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Research Papers

Quantify Resonance Inspection With Finite Element-Based Modal Analyses

[+] Author and Article Information
C. Lai

 Pacific Northwest National Laboratories, 902 Battelle Boulevard, P.O. Box 999, MSIN K7-90, Richland, WA 99352

X. Sun1

 Pacific Northwest National Laboratories, 902 Battelle Boulevard, P.O. Box 999, MSIN K7-90, Richland, WA 99352xin.sun@pnl.gov

C. Dasch

 Highwood Technology LLC, Bloomfield Hills, MI 48304

G. Harmon

 Chrysler LLC, Auburn Hills, MI 48326

M. Jones

 Ford Motor Company, Livonia, MI 48150

1

Corresponding author.

J. Vib. Acoust. 133(3), 031004 (Mar 25, 2011) (9 pages) doi:10.1115/1.4002955 History: Received October 26, 2009; Revised May 26, 2010; Published March 25, 2011; Online March 25, 2011

Resonance inspection uses the natural acoustic resonances of a part to identify anomalous parts. Modern instrumentation can measure the many resonant frequencies rapidly and accurately. Sophisticated sorting algorithms trained on sets of good and anomalous parts can rapidly and reliably inspect and sort parts. This paper aims at using finite element-based modal analysis to put resonance inspection on a more quantitative basis. A production level automotive steering knuckle is used as the example part for our study. First, the resonance frequency spectra for the knuckle are measured with two different experimental techniques. Next, scanning laser vibrometry is used to determine the mode shape corresponding to each resonance. The material properties including anisotropy are next measured to high accuracy using resonance spectroscopy on cuboids cut from the part. Then, the finite element model of the knuckle is generated by meshing the actual part geometry obtained with computed tomography. The resonance frequencies and mode shapes are next predicted with a natural frequency extraction analysis after an extensive mesh size sensitivity study. The good comparison between the predicted and the experimentally measured resonance spectra indicates that finite element-based modal analyses have the potential to be a powerful tool in shortening the training process and improving the accuracy of the resonance inspection process for a complex production level part. The finite element-based analysis can also provide a means to computationally test the sensitivity of the frequencies to various possible defects such as porosity or oxide inclusions, especially in high stress regions that the part will experience in service.

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Copyright © 2011 by American Society of Mechanical Engineers
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Figures

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Figure 1

Automotive knuckle from casting

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Figure 2

Spectra comparison of RI-P and RI-M in a common measurable frequency range

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Figure 3

Detailed spectra comparison in the frequency range of 30–40 kHz

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Figure 4

Variation of resonance frequencies for ten RI-M measurements

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Figure 5

Scanned images for three-dimensional scanning laser vibrometer tests: left: surface M1 and right: surface M23

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Figure 6

Typical knuckle mesh with 1.75 mm tetrahedron linear elements

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Figure 7

Frequency convergence for knuckle mode 60 as element size decreases

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Figure 8

Comparison of predicted and measured (RI-M) resonance spectra for the knuckle

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Figure 9

Examples of mode shape correlations between FEM prediction and LV measurements

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Figure 10

Steady state dynamics boundary condition

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Figure 11

Steady state dynamics comparison for the first 20,000 resonance frequencies

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Figure 12

Steady state dynamics for the second 20,000 resonance frequencies

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