Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias

Studies on the effect of various factors on engine noises have been conducted in many ways involving component simulation, sound quality analysis, and product testing. However, the solution remains exclusive and testing may be expensive yet to solve the engine noise issues totally for several Origin...

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Main Author:	Mohd Alias, Mohd Shahrudin
Format:	Thesis
Language:	English
Published:	2016
Subjects:	Noise pollution Noise and its control
Online Access:	https://ir.uitm.edu.my/id/eprint/69726/1/69726.pdf
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id	my-uitm-ir.69726
record_format	uketd_dc
institution	Universiti Teknologi MARA
collection	UiTM Institutional Repository
language	English
advisor	Saad, Nor Hayati
topic	Noise pollution Noise and its control
spellingShingle	Noise pollution Noise and its control Mohd Alias, Mohd Shahrudin Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias
description	Studies on the effect of various factors on engine noises have been conducted in many ways involving component simulation, sound quality analysis, and product testing. However, the solution remains exclusive and testing may be expensive yet to solve the engine noise issues totally for several Original Equipment Manufacturers (OEMs). Manufacturing has many factors that much to be considered and this includes the uncontrolled factors that exist within the production system and engine operation. The main research objective is to investigate the most significant factors affecting the valvetrain tapping noise level by using Design of Experiment (DOE) via Taguchi method. The aim is to determine the optimum combination of valvetrain parameters in order to reduce the valvetrain tapping noise level. The intention is also to compare the optimum valvetrain tapping noise on bench and vehicle test, while further testing to verify and validate the engine performance and emission. The Orthogonal Array design for seven factors, two-level experiment and eight runs (Lg2 ) was employed with the pre-test run conducted at the manufacturing plant in the actual engine running condition. The data were collected and analyzed using Signal-to-Noise (S/N) ratio, ANOVA, Main Effects Chart, Box Plot and Interaction Plot available in Minitab software. Through Minitab software, the predicted optimum combination of factor was proposed according to Signal-to-Noise (S/N) ratio value. The optimal valvetrain parameters were then built into a completed engine to confirm the valvetrain noise level on bench test. The optimal valvetrain parameters was further verified and validated by the performance test, emission test and vehicle integration for noise level inspection. From DOE experiment result, as the most significant factor, the Camshaft Exhaust Waviness was further taken for improvement and implemented at the engine production line. The pilot batch of engine production was continuously monitored and 10 unit production cars were measured for noise level in one week duration. The study had discovered the optimum factors combination which comprised of the Cylinder Head Bore Diameter (Max: 32.018 cm), Mechanical Tappet Diameter (Min: 31.973 cm), Spring Force (Max: 367 N), Camshaft Intake Waviness (Min: 0.5um WCM), Camshaft Exhaust Waviness (Min: 1.5um WCM), Tappet Clearance Intake (Max: 0.326 mm) and Tappet Clearance Exhaust (Max: 0.205 mm). The confirmation of the optimal valvetrain setting on bench test yields a lower noise level around 70.4 dB SPL and identical with the value predicted by the software (70.3 dB SPL). The validation result shows a positive outcome with the vehicle integration test recorded around 69.5 dB SPL (main location) which had met the maximum allowable noise at 72.0 dB SPL. Meanwhile for the performance and emission level, the results were complied with the target as specified by PROTON designer. The results of the experiment clearly showed that, the most significant factor affecting the engine valvetrain tapping noise is the Camshaft Exhaust Waviness (P-value 0.044 < a-level 0.05) with the optimal parameter found to be at minimum level (< 2.0/xm WCM). From the verification of production vehicles with improved camshaft parameter, the valvetrain tapping noise is reduced approximately 7.9% from the average 73.8 dB SPL to the average 68.0 dB SPL. Since the performance and emission data on the improved engine samples were complied with the OEM standard, the improved camshaft parameter implementation was justified as successful. In overall, this research had met the main objective to apply Taguchi methodology in investigating and determining the factors causing the product failures through a structured experimentation.
format	Thesis
qualification_level	Master's degree
author	Mohd Alias, Mohd Shahrudin
author_facet	Mohd Alias, Mohd Shahrudin
author_sort	Mohd Alias, Mohd Shahrudin
title	Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias
title_short	Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias
title_full	Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias
title_fullStr	Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias
title_full_unstemmed	Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias
title_sort	analysis on the factors and effects of engine tapping noise by design of experiment (doe) / mohd shahrudin mohd alias
granting_institution	Universiti Teknologi MARA (UiTM)
granting_department	Faculty of Mechanical Engineering
publishDate	2016
url	https://ir.uitm.edu.my/id/eprint/69726/1/69726.pdf
_version_	1783735904662192128
spelling	my-uitm-ir.697262023-01-27T02:51:34Z Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias 2016 Mohd Alias, Mohd Shahrudin Noise pollution. Noise and its control Studies on the effect of various factors on engine noises have been conducted in many ways involving component simulation, sound quality analysis, and product testing. However, the solution remains exclusive and testing may be expensive yet to solve the engine noise issues totally for several Original Equipment Manufacturers (OEMs). Manufacturing has many factors that much to be considered and this includes the uncontrolled factors that exist within the production system and engine operation. The main research objective is to investigate the most significant factors affecting the valvetrain tapping noise level by using Design of Experiment (DOE) via Taguchi method. The aim is to determine the optimum combination of valvetrain parameters in order to reduce the valvetrain tapping noise level. The intention is also to compare the optimum valvetrain tapping noise on bench and vehicle test, while further testing to verify and validate the engine performance and emission. The Orthogonal Array design for seven factors, two-level experiment and eight runs (Lg2 ) was employed with the pre-test run conducted at the manufacturing plant in the actual engine running condition. The data were collected and analyzed using Signal-to-Noise (S/N) ratio, ANOVA, Main Effects Chart, Box Plot and Interaction Plot available in Minitab software. Through Minitab software, the predicted optimum combination of factor was proposed according to Signal-to-Noise (S/N) ratio value. The optimal valvetrain parameters were then built into a completed engine to confirm the valvetrain noise level on bench test. The optimal valvetrain parameters was further verified and validated by the performance test, emission test and vehicle integration for noise level inspection. From DOE experiment result, as the most significant factor, the Camshaft Exhaust Waviness was further taken for improvement and implemented at the engine production line. The pilot batch of engine production was continuously monitored and 10 unit production cars were measured for noise level in one week duration. The study had discovered the optimum factors combination which comprised of the Cylinder Head Bore Diameter (Max: 32.018 cm), Mechanical Tappet Diameter (Min: 31.973 cm), Spring Force (Max: 367 N), Camshaft Intake Waviness (Min: 0.5um WCM), Camshaft Exhaust Waviness (Min: 1.5um WCM), Tappet Clearance Intake (Max: 0.326 mm) and Tappet Clearance Exhaust (Max: 0.205 mm). The confirmation of the optimal valvetrain setting on bench test yields a lower noise level around 70.4 dB SPL and identical with the value predicted by the software (70.3 dB SPL). The validation result shows a positive outcome with the vehicle integration test recorded around 69.5 dB SPL (main location) which had met the maximum allowable noise at 72.0 dB SPL. Meanwhile for the performance and emission level, the results were complied with the target as specified by PROTON designer. The results of the experiment clearly showed that, the most significant factor affecting the engine valvetrain tapping noise is the Camshaft Exhaust Waviness (P-value 0.044 < a-level 0.05) with the optimal parameter found to be at minimum level (< 2.0/xm WCM). From the verification of production vehicles with improved camshaft parameter, the valvetrain tapping noise is reduced approximately 7.9% from the average 73.8 dB SPL to the average 68.0 dB SPL. Since the performance and emission data on the improved engine samples were complied with the OEM standard, the improved camshaft parameter implementation was justified as successful. In overall, this research had met the main objective to apply Taguchi methodology in investigating and determining the factors causing the product failures through a structured experimentation. 2016 Thesis https://ir.uitm.edu.my/id/eprint/69726/ https://ir.uitm.edu.my/id/eprint/69726/1/69726.pdf text en public masters Universiti Teknologi MARA (UiTM) Faculty of Mechanical Engineering Saad, Nor Hayati

Analysis on the factors and effects of engine tapping noise by Design of Experiment (DOE) / Mohd Shahrudin Mohd Alias

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