During the MBS Tech Days 2021, Akshay Nanda from Mercedes-Benz R&D India held a presentation titled "Model Reduction Methodology for Large-Scale Gear Design Optimization".
Developing transmission with optimal NVH performance is one of the biggest challenges in the automotive industry due to the shift towards quiet electric drives. Gear whine, a structure-borne vibration of the transmission system, has emerged as a significant NVH concern. Static transmission error is considered a key factor causing gear whine and therefore has also become a standard parameter for gear-train NVH optimization. However, the dynamic response of hypoid gear systems is a complex combination of various other time-varying mesh parameters like the movement of mesh point and mesh stiffness variation. Evaluating the dynamic response of the hypoid gear driveline system is computationally costly and, therefore, cannot be directly used as a parameter for large-scale design optimization. We have developed a reduced-order simulation model, which can accurately predict the dynamic response of the hypoid gear system within a few seconds, thus allowing it to be used directly as a parameter for optimization. Also, many simulations are required to analyze the robustness and sensitivity of the gear design to various manufacturing and assembly uncertainties that can now be performed efficiently.
Akshay Nanda works as CAE Analyst at Mercedes-Benz R&D India. Akshay has around five years of experience in NVH simulations and is currently supporting rear axle whine simulations for Mercedes-Benz Cars.
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