A Modeling Framework to Develop Materials with Improved Noise and Vibration Performance for Electric Vehicles

The automotive and aerospace industries increasingly use lightweight materials to improve performance while reducing fuel consumption. Lightweight materials are frequently used in electric vehicles (EVs). However, using these materials can increase airborne and structure-borne noise. Furthermore, EV noise occurs at high frequencies, and conventional materials have small damping. Thus, there is an increasing need for procedures that help design new materials and coatings to reduce the transferred and radiated noise at desired frequencies. This study pioneered new techniques for microstructure modeling of coated and uncoated materials with improved noise, vibration, and harshness (NVH) performance. This work uses the microstructure of materials to study their vibration-damping capacity. Images from an environmental scanning electron microscope (ESEM) show the microstructure of a sample polymer and its coating. Tensile tests and experimental modal analysis were used to obtain the material properties of the polymer for microstructure modeling. The current work investigates how different microstructure parameters, such as fiberglass volume fraction and orientation, can change the vibration performance of materials. The damping ratio in the study was found to be affected by changes in both the direction and volume ratio of fiberglass. Furthermore, the effects of the coating are investigated in this work. Through modal analysis, it was observed that increasing the thickness of aluminum and aluminum bronze coatings caused a rightward shift in resonance frequency. Coatings with a thickness of 2 mm were found to perform better than those with lower thicknesses. Furthermore, the aluminum coating resulted in a greater shift in frequency than the aluminum bronze coating. Additionally, the coating with a higher damping ratio (i.e., aluminum bronze) significantly reduced the amplitude of surface velocity due to excitation, particularly at higher frequencies. This study provides engineers with an understanding of the effects of layer coating on the NVH performance of components and a modeling approach that can be used to design vehicles with enhanced noise and vibration performance.