TMF - Development for Thermal Mechanical FatigueFast and reliable development of thermally loaded components using simulation to pre - optimise the hardware
Customer RequirementsEngines developed for future requirements of higher power density and low emission are subject to high thermal load and peak firing pressure.
Traditional trial and error testing fails to meet the development targets in a reasonable short time. A methodology is needed to quickly optimise the structural concept and local material properties to meet the durability targets also for highly loaded engines.
![]() |
AVL Strengths- Definition of accelerated durability test routines with simulation of damaging mechanism for good correlation to real world conditions
- Simulation replacing trial and error development
- Generic engine development process as a proven guideline to cover all steps from concept to series production
- Experience in high performance engine development combined with advanced simulation technologies and modern test systems
- Material database for all engine components and operating conditions
Customer Benefits- Low risk in high performance engine design
- Shorter time to market through development time reduction
- Hardware testing for validation only
- Accelerated thermal shock testing
- Better quality of development result
- With simulation, the root cause of thermal fatigue failures is found and corrected in the conceptual stage
|
AVL Approach- The development for thermal fatigue requires to know exactly the damaging mechanism of the cyclic thermal load, and the correlation of the durability test data to the real world.
- The experience gained in many years of testing high performance engines is applied in a new methodology, simulating thermal mechanical fatigue under realistic cyclic conditions.
- The material data are established in close co-operation with the series supplier, also resulting in improved manufacturing processes and material specifications.
- The simulation of thermal fatigue is integrated in AVL's engine development process, aiming to reduce the overall development time by reducing loops of hardware development.
|
|
|
Services- Accurate assessment of material data for simulation under actual production and operating conditions
- Recommendations for material improvements referring to AVL material data base
- Material and casting process development
- Fatigue simulation under cyclic thermal load for lifetime prediction
- Design assessment
- Re-design of pre-optimised hardware
- Validation with accelerated durability testing under cyclic thermal load
Tools, Methods & Technologies |