Multiphysics Modeling and Simulation of NVH Phenomena in Electric Vehicle Powertrains

The rapid electrification of road vehicles has fundamentally reshaped the priorities of noise, vibration, and harshness (NVH) engineering. In the absence of combustion-related broadband masking, tonal and order-related phenomena originating from the electric machine, inverter switching, and high-speed reduction gearing have become clearly perceptible and, in many cases, acoustically dominant. Consequently, drivetrain noise in electric vehicles can no longer be assessed at component level alone; it must be understood as a coupled system response shaped by excitation mechanisms, structural dynamics, transfer paths, radiation efficiency, and ultimately human perception. This review adopts a source-to-perception perspective and consolidates the principal physical mechanisms governing vibro-acoustic behavior in integrated electric drive units. Electromagnetic force harmonics and torque ripple are discussed alongside transmission-error-driven gear mesh excitation, while bearing and shaft nonlinearities are examined in the context of high-speed operation. In addition, ancillary thermoacoustic and aerodynamic contributions are considered, reflecting the increasingly integrated packaging of modern e-axle architectures. On this mechanism-oriented basis, dominant excitation types are linked to frequency-appropriate modeling strategies, spanning electromagnetic force extraction, multibody drivetrain simulation, structural finite element analysis, transfer path analysis, and acoustic radiation prediction. Particular attention is given to workflow integration across domains. Finally, the paper identifies research challenges that predominantly arise at system level, including multi-source interaction effects, installation-dependent transfer-path variability, emergent resonances in assembled structures, manufacturing-induced tonal artifacts, and the still limited correlation between predicted vibration fields and perceived sound quality.