Analytical Validation of Diesel Engine Components through FEA
Customer background: US based customer who is a manufacturer of wide range of diesel and gasoline type engines and diesel generators operating in varied applications and geographies – We supported this customer on a power uprate program that was aimed at increasing the engine power for genset application with minimal design changes.
Objective of the project: To validate the major components and sub-systems of the diesel engine (uprated with higher combustion pressure) for the given operating as well as accelerated abusive testing conditions through Finite Element Analysis (FEA).
Key challenges:- To capture physics appropriately for simulating both operating as well as accelerated testing conditions by deploying appropriate analytical methods.
- Correlation of the analyses results with past experimental test data for the baseline design to verify the approach used.
- Program involved much larger dependence on analytical validation for making design decisions thus calling for accurate simulations to avoid failures in testing or field.
- Design optimization for weight for gaining significant cost benefit for the product which sells in high volumes.
4Dimensions Infotech supported the entire analytical validation and optimization of the Engine components such as Crankcase (Cylinder Block), Cylinder Head, Exhaust Manifold, and other Engine peripheral components (CAC / Air Cleaner / Charging Alternator mounting brackets etc.) through Finite Element Analysis (FEA).
- Three engineers worked on this project for the period of five months. Analysis was done in ANSYS FEA software (ANSYS-Workbench and APDL).
- High Cycle Fatigue (HCF) durability analysis of the Crankcase assembly and Cylinder Head.
- Thermal duty cycle and Low Cycle Fatigue (LCF) life assessment of the Exhaust Manifold and Cylinder Head.
- Vibration (Modal/Pre-stressed modal) analysis of engine peripheral components.
- Quicker to market product due to significant reduction in testing time and cost due to design optimization through analytical techniques.
Analytical Validation of Diesel Engine Components through FEA
Customer background: US based customer who is a manufacturer of wide range of diesel and gasoline type engines and diesel generators operating in varied applications and geographies – We supported this customer on a power uprate program that was aimed at increasing the engine power for genset application with minimal design changes.
Objective of the project: To validate the major components and sub-systems of the diesel engine (uprated with higher combustion pressure) for the given operating as well as accelerated abusive testing conditions through Finite Element Analysis (FEA).
Key challenges:- To capture physics appropriately for simulating both operating as well as accelerated testing conditions by deploying appropriate analytical methods.
- Correlation of the analyses results with past experimental test data for the baseline design to verify the approach used.
- Program involved much larger dependence on analytical validation for making design decisions thus calling for accurate simulations to avoid failures in testing or field.
- Design optimization for weight for gaining significant cost benefit for the product which sells in high volumes.
4Dimensions Infotech supported the entire analytical validation and optimization of the Engine components such as Crankcase (Cylinder Block), Cylinder Head, Exhaust Manifold, and other Engine peripheral components (CAC / Air Cleaner / Charging Alternator mounting brackets etc.) through Finite Element Analysis (FEA).
- Three engineers worked on this project for the period of five months. Analysis was done in ANSYS FEA software (ANSYS-Workbench and APDL).
- High Cycle Fatigue (HCF) durability analysis of the Crankcase assembly and Cylinder Head.
- Thermal duty cycle and Low Cycle Fatigue (LCF) life assessment of the Exhaust Manifold and Cylinder Head.
- Vibration (Modal/Pre-stressed modal) analysis of engine peripheral components.
- Quicker to market product due to significant reduction in testing time and cost due to design optimization through analytical techniques.
Analytical Validation of Diesel Engine Components through FEA
Customer background: US based customer who is a manufacturer of wide range of diesel and gasoline type engines and diesel generators operating in varied applications and geographies – We supported this customer on a power uprate program that was aimed at increasing the engine power for genset application with minimal design changes.
Objective of the project: To validate the major components and sub-systems of the diesel engine (uprated with higher combustion pressure) for the given operating as well as accelerated abusive testing conditions through Finite Element Analysis (FEA).
Key challenges:- To capture physics appropriately for simulating both operating as well as accelerated testing conditions by deploying appropriate analytical methods.
- Correlation of the analyses results with past experimental test data for the baseline design to verify the approach used.
- Program involved much larger dependence on analytical validation for making design decisions thus calling for accurate simulations to avoid failures in testing or field.
- Design optimization for weight for gaining significant cost benefit for the product which sells in high volumes.
4Dimensions Infotech supported the entire analytical validation and optimization of the Engine components such as Crankcase (Cylinder Block), Cylinder Head, Exhaust Manifold, and other Engine peripheral components (CAC / Air Cleaner / Charging Alternator mounting brackets etc.) through Finite Element Analysis (FEA).
- Three engineers worked on this project for the period of five months. Analysis was done in ANSYS FEA software (ANSYS-Workbench and APDL).
- High Cycle Fatigue (HCF) durability analysis of the Crankcase assembly and Cylinder Head.
- Thermal duty cycle and Low Cycle Fatigue (LCF) life assessment of the Exhaust Manifold and Cylinder Head.
- Vibration (Modal/Pre-stressed modal) analysis of engine peripheral components.
- Quicker to market product due to significant reduction in testing time and cost due to design optimization through analytical techniques.