Injecting Innovation in Performance Engine Design

© MAHLE

Mehrdad Ghanbari

MAHLE Powertrain - Predictive Analysis

Costin House, St. James Mill Road

Northampton NN5 5TZ

United Kingdom

Phone +44(0)870 157 3032

[email protected]

Injecting Innovation in Performance Engine Design

2MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE


MAHLE POWERTRAIN (MPT)

LondonNorthampton

� www.mahle-powertrain.com

� MAHLE POWERTRAIN is Based in

Northampton, UK

� Predictive Analysis Department

� GT Power, Computational Fluid Dynamics,

Structural and Dynamic analysis.

� ABAQUS, NASTRAN, PATRAN, EXCITE,

HyperWorks, PATRAN, STAR CD, AMEsim,

FLOWMASTER, FEMFAT.

� Non-Linear Structural Mechanics + Life

Prediction


MAHLE Downsizing Engine

� MAHLE’s own design

� Small engine with high output power



MAHLE Downsizing Engine - Structural Solutions

� Connecting rod

� Crankshaft

� Cylinder block bearing panel

� Head and Block Assembly

� Exhaust Manifold



MAHLE Downsizing Engine - Solution Partners

: Provided by Altair (Platform Windows XP 64 bit)

�HyperMesh version 8.0 SR1.

�DELL workstation, INTEL CORE 2 DUO, 8GB RAM,

500 GB Disk Space, ATI FireGL V7200

�WINDOWS XP 64 bit version

: Provided by SIMULIA (Platform LINUX Redhat)

: Provided by Magna (Platform Window XP 64 bit )

�For Full Structural, Thermal and Life assessment for I3 Engine, following solution

partners are chosen:


New Addition


MAHLE Downsizing Engine - Head and Block Thermo mechanical analysis

Aims of analysis :

� Temperature Map for Head and Block (Heat input and Cooling)

� Head Durability due to firing load ( Infinite Life ).

� Assessing Damage in Head Water Jacket (TMF).

� Cylinder Bore Distortion

� Gasket Durability




Inlet Valve13

Ladder Bolts12

Exhaust Valve14

Block2

Spark Plug5

Ladder3

Head1

Inlet Seat9

Inlet Guide7

Head Bolts11

10

8

6

4

Part

No

Exhaust Seat

Exhaust Guide

Fuel Injector

Nut Plate

Part ID

10 9

78

1314


2

1

4

312

11



- Minimum Expectation :

� Able to handle large CAD data (1000s of surfaces)

� Create suitable meshes

� Good support for ABAQUS Solver

� Able to handle contacts with ease

� Able to handle large FE model ( around 3 million DOFs)

� Post Processing results (Thermal & Structural) with ease

� PLUS MORE !



HyperMesh - Handling large CAD data


� Complex geometry. Rarely a closed volume

� Need to partition

� Easy edits on surfaces or volumes

� Feature suppression

� Easy management/visualization


� Powertrain parts are solid parts with intricate internal geometry

� Need to manage and isolate internals

� Different meshing requirements

- Hand mesh / free mesh / mapped mesh / detailed mesh / coarse mesh


HyperMesh- Creating Suitable 2D Meshes



HyperMesh - Batch Meshing

� Batch mesh for large complex surfaces

� Preserve boundaries between components

� No user intervention

� Final mesh 95% correct

� Minor hand fixes

� Short coming : Requires stitching


HyperMesh - Tetrahedral Meshing

� 2D mesh quality check

� Identify edges and Equivalence nodes

� Generate linear Tetrahedron elements.

� Conversion to 2nd order tetra (10 nodes)

� No Support for in internal partitioning



HyperMesh - Simple Solid Meshes

� Revolt

� Drags

� SOLID MAP

� Reflect

� Minimize node count

� Full support for Hexahedral mesh (C3D8 and Incompatible mode)




HyperMesh - GASKET

0

50

100

150

200

250

300

350

400

450

500

0.00 0.05 0.10 0.15 0.20

Lo

ad

(N

/mm

)

� Split/edit surfaces

� 2D automesh

� Extrude into 3D mesh

� Gasket elements are fully supported

� Gasket Contact are fully supported (SPOS, SNEG)


HyperMesh - Defining Thermal Regions (Heat Input and Cooling)




HyperMesh - Defining Thermal Regions (Heat Input and Cooling)


HyperMesh - Thermal (HTC) Mapping

� Mapping HTC in HM

� Import CFD results as pressure

� Convert pressure to shapes

� Position shapes

� Convert Shapes to pressures

� Disadvantage : Cumbersome !

Structural Mesh CFD Mesh



HyperMesh – Contact Support

� Contact Manager

� *SURFACE generation/management

- Element based (3D solid, gasket)

- Element based (3D solid with skin)

- Node based

� Pairing

� Interaction (tied, friction, no separation…)

� *TIE

� *SURFACE for pressures (*DSLOAD)

� *SURFACE for *PRE-TENSION SECTION



HyperMesh - ABAQUS Support

� Extensive keyword support

� *CONTACT INTERFERENCE, *CLEARANCE, *PHYSICAL CONSTANTS, *AMPLITUDE, *HEADING, *RESTART, ….

� Some Keywords missing: *FILM PROPERTY, *GAP CONDUCTANCE, dynamics…



HyperMesh- ABAQUS Support

� STEP MANAGER

� Initial conditions

� *STATIC, *HEAT TRANSFER

� Restraints

� Loads, bolt loads (incl FIXED)

� *MODEL CHANGE

� Output requests

� *NSET, *ELSET (Set Manager)

Bore distortion




HyperView - Temperature Solutions

Low Temperature

High Temperature



HyperView - Structural solutions

� ODB upgrade

� Multiple ODBs

� Very large ODBs ( > 30Gb)

� Load step manipulation

� Signed Von Mises

� High quality images & animations

� Node history tracking


Conclusions

� No need for separate geometry clean-up software (I.e. CADFIX)

� Comprehensive ABAQUS Keyword support

� Increased productivity

� Good technical support


Documents

Injecting Innovation in Performance Engine Design