle to variations in torque transmitted
by the driveline. SAE Technical Paper Series 2001-01-3334 (2001).
- C. K. Chae, Y. W. Lee, K. M. Won and K. T. Kang, Experimental and analytical approach for identification of driveline clunk source and
transfer path. SAE Technical Paper Series 2004-01-1231 (2004).
- Theodossiades, S., Gnanakumarr, M., Rahnejat, H. and Kelly, P. On the effect of dual mass flywheel upon impact induced noise in vehicular
powertrain systems. Proc. of the Inst. of Mech. Eng. Part D: Journal of Automobile Engineering, 2006, 220 (6), 747-761.
- Theodossiades, S., Gnanakumarr, M. and Rahnejat, H. Root cause identification and physics of impact induced driveline noise in vehicular
powertrain systems. Proceedings of the Institution of Mechanical Engineers Part D: Journal of Automobile Engineering, 2005, 219, 1303-1319.
- Gnanakumarr, M., Theodossiades, S., Rahnejat, H. and Menday, M. Impact Induced Vibration in Vehicular Driveline Systems: Theoretical
and Experimental Investigations. Proc. of the Inst. of Mech. Engineers Part K: Journal of Multi-body Dynamics, 2005, 219, 1-12.
- M. Gnanakumarr, S. Theodossiades, H. Rahnejat and M. Menday, Elasto-multibody dynamic simulation of impact induced high frequency
vehicular driveline vibrations. Proceedings of the ASME IMECE 2003, Washington, USA, 2003.
- S. Theodossiades, M. Gnanakumarr, H. Rahnejat and M. Menday, Mode identification in impact-induced high-frequency vehicular driveline
vibrations using an elasto-multibody dynamics approach. Proceedings of the Institution of Mechanical Engineers, Part K: Journal of Multi-body
Dynamics 218 (2004) 81-94.
- K. R. Fyfe and F. Ismail, An investigation of the acoustic properties of vibrating finite cylinders. JSV, 128(3) (1989) 361-375.
- Moetakef, M., Bresky, A., Zilberman, M., Pham, T. et al., "Reducing High Frequency Driveshaft Radiated Noise by Polymer Liners, SAE
Technical Paper 2005-01-3554, 2005, doi:10.4271/2005-01-3554.
- Nitin Y. Wani, Vinod K. Singh, Greg Falbo and Vincent D. Monkaba, Finite Element Model Correlation of an Automotive Propshaft with
Internal and External Dampers, SAE Technical Paper 2004-01-0862
- Martin G. Foulkes, James P. De Clerck and Rajendra Singh, Vibration Characteristics of Cardboard Inserts in Shells, SAE Technical
Paper 2003-01-1489

Any public or commercial use requires the agreement of the author.