TMF - Thermo Mechanical Fatigue SimulationLifetime prediction of thermally loaded componentsCritical issues in industry:- Increased power density and Peak Firing Pressure (PFP) may lead to low cycle fatigue failure for cylinder heads, -liners, exhaust manifolds and pistons.
- Thermal shock testing (sign off criteria) is executed late in the development process and causes a high development risk.
- A “complete” and thorough simulation process for lifetime prediction is missing. Also material properties under thermal mechanical loading conditions do generally not exist.
- Methods for accelerated engine thermal shock testing are missing. The field load correlation is not established.
Requirements:- Prediction of engine component lifetime before actual hardware testing
- Decision on critical design features on factual information
- Benchmark of different materials based on properties relevant for engine design
- Modification of existing materials in view of TMF properties
- Schemes for Development time reduction
- TMF simulation process required
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AVL Strengths- Experience in high performance engine development including production engineering
- In-house developed advanced simulation tools and test systems
- Close co-operation with material and component supplier
- Material database for all engine components and operating conditions
- Unique and complete simulation process for lifetime prediction
Customer Benefits- Lifetime prediction in conceptual stage
- Root cause of TMF failure shown with simulation
- Optimisation focused on root cause
- Accelerated thermal shock testing
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AVL has developed:- Unique material model coupled with damage/life prediction model
- Thorough knowledge chain from application, material development to engine testing and production engineering
- Thorough and complete simulation process for engine lifetime prediction considering:
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Services- Lifetime prediction (cylinder head, -liner, piston, exhaust manifold)
- Material benchmark, recommendations and development
- Material and casting process development
- Design assessment and re-design of pre-optimised hardware
- Test cycle optimisation
Tools, Methods and Technologies |