Dans un contexte automobile électrique et hybride, la part des machines synchrones à aimants permanents s'est accrue exponentiellement. Cette évolution s'accompagne d'exigences en termes d'émissions vibro-acoustiques. En termes de dimensionnement de la chaîne de traction, l'analyse multiphysique du moteur s'avère être un enjeu crucial pour son développement. La nécessité de disposer de codes informatiques de conception possédant des temps de calcul faibles pour une précision maximale se fait ressentir pour l'exploration de solutions potentiellement performantes dans les premières étapes du processus de dimensionnement. A ce titre, les aspects vibratoires et acoustiques sont modélisés analytiquement et par éléments finis dans la présente thèse. Ainsi, au moyen du modèle magnétique, l'analyse magnéto-vibro-acoustique faiblement couplée (résolution itérative des différentes physiques) peut être réalisée.La thèse est découpée en quatre parties. La première expose un état de l’art sur les émissions vibro-acoustiques des machines et notamment la modélisation du bruit d’origine magnétique. Les problématiques de la modélisation sont détaillées. Dans une deuxième partie, les modèles sont largement décrits. Les modèles éléments finis sont validés expérimentalement. Une troisième partie se propose de valider les modèles analytiques par éléments finis, en complexifiant progressivement la géométrie d’une machine à aimants montés en surface à flux radial. Enfin, la dernière partie utilise les modèles éléments finis pour étudier des machines non-conventionnelles comme les machines à commutation de flux et les machines à aimants en surface à flux axial. / The proportion of permanent magnets synchronous motors used for electric and hybrid automotive traction has exponentially increased during the past decade. This evolution comes with ever-demanding low noise and vibrations requirements. Multi-physics analysis of the motor is a decisive issue for the development of the powertrain. For the exploration of potentially efficient motor solutions in first design steps, it is thus a necessity to have at disposal fast and accurate computer codes. In this respect, acoustic and vibratory aspects are modeled using finite element and analytical models in this thesis. As a result, using an electromagnetic model, the weakly-coupled magneto-vibro-acoustic analysis (iterative solving of each physic) can be performed.The thesis is divided into four parts. The first part states the art on machine vibro-acoustic emissions and focuses on noise of magnetic origins modeling. Issues of modeling are detailed. Then, models are described to a great extent in the second part. Finite element models are favorably compared to experimental measures. A third part validates analytical models in comparison to finite element analysis, by gradually complicating the geometry of a surface permanent magnets radial flux machine. Finally, a fourth part uses finite element models to study non-conventional machines such as flux switching radial flux machines and surface permanent magnets axial flux machines.

This project was conducted as a case study at Öhlins Racing AB, a manufacturer of suspension systems for automotive applications. Öhlins usually manufacture their components by traditional methods such as forging, casting, and machining. The project aimed to investigate how applicable Additive Manufacturing (AM) is to manufacture products for suspension systems to add value to suspension system components. For this, a proof of concept was designed and manufactured. The thesis was conducted at Öhlins in Upplands Väsby via the consultant firm Combitech.  A product catalog was searched, screened, and one part was selected. The selected part was used as a benchmark when a new part was designed for AM, using methods including Topology Optimization (TO) and Design for Additive Manufacturing (DfAM). Product requirements for the chosen part were to reduce weight, add functions, or add value in other ways.  Methods used throughout the project were based on traditional product development and DfAM, and consisted of three steps: Product Screening, Concept Development, and Part Design. The re-designed part is ready to be manufactured in titanium by L-PBF at Amexci in Karlskoga.  The thesis result shows that at least one of Öhlin's components in their product portfolio is suitable to be chosen, re-designed, and manufactured by AM. It is also shown that value can be added to the product by increased performance, in this case mainly by weight reduction. The finished product is a fork bottom, designed with hollow structures, and is ready to print by L-PBF in a titanium alloy.