Damper Engine Family 1 GEN. 3 presentation at Daewoo on 30 th of March

1. Damper Engine Family 1 GEN. 3 presentation at Daewoo on 30th of March

2. GENERAL PRESENTATION NVH PRODUCTS

3. NVH PRODUCTS RUBBER DAMPERS

4. Rubber technology

5. Rubber damper assembly technology

6. torsional vibration damper design Aluminium hub Hub in steel or cast iron Cast iron ring

7. torsional vibration damper design Direct drive damper Bending damper Camshaft damper

8. torsional vibration damper design Dual mass damper

9. NVH PRODUCTS ISOLATION PULLEYS

10. Damper stage Isolation stage Inertia ring Journal bearing Pulley Elastic member Rubber coupling Hub Thrust bearing Coupling flange Hub Isolation Pulley design

11. Isolation pulley

12. NVH PRODUCTS VISCOUS DAMPERS

13. Viscous dampers • Viscous Dampers • Our expertise : • 40% market of worldwide market • More than 25 years of experience • 288K parts produced /year • Co-development with 3 OEMs for applications on passengers car • Our products : • Suited to new more compact and more powerful engines, the viscous damper offers an better thermal endurance and longer life when compared to rubber dampers. • Attenuate torsional vibrations on a wide frequency range

14. Viscous dampers • Viscosity up to 1 000000 Cst • Development of a high temperature silicon fluid

15. PROJECT DEVELOPMENT

16. Project development (MLP)

17. Purchase Sales Logistic Quality Process Design Project development (MLP) Plant Metaldyne Project manager Work in project team organization

18. PRODUCT DEVELOPMENT DESIGN

19. CAD and FEA system • CATIA V4 and V5 • Pro Engineer 2000 I² and Wild fire • UG • Cosmos • Abaqus • Promechanica • Nastran

20. Simulation • FREDA • Metaldyne (Matlab based) standard software for TV simulations • TVS2 • Metaldyne (Matlab based) software for TV simulation and damper optimization • Rubber dampers (single and multi mass) • Viscous dampers • Rubber-viscous dampers • Isolation pulleys • Pendulum absorbers

21. Moment [Nm] Verdrehwinkel[Grad] Simulation • CONTECS Software SIMDRIVE • Simulation of non-linear systems in time domain

22. Rubber development • In-house Rubber Development • Metaldyne compounds • NR • NBR • SBR • EPDM • AEM • HNBR • Silicon rubber • Dynamic Testing Equipment • Alpha Technologies • Frequency testing onstandard dampers

23. PRODUCT DEVELOPMENT PROTOTYPE

24. Prototyping washing coating sandblasting rubber injection oven assembly balancing

25. PRODUCT DEVELOPMENT TESTING

26. Standard Damper DVP&R

27. Servotest rigs Oven Servo-hydraulic Actuator (280 bar) Output shaft

28. Team rig Servo-hydraulic Actuator (280 bar) Inertia disc Variable speed Belt drive

29. Stroker rig • Isolation pulley endurance testing in environmental chamber to test all aspects of a specimen life. Rubber coupling • Continuous logging of temperature on each sample • 12 test stations in total

30. Rotating rig • Facilities for testing up to 5 components simultaneously. • The rigs are typically used for fatigue testing of damper hub and isolation pulley hub assemblies with either in line or cantilevered load

31. On-site measurement • Extensive Measurements at customer sites • Torsional vibration • Accelerations • Temperature • Noise • Belt behaviour (film)

32. Damper analysis Stereomicroscope with digital camera Slicing machine Polishing machine

33. FAMILY 1 GEN.3 METALDYNE DAMPER DESIGN

34. Current design The current damper is a in-moulded damper with AEM rubber

35. Metaldyne design proposal Spun pulley in DD13 steel Pressed rubber ring PV bonded in EPDM Pressed steel hub in DD13

36. Metaldyne design proposal Gullwing shape Rubber bonded

37. Comparison with current design

38. Advantages of Metaldyne Design • Rubber choice: EPDM vs AEM • EPDM is better because it has a flatter frequency vs. temperature behaviour. • 0.1° design bogey can be kept for all temperatures with EPDM, whereas with a AEM tuning compromise has to be found • AEM is used only because of T = 180°C during e-coating process.

39. Advantages of Metaldyne Design • PV-Bonding vs In-Moulded Bonding: • IM-bonding requires conical rubber geometry to compensate shrinkage. • PV-bonding has a axial rubber shape and a rubber under compression which gives a better reduction of internal rubber stresses. • the currenr design has a conical rubber shape which creates movement of poly-vee with rubber temperature. PV bonding has no movement of poly-vee with rubber temperature. • IM-bonding causes severe failures if debonding or weak bonding occurs.The current supplier had several field failures especially in hot countries. PV-bonding is robust due to rubber under compression. • IM-bonding was carry-over from GEN 2, where the tone wheel for speed monitoring was part of the secondary side (the ring was used for the tone wheel) • Spray-Painting vs E-Coating • Sufficient corrosion resistance. • less expensive • EPDM possible.

40. DAMPER TV CALCULATION

41. TV calculation (mass elastic system & gas pressure) The TV simulation has been made with assumptions for gas pressures and mass elastic sytem as exact data for this engine were not available

42. Simulation on current damper in production ABS angle at Cranknose (full load) NOK AEM 80°C AEM 60°C AEM 120°C The current damper in production with AEM rubber is not OK when the temperature is at 60° or at 120°C: The max single orders amplitudes are below 0,1°. This is due to the AEM rubber which has a severe temperature dependency for the frequency

43. MAX ABS ANGLE C/S NOSE: ORDERS 4.0, 6.0 0.025 0.22 0.1 0.1 0.08 0.08 0.05 0.2 0.06 0.06 0.07 0.02 0.09 0.18 0.09 0.07 0.16 0.14 0.015 0.1 0.1 0.08 2 0.12 0.08 Ring Inertia kg.m² 0.1 0.07 0.01 0.09 0.09 0.08 0.06 0.005 0.1 0.04 0.08 0.1 0.09 0.02 0 0 100 200 300 400 500 600 RD FREQUENCY f / Hz TV simulation: damper optimization VARIATION OF SEC INERTIA AND FREQUENCY MAXIMA ABS ANGLE C/S NOSE MAIN ORDERS 4.0, 6.0 FULL LOAD n > 2500 1/min Single order amplitude < 0.1° is OK for a frequency range 340 Hz – 425 Hz

44. TV simulation: damper optimization Q2 = 0.00288 kgm2 340 Hz – 425 Hz f80MID = 390 Hz f80RANGE = 375 ... 415 Hz 425 Hz MAX MID MIN 340 Hz In the damper temperature range, the torsional vibration are acceptable (single order below 0.1°)

45. TV simulation with Metaldyne damper Full Load ABS ANGLE @ C/S NOSE (80°C) All single order amplitudes are below 0,1°

46. TV simulation with Metaldyne damper Dyn. torque in the rubber FULL LOAD MAX DYN TORQUES (60°C) The max. dynamic torque in the rubber is 147 N.m

47. TV simulation with Metaldyne damper FIG 5.2: FL DISSIPATED POWER @ RUBBER (80°C) The max dissipated power is 90 W which is OK for this damper

48. TV simulation: Conclusion • The Metaldyne damper design proposal gives better torsional vibration amplitudes than the current damper in production by using a EPDM rubber: all single order amplitudes are below 0,1° within the temperature range • the dissipated power in the rubber is acceptable • the dynamic torque in the rubber is not very high. We may be not need to bond the rubber (cost reduction opportunity). This option has be validated with further calculation and measurements on a engine

49. DAMPER PROCESS FLOW CHART

50. Process flow chart Hub pulley WASHING COATING Rubber ring ASSEMBLY BALANCING