Squeak and Rattle Prevention by Geometric Variation Management Using a Two-Stage Evolutionary Optimisation Approach

Volume 2B: Advanced Manufacturing ◽

10.1115/imece2020-23552 ◽

2020 ◽

Author(s):

Mohsen Bayani ◽

Casper Wickman ◽

Lars Lindkvist ◽

Rikard Söderberg

Keyword(s):

Objective Function ◽

Management Approach ◽

Two Stage ◽

Second Stage ◽

Evolutionary Optimisation ◽

Dimensional Variation ◽

Minimum Variation ◽

Geometric Variation ◽

Fine Tune ◽

Variation Management

Abstract Squeak and rattle are annoying sounds that often are regarded as the indicators for defects and quality issues by the automotive customers. Among the major causes for the generation of squeak and rattle sounds, geometric variation or tolerance stack-up is a key contributor. In the assembly process, the dimensional variation in critical interfaces for generating squeak and rattle events can be magnified due to tolerance stack-up. One provision to manage the tolerance stack-up in these critical interfaces is to optimise the location of connectors between parts in an assembly. Hence, the focus of this work is to prevent squeak and rattle by introducing a geometric variation management approach to be used in the design phase in the automotive industry. The objective is to identify connection configurations that result in minimum variation and deviation in selected measure points from the critical interfaces for squeak and rattle. In this study, a two-stage evolutionary optimisation scheme, based on the genetic algorithm employing the elitism pool, is introduced to fine-tune the connectors’ configuration in an assembly. The objective function was defined as the variation and the deviation in the normal direction and the squeak plane. In the first stage, the location of one-dimensional connectors was found by minimising the objective function in the rattle direction. In the second stage, the best combination of some of the connectors from the first stage was found to define planar fasteners to optimise the objective function both in the rattle direction and the squeak plane. It was shown that by using the proposed two-stage optimisation scheme, the variation and deviation results in critical interfaces for squeak and rattle improved compared to the baseline results.

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SQUEAK AND RATTLE PREVENTION BY GEOMETRIC VARIATION MANAGEMENT USING A TWO-STAGE EVOLUTIONARY OPTIMISATION APPROACH

Journal of Computing and Information Science in Engineering ◽

10.1115/1.4051343 ◽

2021 ◽

pp. 1-40

Author(s):

Mohsen Bayani ◽

Casper Wickman ◽

Lars Lindkvist ◽

Rikard Söderberg

Keyword(s):

Lower Order ◽

Uniform Space ◽

Order Effect ◽

Objective Functions ◽

Two Stage ◽

Second Stage ◽

Evolutionary Optimisation ◽

Space Filler ◽

Computationally Expensive ◽

Geometric Variation

Abstract Squeak and rattle are annoying sounds that are often regarded as the failure indicators by car users. Geometric variation is a key contributor to the generation of squeak and rattle sounds. Optimisation of the connection configuration in assemblies can be a provision to minimise this risk. However, the optimisation process for large assemblies can be computationally expensive. The focus of this work is to propose a two-stage evolutionary optimisation scheme to find the fittest connection configurations that minimise the risk for squeak and rattle. This was done by defining the objective functions as the measured variation and deviation in the rattle direction and the squeak plane. In the first stage, the location of the fasteners primarily contributing to the rattle direction measures are identified. In the second stage, fasteners primarily contributing to the squeak plane measures are added to the fittest configuration from phase one. It was assumed that the fasteners from the squeak group plane have a lower-order effect on the rattle direction measures, compared to the fasteners from the rattle direction group. This assumption was falsified for a set of simplified geometries. Also, a new uniform space filler algorithm was introduced to efficiently generate an inclusive and feasible starting population for the optimisation process by incorporating the problem constraints in the algorithm. For two industrial cases, it was shown that by using the proposed two-stage optimisation scheme the variation and deviation measures in critical interfaces for squeak and rattle improved compared to the baseline results.

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Method for Geometric Variation Management from Key Characteristics to Specification

Geometric Product Specification and Verification: Integration of Functionality ◽

10.1007/978-94-017-1691-8_22 ◽

2003 ◽

pp. 217-226 ◽

Cited By ~ 3

Author(s):

Benoit Marguet ◽

Luc Mathieu

Keyword(s):

Key Characteristics ◽

Geometric Variation ◽

Variation Management

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Two-stage self-seeding method for preparation of single crystals of poly(phenylene sulfide)

Proceedings, annual meeting, Electron Microscopy Society of America ◽

10.1017/s0424820100153816 ◽

1989 ◽

Vol 47 ◽

pp. 368-369

Author(s):

Sengshiu Chung ◽

Peggy Cebe

Keyword(s):

Single Crystals ◽

High Performance ◽

Dilute Solution ◽

Two Stage ◽

Annealing Behavior ◽

High Performance Polymers ◽

Seeding Method ◽

Phenylene Sulfide

We are studying the crystallization and annealing behavior of high performance polymers, like poly(p-pheny1ene sulfide) PPS, and poly-(etheretherketone), PEEK. Our purpose is to determine whether PPS, which is similar in many ways to PEEK, undergoes reorganization during annealing. In an effort to address the issue of reorganization, we are studying solution grown single crystals of PPS as model materials.Observation of solution grown PPS crystals has been reported. Even from dilute solution, embrionic spherulites and aggregates were formed. We observe that these morphologies result when solutions containing uncrystallized polymer are cooled. To obtain samples of uniform single crystals, we have used two-stage self seeding and solution replacement techniques.

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