Thermomechanics

FEV offers advanced Finite-Element-Analyses (FEA) of complex engine assemblies as well as comprehensive testing activities for thermomechanical development and troubleshooting. This analysis, testing and troubleshooting is mainly comprised of:

Bottom End Development

• Temperature, deformation, stress and strain
• High Cycle Fatigue (HCF)
• Cylinder bore distortion
• Surface contacts / fretting fatigue
• Bolting (loads, concepts and durability)
• Hybrid solutions / liner and insert mold
• Dynamic structure analysis
  

T op End Development

• Temperature, deformation, stress and strain
• High Cycle Fatigue (HCF)
• ThermoMechanical Fatigue / Low Cycle Fatigue (TMF / LCF)
• Transient fatigue effects
• Gasket functionality / durability
• Injector clamping / durability
• Camshaft bearing misalignment

  Peripherals Layout / Optimization

• Intake / exhaust manifold durability
• Oil pan dynamic load / durability
• Engine and accessory brackets
  

  Simulation of Process History

• Casting process and local material characteristics
• Heat treatment and residual stress
• Machining
  

Automatic Structure Optimization

• Linear topology optimization
• Nonlinear shape optimization (considering thermomechanical load history)

One of the most challenging measurement methods is the strain gage application for measuring component surfaces exposed to the combustion flame, such as the cylinder head flame deck or piston top land. FEV has successfully performed flame deck measurements several times in order to identify elastic-plastic strain within the valve bridges under the fired engine operation mode. FEV provides comprehensive and proficient engineering resources and know-how in this field.

Additional measurement methods for thermomechanical validation and troubleshooting that FEV provides:

• Temperature field measurements (by means of thermography, thermocouple, thermal paints or temperature gages)
• Flame deck strain gage applications (TMF)
• Residual stress analysis
• Material specs / testing
• Single component rig testing
• Engine hydro-pulse testing
• Thermal exhaust manifold tests (thermo-pulse)