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SAE TECHNICAL

PAPER SERIES 2007-01-2434

Engineering Challenges with Vehicle Noise


and Vibration in Product Development
Abdul Hafiz Afaneh and Mohamed Khalid Abdelhamid
Robert Bosch Corporation

Mohamad S. Qatu
Ford Motor Co.

Noise and Vibration Conference and Exhibition


St. Charles, Illinois
May 15-17, 2007

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Printed in USA
2007-01-2434

Engineering Challenges with Vehicle Noise and Vibration


in Product Development
Abdul Hafiz Afaneh and Mohamed Khalid Abdelhamid
Robert Bosch Corporation

Mohamad S. Qatu
Ford Motor Co.

Copyright © 2007 SAE International

ABSTRACT engineer. Little work is done on such challenges


(e.g. [7]).
Vehicle noise and vibration (NVH) is among the
Vehicle noise and vibration is one of many
important attributes of the vehicle. This attribute has
attributes of the vehicle. Other attributes include
to be designed for in the product development
styling, ride, handling, performance, cost, safety,
process. This produces challenges that are usually
reliability, durability, fuel economy as well as others.
overlooked by researchers in the field.
These attributes are on the customers' mind when
These challenges are assessed in this manuscript. they shop for a new vehicle. Customers' priorities
The emphasis here is on the NVH phenomenon at regarding these attributes vary depending on many
the vehicle level. Little work is being done to study factors. Some customers give high priority in their
the vehicle noise and vibration from a system or vehicle selection to styling, while other give more
customer perspective. This manuscript brings to the priority to vehicle safety or its reliability. Vehicle
attention of researchers and the NVH community at noise and vibration is rarely the top attribute when
large the various NVH challenges that constitute purchasing a vehicle, but is always among the top
complexities to the development engineer and may regardless of the customer. In fact, there is
deserve closer attention. evidence that vehicle noise and vibration is almost
always among the top five attributes of the vehicle
in any customers' mind when purchasing a vehicle.
INTRODUCTION
Many of the vehicle attributes can be determined
There is considerable emphasis by researchers
from the literature available on the internet or by the
world-wide to study vehicle noise, vibration, and
government about the vehicle. These attributes
harshness (NVH) at the component or subsystem
include cost, weight, fuel economy, and
levels. Such work include research done at the
performance. Other attributes can be assessed by
engine level (e.g. [1,2]), other powertrain
visiting a dealer and assessing the vehicle. These
subsystems (e.g. [3]), other vehicle subsystems like
attributes include its package and styling. Attributes
brakes (e.g. [4]) or seats (e.g. [5-6]). There have
like vehicle durability and reliability require the
been important improvements there. On the other
vehicle to be in service for a certain period of time.
hand, there are a wide variety of other issues and
Three months in service (MIS) and 36 months in
challenges that are faced by the NVH development

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There are two other main pillars of such marketing manufacturers must take such a risk often to
studies. The first is to recognize where the remain competitive and leaders in the marketplace.
competition is (and will be) regarding meeting the
These early market studies will produce a target
customer's wants and needs. This will make it
customer of the vehicle who represents enough
necessary to develop corporate intelligence. In
groups of potential customers to make the business
addition, it will require significant efforts by vehicle
case for the vehicle. Two outcomes are key factors
manufacturers to perform benchmarking studies.
that should be made from these market studies.
The second pillar is to recognize the fact that typical These are the size of the market (how many
customers require conflicting demands. They will potential buyers are out there) and how much is the
always demand the 'best' vehicle at the lowest cost. market willing to pay for the potential vehicle. If the
It is the work of business analysts and engineers to business case of the vehicle is met, the product
find out how much of the 'best' vehicle can they development cycle will be kicked off.
produce and deliver to the market where the
NVH engineers will begin their task with setting
product remains competitive and the customer is
objective vehicle level targets for the NVH
still willing to pay more than the cost of developing
characteristics of the vehicle. These include
and building the vehicle.
'translating' the subjective demands of the target
Market analysts should not only find what the customer to objective targets, which can be tested
market demands now, but what it will demand in 2, under standard tests and measured with NVH
5, 10 years (and longer). A vehicle should be ready equipment. It is of interest to vehicle manufacturers
when the market is ready. Vehicle development is a to develop an NVH rating criteria that can be used
process that takes anywhere between 2 and 5 for the various vehicle segments available to the
years (possibly longer), depending on the degree of customer.
change made to an original vehicle platform and
other factors. Keeping that in mind, marketing TARGET SETTING
analysts should always have an understanding of The first aspect of the target setting process is to
where the market will be few years from now to a determine, in subjective terms, the NVH
very detailed degree of specificity that engineers characteristics of the vehicle. This is based on the
can transform into products. Many automobile market studies made a priori and the verbatim of
manufacturers lost substantial profit because their potential customers. Subjective rating is typically
products hit the market one or two years too late. used to rate these subjective wants and needs. As
Vehicle development engineers, including NVH mentioned earlier, these ratings usually range from
engineers, should then of setting targets based on 0 (the worst) to 10 (the best). A rating of 6 is
where the customers needs and wants will be in the typically the minimum acceptable in product
future (when the actual vehicle is produced). This development for the vehicle to be competitive, while
point brings serious questions to engineers who are that of 8 or higher defines leading status for that
always challenged with having to produce vehicles attribute. Engineers can not engineer for subjective
in shorter times to respond to changing market measures. They first need to translate these
demands. The use of computer aided engineering subjective wants by customers into objective ones.
(CAE), fast prototyping and other technology This is shown to be a sophisticated task. What do
advances have become necessary tools at the the customers mean by words like sporty, luxurious,
disposal of automobile manufacturers in today's powerful and others in objective terms? What
market. This challenge of 'speed to market' will caused them to describe the NVH phenomenon as
remain in the future. Advancing the tools used by such? All of these questions and more is an
the product development teams will remain an interesting corner of research frequently referred to
important field of research. as 'psychoacoustics'. In addition, engineers need to
work hard to make sure that potential concerns of
The above general description of the business case
customers are addressed. The complexity of the
is probably a part of any automobile manufacturer's
issue to the engineer takes different forms:
product development process. In addition,
frequently, it will take visionaries to define certain 1. Recreating the same phenomenon that
attributes or features that the market may not be caused the concern to the customer. This requires
demanding now, but will certainly like them when finding conditions like the vehicle speed,
they are produced. Developing such products, environmental temperature, gear and others.
features and attributes is always a risk. More often
than not, history taught us that automobile

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2. Determining what needs to be measured to Target setting is typically performed based on the
best describe the driver's interaction with the following input:
vehicle. Is it sound pressure levels, steering wheel
1. Customer wants and needs. As described
vibrations or others?
earlier, translating the customers' needs and wants
3. Determining the 'annoyance' or into target will constitute the first step in target
'satisfaction' levels of these measurements under setting.
the given conditions. To what level these
2. Benchmarking. For well-established targets
measurements need to be brought to remove the
where the customers' needs and wants are clear,
annoyance and replace it with satisfaction in the
target setting can be based on benchmarking. This
customer's mind
is done by testing the competitive set of vehicles
Objective measures must satisfy certain under the same conditions and finding where the
requirements to be acceptable objective targets for competition is regarding such target. It is assumed
engineers: that bringing the NVH levels closer to the customer
wants as compared with the competition will put the
1. They should have a clear metric. This could
product in a competitive status.
be vibration amplitude (measured in feet or meters),
vibration velocity (measured in ft/sec or m/sec), 3. Cross-functional optimization (trade-off).
acceleration (measured in ft/sec2 or m/sec2), sound Based on customers' insight, it may be decided to
pressure levels (measured in Pascal, Pa, or move certain target levels (like NVH) to a less
decibels, dB) or other metrics. competitive status in favor of other targets that are
moved to a more competitive level, where
2. The metric should be measurable. In other
customers are known to pay more attention to
words, there should be devices or techniques at the
these targets in their buying decision. This should
disposal of the NVH engineers to measure these
be done very carefully; otherwise the competitive
metrics.
edge of the products can be lost.
3. The condition of the vehicle, driving
Targets should be set at the customers' level. For
condition and environment should be well defined.
NVH, these targets should be set for the customers
The driving condition could be idling with the
touch points like steering wheel, transmission
transmission in drive and the air conditioning is off.
shifter, seat, gas pedal, floor pan and customers
The environment could be at a certain temperature
ears. They should be set for various standard
and atmospheric pressure (altitude). Other
conditions and potentially for some of the special
parameters could be specified depending on the
condition where NVH concerns are known to
target.
surface.
4. The NVH phenomenon should be
In theory, the next step is down-cascading these
repeatable. In other words, if the measurements are
vehicle level targets into subsystem and component
retaken on the same vehicle under the same
level targets. The difficulties and challenges
conditions, they should be reasonably close to the
engineers face in this process is that the process is
original measurements.
not robust enough and the down-cascading
5. The NVH phenomenon should be technology is not deterministic. Following this
reproducible. There should be enough description process for years taught NVH engineers that they
of the phenomenon or test that if another NVH frequently end up with under-designing some
engineer (who could be elsewhere in the world) systems or components while over-designing
applies the same conditions of the phenomenon or others systems or components. Under-designing
test, he or she will find similar results. the system is the case when the down-cascade
process ends with certain requirements at the
It is interesting to find how many engineers spend
subsystem or component level that even when they
considerable time trailing a phenomenon or a
are met, NVH concerns surface at the vehicle level.
customer demand that can not satisfy the above
Over-designing, on the other hand, will occur when
conditions. The danger of doing that is, even if
down cascading results in requirements that are
success is claimed in meeting the customer's
difficult or costly to meet at the component level
subjective demands, it generally is not possible to
and yet when released, no issues surface at the
recognize how these demands are met and thus is
vehicle level. Both under-designing and over-
difficult (or even impossible) to engineer for them.
designing in the down cascading process are
experienced by the NVH community at large. This

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raises the issue that the system engineering database of the NVH behavior of various
process of down cascading lacks maturity to be components and subsystems should be developed.
implemented for NVH. Research is much needed to Developing test benches and database will require
relate component and sub-system requirements to investment early in the process to make educated
the NVH phenomenon at the vehicle level. decisions about hardware. Once implemented,
however, it will make the product development
The second challenge the down cascading process
process more robust and faster.
presents is the trade-off nature between various
components in delivering the vehicle level target.
For example, over achieving in the vehicle sound
VEHICLE NVH ASSESSMENT AND
package will allow under achieving in the engine
EVALUATION
noise. Thus the engineers face the questions of the
NVH design impact on other attributes, mainly cost, There are probably tens of possible NVH
packaging and weight. Which process or design evaluations that can be performed on vehicles to
achieves better over all vehicle design, whether to assess their characteristics. These include many
invest in the sound package of the vehicle (adding conditions under idle, acceleration with certain
cost and weight there) or apply strict requirements throttle including wide open throttle (WOT),
at the subsystem level, which typically adds cost decelerating or coast down, braking, steering,
and/or weight there. Frequently, engineers may driving over different roads, driving over different
need to visit the business case of the road holes, driving at various speeds, driving with
enhancements seeked to make their case for different transmission gears engaged, and many
added NVH performance. more. These driving conditions may reveal certain
types of desired and/or undesired NVH
The third challenge met by engineers using the
phenomenon. An experienced vehicle evaluator will
down-cascading process to develop component
spend up a good amount of time (hours) trying to
level target is cross functional optimization. Ultimate
assess the NVH characteristics of a vehicle
cross-functional optimization is performed on actual
subjectively. At various stages of product
prototypes. It is there, where there is no or little time
development, such assessment is needed for
left for the product to hit the market, that NVH
various types or levels of prototypes. Error states or
engineers may find out that there down-cascaded
undesired noises and vibrations are distinguished.
NVH targets, although met or can be met, cause
Objective data can then be collected for these
undesirable effects to other attributes like safety
conditions that gave the undesired noises and
and durability. With the little time left, NVH
vibrations for possible root cause analysis. It is
engineers frequently scramble their way and
quite time consuming to try to assess vehicle
implement 'solutions' that are costly and not
behavior objectively under all possible driving
competitive.
conditions. Instead, the vehicle is evaluated, with
In engineering practice, it is not a straight forward objective data collected, under the possible
task to translate these vehicle NVH targets into conditions encountered by most of the customers
specific hardware designs. The down-cascading most of the time. These conditions are also used to
process, although theoretically 'neat', produces benchmark vehicles against their competitive sets.
challenges to the practicing engineers and is not a
There are two different types of NVH phenomenon
robust method in product development. Instead, we
experienced by customers:
propose here component and subsystem target
setting based on component and subsystem 1. Usual or expected NVH. These include the
benchmarking. This will require component (or types of noises that are expected by the customer.
subsystem) level test procedures and test bench These include powertrain, road and wind NVH
development. This, although challenging and will (Figure 2). The question to the vehicle development
require time, is the direction that should be adopted team is to bring these levels to a competitive, or a
to develop a robust NVH target setting process. It leading status. This includes reducing noise and/or
will also enable automobile manufacturers to vibration levels, eliminating characteristics that are
compare various supplier products and make annoying to the customer, and enhancing those
decisions about suppliers early in the development that are delightful to the customer. Delightful NVH
process. In order to achieve this, however, phenomenon includes producing the sounds that
standardized test benches must be developed for give the customer the needed impression about the
all the components and/or subsystems that affect vehicle like its sportiness, responsiveness or
the NVH characteristic of the vehicles. In addition, a

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There is another reason for engineers to voice their presenting the data. They should also present their
assessment as early as the program starts. That is, confidence level of the model at hand as they
at that point they have more freedom in making present the results. Furthermore, results that are
changes and thus build all the NVH enabler into the presented should make engineering sense. This is
hardware. This is proven to make their task in important to increase the level of confidence in the
product development more robust, relatively method and model in the eyes of the users and the
straightforward and more economical. engineering community at large.
4. Engineering judgment. In brainstorming
It is thus desired for engineers to give the most sessions, where many ideas pass through the table
important directions early in the program, with the and need fast assessment, experienced engineers
least amount of information. This dilemma is real should go back to their experience and lessons
and engineers must face it very cautiously. They learned as they deliver their fast on the spot
need to implement every assessment tool they assessment. In other areas where there is simply
have early in the program to give a good judgment little information to build any reasonable
about the capability of the hardware and alter assessment using hardware (even surrogate one)
design to the favor of NVH, talking into account the or build models, engineering judgment should be
impact on all related other attributes. For that used to deliver program direction. Obviously,
reason, engineers need to be aware of all tools engineers should be aware of the substantial risk
available to them and use them effectively as early associated with using judgment only and should
as possible. Among these tools are: always test such judgment as the hardware
1. Testing actual hardware. While the vehicle assumptions become more clear.
goes through serious changes in every new product Engineers should be always aware of the
cycle, many systems or components do not assessment tool they use (surrogate testing, CAE
change. Even in totally new vehicle development, modeling, judgment, … ), its strengths and
many systems are carried over from existing weaknesses, and the risk associated with using
products. Testing actual hardware, even at the such tool. They should also be aware of the
system or component level, is the most accurate consequences of the decision that will be based
assessment one can present to minimize the risk upon information received using these tools and
and build confidence about the product. how important it is in the overall development
2. Testing surrogate hardware. In many process. They may need to be stubborn and insist
cases, major systems or components are changed on testing actual hardware in some cases where
only slightly from an existing (in production) system the technology is quite new, the risk is high or the
or component. Surrogate testing requires testing consequences of the decision are serious.
the closest in-production, as produced or slightly
modified, system to that desired. Modifications can There is continuous pressure on the marketing
be made to the existing product before testing it to teams to respond to the markets and market
mimic design direction. While this is not perfect, changes fast. This requires the use of more
practical experience proved that testing of sophisticated tools for assessment, and taking
surrogate hardware gives important information some risk. Engineers, however, should not kid
about the hardware capability. themselves about the engineering process, and
3. Computer-aided-engineering (CAE). This is should insist on having the resources needed
fast becoming a must-have capability in today's upfront to deliver the best assessment of the
engineering environment. CAE is quite mature in attributes in general and NVH in particular.
many areas like solid mechanics and structures
using powerful codes that implement advanced One more point that must be made in regard to
technology like finite element methods (FEM). This NVH and that is NVH is an attribute where
includes assessment of many NVH issues and surprises may still happen. The development and
concerns. On the other hand, CAE still needs quite assessment technology is not mature to implement
many improvements in areas like computational hardware solutions early in the development
fluid dynamics (CFD), boundary element methods process to refine NVH. Many characteristics of NVH
(BEM) and multi-body dynamic modeling. are typically not found until a reasonably
Engineers should not be handcuffed with the representative hardware is built. NVH engineers
question of correlation in a 'hostile' engineering frequently find themselves spending much more
environment, instead, they should make sure that time solving unintended NVH concerns later in
the models are accurate and every piece of product development than engineering-in intended
information is used in their modeling before NVH characteristics. More attention need to be

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made to manufacturing processes, quality and periodic) motion of surfaces, others result from a
control. This will minimize unintended NVH transient phenomenon which decays with time. This
concerns. vibration energy (form of elastic energy) is 'born' at
a certain component and/or location. In most cases,
POST PRODUCTION the 'birth' of the vibration or noise (i.e. sound)
energy happens at a solid component. This could
NVH work should not end with job 1 or start of be a rotating component like the crank shaft of the
production. In fact, there is considerable work that engine, the vanes in a pump, the magnets/brush in
should be done after that point. The first is probably a motor or a stationary component like the vehicle
to continuously measure or evaluate the produced mirrors for wind noise. Such energy can migrate to
vehicles for error states and production variability. the driver through air, structure or fluid. If the
These error states can be due to improper energy is transformed from the source through the
assembly practices, large vehicle to vehicle structure to the customer as vibrations and it
variability or malfunctioning components. Root manifests it self potentially as noise sensed by the
cause(s) of the problems discovered must be driver's ears were the only air pulsation along the
identified. Solutions can then be developed for the path), it is referred to structural born noise (SBN). If
short and long terms. Typically, short term solutions the energy path from the source was a fluid, where
are focused more on the path while long term ones the noise was or had become pulsation in the fluid,
emphasize improving the hardware that is the root the noise is then referred to as fluid born noise
cause of the NVH concern. (FBN). Also, if the noise is directly born as air
The second task NVH engineers face in a pressure pulsations at the source, then it is referred
production environment is considering the NVH to as air born noise (ABN).
actions that are fought for and implemented during To distinguish these three types of noises, one
the product development cycle to avoid the needs to think of any component and/or subsystem
occurrence of an NVH concern (adding dampers, as a 'black box', that emits energy in a periodic (or
using sophisticated technology, … ). These actions semi periodic) fashion to its surroundings. If it emits
need to be re-evaluated in the post production this energy as pulsation in fluids (like pumps), the
environment to make sure that the customer noise perceived at the customer is FBN, if it emits
receives the best value. If the hardware dictated by this energy as vibration traveling through solid
NVH is not delivering the signals desired and connections like brackets, the noise is referred to
costing added material and cost, then it is waste as SBN, and finally if it emits this energy as
that should be eliminated. Having the production pulsation in the surrounding air, the noise is ABN.
vehicle as the test vehicle will build the needed
confidence for the removal of certain cost and It should be mentioned that the level of the
weight, as long as it does not compromise the transferring energy as it moves from the source to
vehicle NVH performance. the driver may increase or reduce depending on the
path. If this energy passes in its path through a
In addition, NVH engineers should keep a close eye component at the frequency of its resonance, the
on the quality system implemented through out the levels are magnified. All options in root cause
company to identify any NVH concerns reported by analysis and solution finding process must be
the customer. NVH can count 20 % of the total considered. These include controlling the vibration
concerns the customers report. This shows the energy at the source, modal separation with all
significant opportunity a company has by fixing systems the energy goes through as it passes
NVH concerns. This reduces warranty costs and another system or component on its way to the
achieves higher levels of customer satisfaction. customer and potentially reducing NVH levels at the
As advances are made in the NVH technical world, customer by using barriers. The task in these cases
it is expected that engineers will put less effort in is to work on the frequency separation between the
the post production period. This, however, seems at NVH emitted by the source and that of the
the present time to be quite a distance away. components along the path of this energy to
eliminate the possibility of resonance On the other
hand, if the energy passes through components
ROOT CAUSE ANALYSIS with considerable internal damping, like rubber, the
levels are reduced.
The NVH phenomenon is distinguished by the fact
that it is sensed by human senses. While much of Defining the NVH source and path is critical in
the noise and vibration result from periodic (or semi finding an effective solution to the undesired NVH

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phenomenon at hand. The NVH engineers need [3] Saeed J. Siavoshani, Dale W., "Converse
often to way many potential solutions to the NVH Methodology to determine component shell
concern including some that will solve the problem noise targets of vehicle induction systems,"
at the sources and others that will control the NVH International Journal of Vehicle Noise and
phenomenon in the path. Solving an NVH problem Vibration 2006 - Vol. 2, No.2 pp. 91-100.
is simply bringing the NVH levels from values that
[4] Huajiang Ouyang, Wayne Nack, Yongbin
cause driver discomfort or dislike to levels that are
Yuan, Frank Chen, Numerical analysis of
tolerable or even pleasing to the customer.
automotive disc brake squeal: a review,
International Journal of Vehicle Noise and
Vibration 2005 - Vol. 1, No.3/4 pp. 207-231.
CONCLUSIONS
[5] Jian Pang, Mohamad Qatu, Rao Dukkipati,
NVH engineers working in a product development Gang Sheng. "Nonlinear seat cushion and
environment face considerable challenges during human body model," International Journal of
their daily practice. They have to translate Vehicle Noise and Vibration 2005 - Vol. 1, No.
subjective terms used by the customer to objective 3/4 pp. 194–206.
metrics. They also have to be aware of market
trends and changes and build the intelligence [6] Jian Pang, Mohamad Qatu, Rao Dukkipati,
needed to know where NVH will be competitive in Gang Sheng, William N. Patten ,"Model
the future. identification for nonlinear automotive seat
cushion structure," International Journal of
NVH engineers will have to address the conflicting Vehicle Noise and Vibration 2004 - Vol. 1,
demands of the customer to perform proper No.1/2 pp. 142–157.
optimization or trade-off studies. They should seek
new technologies to increase their speed of [7] Klaus Genuit, "The sound quality of vehicle
producing vehicles to remain competitive. This interior noise: a challenge for the NVH-
makes it necessary to stay at the cutting edge of engineers," International Journal of Vehicle
technology both in NVH control and NVH Noise and Vibration 2004 - Vol. 1, No.1/2 pp.
assessment technologies like CAE. 158 –168.
Another challenge engineers face is cascading
vehicle level NVH requirements into hardware
physical requirements. They not only have to
performe trade-off studies with other attributes, but
also perform these studies with various
components under certain conditions. They
frequently find that the tools they use are not
necessarily mature and the results they get using
these tools are at best marginal (in accuracy).
Also, assessment needs to be delivered early in the
development process, where less information is
available. This makes it important to develop simple
models or 'rules of thumb' instead of sophisticated
tools of analysis.

REFERENCES

[1] Mark French, Maria Nowland, Dan Hedges,


David Greeley, "Reducing noise from gasoline
engine injectors," International Journal of
Vehicle Noise and Vibration 2004 - Vol. 1,
No.1/2 pp. 83–96.
[2] J.A. Calvo, V. Diaz, J.L. San Roman, "
Controlling the turbocharger whistling noise in
diesel engines," International Journal of
Vehicle Noise and Vibration 2006 - Vol. 2,
No.1 pp. 17–28.

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