Internal combustion engines are being supercharged more and more to save fuel and avoid emissions. This trend toward downsizing is increasing the stress and strain on components like cylinder head and turbocharger. Our structural-mechanics experts help you find the right material and optimum geometry for your component – such as alloys of aluminum and silicon that are light in weight and provide good heat-conducting properties. Proceeding from CAD data, we use multi-criteria mathematical optimization processes to ascertain whether all requirements can be met. For example, in a single step, we can harmonize the demands for high rigidity and low weight. And we are also working on the development of plastic components that help reduce fuel consumption even further.
Detailed Picture of Combustion, Friction, Wear and NVH
Using 1D simulation in the field of flow dynamics to examine the charge cycle, we can provide statements on the best supercharging system or the engine’s later performance. We also simulate the coolant and lubricant circulation systems and analyze, for example, the thermal interaction between these systems. 3D simulations with CFD programs deliver a detailed picture of mixture formation, combustion and emissions. Our approach integrates mathematical optimization processes, for example, that enable us to find the best geometry for the intake manifolds and outlet ducts. Our experts can also reliably predict friction and wear. We use modern MBS and FEM methods to simulate the dynamic and acoustic behavior of the overall powertrain and its components. Doing so, we also take account of the direct physical interaction among the various systems and can target the way we optimize them.