In this study, a robust design procedure using the FRF-based substructuring (FBS) method was proposed for vehicle vibration performance. In the robust design procedure, global sensitivity analysis was used to obtain the design information of elastomers in structural systems considering uncertainties. The global sensitivity method combines the random balance design method for variance-based sensitivity information and the FRF-based substructuring (FBS) method for the calculation of vibrational responses, which establishes an efficient tool even in complex real structures. Moreover, a multi-objective optimization formulation was applied to obtain the optimal design of elastomers that give robust vibration responses. The objective functions were set to the mean and variance of the vibration responses. The Pareto optimal front was calculated using the non-dominated sorting genetic algorithm-II (NSGA-II). The genetic algorithm design variables were screened using the global sensitivity analysis results for the elastomers. These formulations were applied to a passenger car problem to obtain the optimal design of the engine mount systems. The numerical results showed that the newly introduced feature enhanced the calculation performance and the proposed procedure can be applied successfully in real complex structural problems.
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