Abstract: A novel sound quality simulation approach was proposed to optimize the acoustic performance of a four-cylinder diesel engine. Finite element analysis, single-input and multiple-output technology, flexible multi-body dynamics, and boundary element codes were used to acquire the hexahedron-element model, experimental modal frequencies, vibration velocities, and structurally radiated noise of the block, respectively. The simulated modal frequencies and vibration velocities agreed well with the experimental data, which validated the finite-element block. The acoustic response showed that considerable acoustic power levels existed in 1500–1900 Hz and 2300–2800 Hz as the main frequency ranges to optimize the block acoustics. Then, the optimal block is determined in accordance with the novel approach, which reduces the overall value, high-frequency amplitudes, and peak values of acoustic power; thus, the loudness, sharpness, and roughness decline to make the sound quieter, lower-pitched, and smoother, respectively. Finally, the optimal block was cast and bench-tested. The results reveal that the sound quality of the optimal-block engine is substantially improved as numerically expected, which verifies the effectiveness of the research approach.

Key words: Diesel engine, Flexible multi-body dynamics, Sound quality simulation, Block optimization, Sound quality improvement

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