1. Introduction
In the evolving landscape of automotive technology, the reduction in traditional combustion engine noise, particularly in electric vehicles, has accentuated the prominence of aerodynamic noise. One of the major aerodynamic sound sources of the car is a side mirror due to its extruded discontinuous geometry. When a vehicle runs over a specific speed, a tonal noise, described as a ‘whistle’, from a narrow gap in the side mirror has been frequently reported to cause inconvenience to the driver. However, because this type of sound is generated from a narrow gap of about 1 mm, the experimental and numerical investigation for finding the generation mechanism of the whistle sound is very challenging.
Chanaud [
1] delineated aerodynamic whistles into three categories based on their feedback mechanisms: near-field, intermediate, and far-field feedback. Lounsberry et al. [
2] delved into the phenomenon of laminar-flow whistling around a vehicle’s side mirror, demonstrating that the boundary layer initially develops as laminar before transitioning towards turbulence, exhibiting high-frequency fluctuations. Their visualization of the flow affirmed the presence of a laminar separation region on the side mirror. Werner et al. [
3] explored the tonal noise associated with side mirrors through particle image velocimetry (PIV), attributing the aeroacoustic feedback loop, a key driver of self-noise emission over airfoils, to instabilities in the shear layer emanating from the side-mirror housing. Frank et al. [
4] employed high-order computational schemes to simulate acoustic feedback phenomena on a side mirror, applying instability analysis and mode decomposition to uncover the whistle’s genesis. However, these studies [
2,
3,
4] are primarily concentrated on tonal noise produced by external flows over side mirrors, rather than internal narrow-gap flows.
Fosas de Pando et al. [
5] undertook a nonlinear numerical simulation and global stability analysis of tonal noise from an airfoil to identify feedback mechanisms. Similarly, Takahashi et al. [
6] investigated the feedback mechanism in an air-reed instrument through compressible Large Eddy Simulation, revealing Lighthill’s sound source and frequency-locking phenomena. Despite the differences in characteristics between airfoil and air-reed instrument flows and narrow-gap flows in side mirrors, the methodologies from these studies were applied in our research.
Wind noise from external appendages—including the A-pillar, side-view mirror, and door region—has been an existing and substantial source of cabin noise at high speeds, and has emerged to become as critical with reduced powertrain noise. Many studies on automotive aeroacoustics [
7,
8,
9,
10,
11] emphasize the significance of separated flows at mirrors and pillars, and both experimental and numerical investigations conducted on single car models have found it to be a significant aeroacoustic problem about the A-pillar–mirror interaction region.
Tonal whistles are frequently products of a self-sustained aeroacoustic feedback loop: a hydrodynamic instability generates sound that is amplified and scattered by a nearby geometry or resonator, while the resulting acoustic field modulates the instability with receptivity at the separation point. Canonical models, such as the edge tone, and the cavity tone, give us appropriate frameworks with which to approach such phenomena, and these mechanisms have been extensively analyzed and reviewed based on stability and reduced-order models [
12,
13,
14,
15,
16].
Fitting well into the automotive model, feedback-driven tones can also originate from narrow openings and leakage paths in doors and seals, in which local jet and edge interaction generates a whistling noise, to which computationally assisted seal-design workflows have been designed to ensure better wind-noise performance [
17,
18].
On the modeling standpoint, the resolution of coherent structures for tone sound generation is not only difficult to capture, but also needed to avoid pollution by artificial reflections in the acoustic field. Therefore, high-fidelity methods are often coupled with non-reflecting boundary conditions and suitable turbulence modeling methods. They are also in line with the general computational aeroacoustics guidance and recent side-mirror feedback simulations. [
11,
19,
20,
21,
22]. As far as suppression, practical applications are to reduce the loop gain or detune the acoustic response—such as by adjusting the edges/gaps to dislocate coherent vortex shedding or by shifting the resonance away from the hydrodynamic amplification range; recent studies in cavity–orifice whistling show that resonator detuning can effectively eliminate tonal instabilities.
Stoffel et al. [
23] experimentally demonstrated that adding a protruding step to a side-view mirror, a design change intended to suppress tonal whistling, successfully eliminates the original noise source. In this research, the aforementioned vortex generator concept is adapted to mitigate whistling caused by internal flows through the narrow gap in a side mirror. According to the authors’ previous research, Lee et al. [
24] focused on whistle sound generation from narrow-gap flows in conventional side mirrors, highlighting the role of acoustic resonance in this process through visualization of standing waves in the compressible pressure field, alongside hydrodynamic pressure fluctuations.
To mitigate the whistling noise emanating from the side mirror, a component referred to as a ‘guide-rib’ is integrated into the inlet flow path of the narrow gap. However, the problem has not been solved and continues at elevated frequencies. Furthermore, Stoffel et al. [
23] investigate the effect of an additional component on the side-view mirror housing, which successfully eliminated the original whistling sound. However, this alteration unexpectedly induced a low-frequency flow intermittency on the side-view mirror’s outer side, transforming the single-tone whistle into a more complex, multi-tone ladder-type acoustic structure.
Because the reason for this new whistling noise is suspected to be different than the prior one, this study focuses on the new generation mechanism of whistle sound and aims to suppress it. The main contributions of the present study are twofold. Firstly, the fact that the whistle sound originated from fluctuations in the vortex sound source, induced by vortex shedding at the trailing edge of the guide-rib, where shear layer separation occurs, is identified. Secondly, the fact that the strategic partial removal of the guide-rib disrupts the core flow structures responsible for the whistling sound is demonstrated. This application of the vortex generator concept effectively eliminates the whistle and are verified simultaneously through comparison with experimental results.
The paper is structured as follows:
Section 2 details the experimental methodologies employed to pinpoint the flow conditions and design factors that trigger the whistle and to visualize the internal flow through the narrow gap.
Section 3 presents the experimental outcomes, including sound pressure spectrum measurements for the real side-mirror and the simplified models. In
Section 4, the numerical investigations employed for high-fidelity flow simulation and identification of aerodynamic sound sources are introduced.
Section 5 discloses the numerical results, elucidating the fundamental mechanism of whistle generation from the narrow-gap flow. Finally,
Section 6 introduces and validates, both numerically and experimentally, a new design that effectively suppresses the whistle sound.
5. Numerical Results
In order to achieve high-fidelity simulation of the boundary layer flow in the narrow gap, grids of fine enough resolution must be used.
Figure 11a–c shows the
distribution predicted on the outer, lower-inner, and upper-inner surfaces of the SSM. The
values are generally observed to be less than one over most of the surfaces. It was found that the Large Eddy Simulation (LES) technique is able to accurately resolve internal and external boundary layer flow for this mesh configuration with a proper resolution of turbulent length scales.
Figure 12 shows the comparison between predicted and measured sound pressure spectra at the same position of the receiver shown in
Figure 6. The measured whistling component is around 7.5 kHz, while the predicted tonal component of the flow field is around 6 kHz. This difference in whistling frequency is probably due to differences in the inflow situation. In experiments, the entry boundary in SSM is directly driven by a small wind tunnel with nozzle exit. Instead, the inlet velocity is homogeneously distributed on the far inlet boundary of the numerical domain in the computational simulation. They attribute the frequency differences to these variations in inflow conditions. Moreover, the predicted sound pressure levels for all frequencies are much lower than the measured values. As explained in the experimental section, the measured spectrum contains noise arising from the motor driving both the fan and jet flow produced by the wind tunnel’s nozzle that is absent in simulation. In spite of the discrepancies in both level and frequency, the calculated bandwidth of the tonal whistle is fairly close to that seen in the measurements.
Figure 13 illustrates the center gap plane, which is aligned parallel to the upper and lower surfaces of the narrow gap and bisects the center of the narrow gap.
Figure 14 displays the iso-contours of instantaneous flow velocity and vorticity on this center gap plane, revealing a typical vortex-shedding structure navigating past the obstacle within the narrow gap of SSM. Notably, the flow velocity near the inlet of the narrow gap is lower than the inflow velocity set at the boundary.
Figure 15 depicts the pressure fluctuation field at the whistling frequency of 6 kHz, derived from a Fourier transform of the temporal pressure signal. The propagation of the whistling sound wave is clearly discernible both within and around the narrow gap. Additionally, incompressible pressure fluctuations linked to the sound source are evident within the narrow gap. These incompressible pressure waves, characterized by significantly shorter wavelengths compared to the compressible sound waves, arise because the convection speed of the vortex is approximately 22 m/s, in contrast to the sound speed of about 340 m/s.
Figure 16 displays the distribution of the predicted velocity and vortex sound sources, as defined in Equation (10), within the center gap plane. As depicted in
Figure 16a, the flow passing through the inlet of the narrow gap encounters the guide-rib which impedes the inflow. This interaction gives rise to a strong shear flow at the guide-rib’s edge. This phenomenon is a marked difference with the results of the previous study [
25] and suspected to be the cause of the whistling sound being shifted to other whistling frequencies without being removed.
Figure 16b shows that the potent vortex sound sources align with the shear flow line, suggesting that instabilities in the shear layer originating from the guide-rib’s edge are likely the primary contributors to the whistling sound.
Further analysis involved extracting the components of the vortex sound source at the whistling frequency of 6 kHz through a Fourier transform of the time-domain vortex sound source field.
Figure 17 presents the vortex sound source field at this frequency, indicating that the primary source of the whistling is the shear layer from the trailing edge of the guide-rib.
More direct evidence of the generation and propagation of the whistling sound is provided in
Figure 18, where snapshots of the temporal fluctuating pressure field at the whistling frequency are displayed. These clearly demonstrate that the compressible sound pressure waves originate from the edge of the guide-rib and propagate from the vortex sound sources aligning with shear flow. Note that the associated incompressible pressure wave, which has a much shorter wavelength, stems from convecting vortices.
6. New Design for Suppression of Whistling Sound
To mitigate the whistling sound, the guide-rib’s geometry is redesigned to incorporate a vortex generator concept aimed at disrupting the strong and coherent vortex structures formed in the rearward direction of the guide-rib.
Figure 19 illustrates the shape of the newly proposed model, in which the guide-rib is segmented into five parts. This segmentation considers the relation between the guide-rib’s length and the wavelength of the whistling frequency. In other words, the length of one divided guide-rib could be half the wavelength of the whistling frequency. The vortex newly generated by this division has a different direction from the one of the whistling sound source in
Figure 17, which is expected to suppress the whistling sound. This redesigned model is referred to as the ‘Suppressed Whistle Model (SWM)’. Subsequent numerical simulations and experimental tests are conducted to validate the effectiveness of SWM in reducing whistling sounds.
Figure 20 illustrates the predicted flow field for SWM. Compared with results of SSM shown in
Figure 16, vorticity distribution from the trailing edge flow of the guide-rib is significantly weakened, resulting in no notable vortex sound sources at the whistling frequency.
To validate this observation, a comparison of the experimental flow visualization results between SSM and SWM, using a He-Ne LASER with oil smog, is shown in
Figure 21. While SSM exhibits strong coherent flow structures originating from the edge of the guide-rib, those in SWM are remarkably removed. These oil-smog patterns are closely matched with numerical predictions, affirming the accuracy of the simulations.
Figure 22 presents a comparison of experimental and numerical sound pressure spectra of SSM and SWM. The experimental sound pressure level of SWM at whistling frequency decreases by about 20 dB compared to the results of SSM, and a similar trend can be confirmed in the numerical results. It is proved that SWM with the vortex generator concept applied can effectively reduce whistling noise only by removing a specific part without significantly changing the guide-rib shape of the original SSM.
7. Conclusions
The previous research [
24] investigated the whistling sound in narrow-gap flow of an automobile’s side mirror. To suppress this tonal noise, of which the generation mechanism was revealed, an obstacle called the guide-rib is installed, but whistling sound still exists at shifted higher frequencies. Because the generation mechanism of this other whistling sound is suspected to be different from the prior one, this research focuses on the new whistling noise.
A new generation mechanism of whistling sound in the narrow-gap flow of an automobile’s side mirror is investigated, both numerically and experimentally. Noise measurements are conducted on the target side mirror to characterize the whistling sound at varying flow velocities. It is observed that the whistling sound starts to occur at a flow velocity of 18 m/s, with its frequency escalating as the flow velocity increases. Subsequent flow noise assessments examined the effects of complex geometrical features, such as holes and cavities in the narrow gap, leading to the development of the Simplified Side-mirror Model (SSM). This model was crafted from transparent acrylic material to facilitate flow visualization experiments using a He-Ne LASER with smog and a high-speed camera.
High-resolution three-dimensional unsteady compressible Large Eddy Simulations technique is performed to explain the whistling sound’s generation mechanism. The sound pressure spectrum obtained at the monitoring points are directly compared with measured one of SSM, validating the accuracy of the numerical methods. In the narrow-gap region, the edge of the guide-rib is identified as a main source of whistling sound. A numerical visualization at whistling frequency apparently explains that vortex sound sources affect the generation of whistling sound, as a result interacting with and producing compressible sound pressure waves.
The study further introduced the Suppressed Whistle Model (SWM), which incorporates a concept of vortex generator designed to disrupt the coherent vortex structures confirmed in numerical results of SSM, and thus mitigate the whistling sound. Subsequent simulations demonstrate that SWM effectively eliminates the sources of whistling sound. Experimental comparison of the sound pressure spectra between SSM and SWM, along with flow visualizations of both models, confirmed that the flow structures within SWM are significantly weaker than those in SSM, affirming the effectiveness of the new design shape with the guide-rib in suppressing the whistling sound.