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In industrial settings, engineering products are often divided into separate components for detailed conception. They often require iterative corrections between different designers/teams to optimize the final product with all components assembled into a system. This article proposes a surrogate modeling approach with functional descriptions of parts in the model and aims to accelerate the design and optimization phase in real projects. The approach is applied to a vibration problem of a two-component plate structure, where the model estimates the dynamic behavior of the assembled system when only the properties of each individual part are available. A database is built using high-fidelity numerical simulations, and neural-network-based regressions provide reliable predictions on unseen data.

RENAULT was the first OEM to introduce mass production Battery Electric Vehicles in Europe with the ZOE in 2012. With the new Megane ETECH, RENAULT set the NVH comfort to higher level to match the customer expectations on BEV vehicles. One of the components that contributes to the silence of Megane is the "Smart Cocoon Technology". This innovative solution has been developed to transform the battery into an acoustically active element. An insulation foam has been embedded between the body floor and the battery casing in order to use the battery mass to improve the floor transparency and damping, and subsequently the Transmission Loss. To support further developments of this technology RENAULT and its CAE partners are developing a simulation methodology to achieve simultaneously three goals: predict the behavior of the smart cocoon technology on the whole vehicle NVH performance, optimize the performance and weight of the insulation package, and secure the assembly process. This paper presents in detail each step of this process. Non-linear simulations of the battery assembly process are used to capture the preloading effects in foam and body panels. The vehicle high frequencies NVH performance is then simulated for vehicle rolling conditions. In a last part of the paper, CAE results are compared with the test measurements on the Megane prototype.