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Efficient engine development by virtual testing

Rainer G.

Journal of KONES

2006

Vol. 13, No. 4

51-60

Reliability, safety and quality are key issues for placing products successfully on the market. To achieve these goals Reliability Engineering has to be employed from the concept phase and throughout the lifetime of a product. During the product development phase it is important for the engineer to better understand the factors that cause components and systems to fail. This precondition should considerably lower the risk of delaying the SOP due to failure of prototypes. It is necessary to intensively use computer simulation tools and application methodologies during the design phase and the prototype development in order to make up front investigations based on accurate digital models under real operation conditions. Targets for such calculations are to •analyze proposed design and evaluate the reliability potential, •ensure that all components, subsystems and systems in a design will behave as the designer anticipates and •prepare procedures for the later test runs on components, subsystems and systems. The prerequisites to successfully develop and employ such efficient and reliable simulation methodologies are development platforms which consist of •various mathematical simulation tools including mathematical optimization capabilities, •testing tools corresponding to the mathematical simulation tools, •data and workflow management based on engineering knowledge. The paper describes the development platform for "NVH and Durability" and the employment to optimize crankshaft design and to evaluate the stresses in the cylinder head - cylinder block compound based on system simulation. Comparisons of simulation and experimental results are shown and an evaluation of the method in terms of maturity and limitations to reduce the risk of failures is outlined.