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Squeak and rattle (S&R) problems in body structure and trim parts have become serious issues for automakers because of their influence on the initial quality perception of consumers. In this study, various CAE and experimental methods developed by Hyundai Motors for squeak and rattle analysis of door systems are reported. Friction-induced vibration and noise generation mechanisms of a door system are studied by an intelligent combination of experimental and numerical methods. It is shown that the effect of degradation of plastics used in door trims can be estimated by a numerical model using the properties obtained experimentally. Effects of changes in material properties such as Young's modulus and loss factor due to the material degradation as well as statistical variations are predicted for several door system configurations. As a new concept, the rattle and squeak index is proposed, which can be used to guide the design.

The BSR(Buzz, Squeak and Rattle) noise is the perceived noise of annoyance and caused by impact or friction in the gap between parts of a system. It is one of the major factors that influence the perception of quality. The BSR noise emerges along the gap, joint and contact surface of a system under external forces such as the road loads and the engine vibration input. Major causes of BSR phenomena are the degradation of materials and the resonance characteristics of a system. BSR issues can be generally found in the field, after the system has seen several cycles of use. BSR issues are challenging to find in the virtual development stage. Our aim is to develop BSR evaluation process driven by CAE, in order to identify the occurrence of BSR at the early stage of the design. Whereas subjective evaluations have been typically required in order to assess the perception of quality, a virtual evaluation method is proposed in this study.