Nonlinear characterization of a bolted, industrial structure using a modal framework

This article presents measurements from a sub assembly of an off-the-shelf automotive exhaust system containing a bolted-flange connection and uses a recently proposed modal framework to develop a nonlinear dynamic model for the structure. The nonlinear identification and characterization methods used are reviewed to highlight the strengths of the current approach and the areas where further development is needed. This marks the first use of these new testing and nonlinear identification tools, and the associated modal framework, on production hardware with a realistic joint and realistic torque levels. To screen the measurements for nonlinearities, we make use of a time frequency analysis routine designed for transient responses called the zeroed early-time fast Fourier transform (ZEFFT). This tool typically reveals the small frequency shifts and distortions that tend to occur near each mode that is affected by the nonlinearity. The damping in this structure is found to be significantly nonlinear and a Hilbert transform is used to characterize the damping versus amplitude behavior. A model is presented that captures these effects for each mode individually (e.g. assuming negligible nonlinear coupling between modes), treating each mode as a single degree-of-freedom oscillator with a spring and viscous damping element in parallel with a four parameter Iwan model. The parameters of this model are identified for each of the structure׳s modes that exhibited nonlinearity and the resulting nonlinear model is shown to capture the stiffness and damping accurately over a large range of response amplitudes.