Noise, vibration, and harshness (NVH) generated by automotive manual transmissions is mainly driven by gear-mesh excitation, bearing compliance, and shaft torsional resonance, and it directly affects vehicle comfort and drivetrain durability. This paper combines a reduced-order gear dynamics model with a 3D finite-element (FE) model of the gearbox housing to predict dominant vibration paths and radiated noise. The gear pair is represented by a time-varying mesh-stiffness model with transmission error excitation, while the full transmission assembly is solved in matrix form to capture coupled housing-shaft dynamics. Experiments were performed on a 5 speed manual gearbox mounted on a dynamometer (0-6000 rpm); (0-300 N·m), using tri axial accelerometers (0-10 kHz) on three housing locations and Class 1 microphones placed at 0.5 m according to ISO 3744; signals were acquired at 51.2 kHz and each condition was repeated three times. The dominant responses were observed at 250-300 Hz (torsional resonance), 800-900 Hz (bearing-related modes), and 1200-1400 Hz (gear-mesh stiffness variation). The FE modal and frequency-response results agreed with the measured peaks with an average deviation below 6%. Microgeometry optimization of the gear teeth and a viscoelastic damping layer in the clutch-flywheel interface reduced the noise level by up to 23% and decreased the peak mesh vibration by 18% in the critical 1-2 kHz band. The novelty lies in a reproducible cyber-physical NVH workflow: coupling a parametric gear mesh model with an implemented FE housing model and an automated MATLAB signal processing/model updating pipeline under ISO compliant measurements to quantify “before vs after” NVH gains.
Keywords
Transmission VibrationGear NoiseDynamic ModelingNVH AnalysisFinite Element Simulation
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