Carmakers crack the seal on mysterious squeaks that plague customers
A new simulation approach explains why car seals fail to prevent annoying stick-slip noise—a leading source of customer complaints. By accounting for how flexible sealing materials actually deform under real-world conditions, engineers can now better predict noise problems before vehicles reach dealerships, potentially cutting costly warranty claims and redesigns.
Originaltitel: Bridging Simulation and Reality: Incorporating Seal Contact Detachment Into Stick–Slip Prediction
Stick-slip-brus i fordon orsakar många kundklagomål, men nuvarande testmetoder förutspår dåligt när tätningsmaterial är flexibla och verkliga körbetingelser är stokastiska. Forskare vid Forschungsinstitut für Leder und Kunststoffbahnen tillsammans med Volvo har utvecklat en algoritm som mäter avståndet till första glidning – den kritiska parameter som hittills saknade mätmetod. Algoritmen bestämmer reproducerbart när en tätningskontakt börjar glida genom att analysera förändringar i friktionskraftens lutning under stokastisk excitation. Detta går långt bortom befintliga metoder som bara studerar redan initierade stick-slip-oscillationer. Eftersom glidning påverkas av profilgeometri, normalkraft, hastighet och miljö krävs denna nyare ansats för att fånga verklighet. För fordonsutvecklare blir detta relevant: överenstämmelse mellan lab och verklighet förbättras, vilket förkortar utvecklingscykler och reducerar brusklagomål i garantiperioden.
<div class="section abstract"><div class="htmlview paragraph">Noise phenomena in automobiles caused by the stick-slip effect are increasingly among the most frequent reasons for customer complaints and therefore represent a critical vehicle quality attribute. To proactively address such issues, stick-slip testing of contacting material pairs is commonly applied during development. However, the predictive capability of current stick-slip test methods remains limited, particularly when highly flexible materials and realistic, stochastic excitation conditions are involved. The flexibility of sealing systems often allows the actual relative motion at the contact interface to be accommodated through adhesion and elastic deformation, thereby delaying or even preventing sliding. To date, this effect has not been represented by any characteristic parameter in conventional stick-slip testing. Instead, existing evaluations focus exclusively on the analysis of occurring stick-slip oscillations. For the initiation of stick-slip phenomena, however, not only the mean displacement between two stick-slip oscillations during the sliding phase is relevant, but also the relative displacement required to initiate the first slip event of the sealing contact.</div><div class="htmlview paragraph">With the algorithm developed in this work, which reproducibly determines the distance to first slip based on changes in the friction force slope, this methodological gap is now closed. The displacement to first slip depends on numerous influencing factors, including profile geometry, normal load, sliding velocity, excitation profile, and environmental conditions, and was previously inaccessible by both experimental and numerical approaches. In particular, the onset of slip in sealing contacts can now be determined under stochastic excitation of the friction pairing, thereby closely reflecting real operating conditions. As a result, the prevention of noise phenomena can be significantly strengthened at an early stage of vehicle development.</div></div>