Broadband Noise Reduction Optimization of Commercial Vehicle Cab Acoustic Packages Using Hybrid FE-SEA Modeling and Mixture Design

A common engineering challenge is that a single sound-absorbing material cannot adequately cover the full frequency range in broadband noise control of commercial vehicle cabs; with the aim of addressing this challenge, this study employs a synergistic noise reduction method integrating hybrid finite element–statistical energy analysis (FE–SEA) with foam mixture design. A hybrid FE–SEA cab model is first established, and panel contribution analysis is used to identify key radiating areas such as the floor and rear panel, as well as their corresponding energy-concentrated frequency bands. High- and low-flow-resistance polyurethane foams and melamine foam are selected as base materials. A simplex-centroid mixture design is adopted to construct a Scheffé regression model using the average noise reduction contribution in frequency bands as the response, and Derringer–Suich multi-response optimization is applied to obtain the optimal proportions. Full-vehicle simulation results show that the optimized formulation achieves noise reduction contributions of 13.87, 16.42, and 10.84 dB in the 200–500 Hz, 800–1600 Hz, and 2000–3150 Hz bands, respectively, without evident weak-band performance, reducing the overall SPL to 68.25 dB(A). The proposed method establishes a bidirectional linkage between vehicle acoustic response and material formulation, providing a reproducible framework for the forward design and broadband acoustic optimization of commercial vehicle acoustic packages.