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© MAHLE
Mehrdad Ghanbari
MAHLE Powertrain - Predictive Analysis
Costin House, St. James Mill Road
Northampton NN5 5TZ
United Kingdom
Phone +44(0)870 157 3032
Injecting Innovation in Performance Engine Design
2MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
Injecting Innovation in Performance Engine Design
MAHLE POWERTRAIN (MPT)
LondonNorthampton
� www.mahle-powertrain.com
� MAHLE POWERTRAIN is Based in
Northampton, UK
� Predictive Analysis Department
� GT Power, Computational Fluid Dynamics,
Structural and Dynamic analysis.
� ABAQUS, NASTRAN, PATRAN, EXCITE,
HyperWorks, PATRAN, STAR CD, AMEsim,
FLOWMASTER, FEMFAT.
� Non-Linear Structural Mechanics + Life
Prediction
3MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
MAHLE Downsizing Engine
� MAHLE’s own design
� Small engine with high output power
Injecting Innovation in Performance Engine Design
4MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
MAHLE Downsizing Engine - Structural Solutions
� Connecting rod
� Crankshaft
� Cylinder block bearing panel
� Head and Block Assembly
� Exhaust Manifold
Injecting Innovation in Performance Engine Design
5MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
MAHLE Downsizing Engine - Solution Partners
: Provided by Altair (Platform Windows XP 64 bit)
�HyperMesh version 8.0 SR1.
�DELL workstation, INTEL CORE 2 DUO, 8GB RAM,
500 GB Disk Space, ATI FireGL V7200
�WINDOWS XP 64 bit version
: Provided by SIMULIA (Platform LINUX Redhat)
: Provided by Magna (Platform Window XP 64 bit )
�For Full Structural, Thermal and Life assessment for I3 Engine, following solution
partners are chosen:
Injecting Innovation in Performance Engine Design
New Addition
6MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
MAHLE Downsizing Engine - Head and Block Thermo mechanical analysis
Aims of analysis :
� Temperature Map for Head and Block (Heat input and Cooling)
� Head Durability due to firing load ( Infinite Life ).
� Assessing Damage in Head Water Jacket (TMF).
� Cylinder Bore Distortion
� Gasket Durability
Injecting Innovation in Performance Engine Design
7MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
MAHLE Downsizing Engine - Head and Block Thermo mechanical analysis
Inlet Valve13
Ladder Bolts12
Exhaust Valve14
Block2
Spark Plug5
Ladder3
Head1
Inlet Seat9
Inlet Guide7
Head Bolts11
10
8
6
4
Part
No
Exhaust Seat
Exhaust Guide
Fuel Injector
Nut Plate
Part ID
10 9
78
1314
Injecting Innovation in Performance Engine Design
2
1
4
312
11
8MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
MAHLE Downsizing Engine - Head and Block Thermo mechanical analysis
- Minimum Expectation :
� Able to handle large CAD data (1000s of surfaces)
� Create suitable meshes
� Good support for ABAQUS Solver
� Able to handle contacts with ease
� Able to handle large FE model ( around 3 million DOFs)
� Post Processing results (Thermal & Structural) with ease
� PLUS MORE !
Injecting Innovation in Performance Engine Design
9MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - Handling large CAD data
Injecting Innovation in Performance Engine Design
� Complex geometry. Rarely a closed volume
� Need to partition
� Easy edits on surfaces or volumes
� Feature suppression
� Easy management/visualization
10MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
� Powertrain parts are solid parts with intricate internal geometry
� Need to manage and isolate internals
� Different meshing requirements
- Hand mesh / free mesh / mapped mesh / detailed mesh / coarse mesh
Injecting Innovation in Performance Engine Design
HyperMesh- Creating Suitable 2D Meshes
Injecting Innovation in Performance Engine Design
11MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - Batch Meshing
� Batch mesh for large complex surfaces
� Preserve boundaries between components
� No user intervention
� Final mesh 95% correct
� Minor hand fixes
� Short coming : Requires stitching
12MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - Tetrahedral Meshing
� 2D mesh quality check
� Identify edges and Equivalence nodes
� Generate linear Tetrahedron elements.
� Conversion to 2nd order tetra (10 nodes)
� No Support for in internal partitioning
Injecting Innovation in Performance Engine Design
13MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - Simple Solid Meshes
� Revolt
� Drags
� SOLID MAP
� Reflect
� Minimize node count
� Full support for Hexahedral mesh (C3D8 and Incompatible mode)
Injecting Innovation in Performance Engine Design
Injecting Innovation in Performance Engine Design
14MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - GASKET
0
50
100
150
200
250
300
350
400
450
500
0.00 0.05 0.10 0.15 0.20
Lo
ad
(N
/mm
)
� Split/edit surfaces
� 2D automesh
� Extrude into 3D mesh
� Gasket elements are fully supported
� Gasket Contact are fully supported (SPOS, SNEG)
15MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - Defining Thermal Regions (Heat Input and Cooling)
Injecting Innovation in Performance Engine Design
Injecting Innovation in Performance Engine Design
16MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - Defining Thermal Regions (Heat Input and Cooling)
17MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - Thermal (HTC) Mapping
� Mapping HTC in HM
� Import CFD results as pressure
� Convert pressure to shapes
� Position shapes
� Convert Shapes to pressures
� Disadvantage : Cumbersome !
Structural Mesh CFD Mesh
Injecting Innovation in Performance Engine Design
18MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh – Contact Support
� Contact Manager
� *SURFACE generation/management
- Element based (3D solid, gasket)
- Element based (3D solid with skin)
- Node based
� Pairing
� Interaction (tied, friction, no separation…)
� *TIE
� *SURFACE for pressures (*DSLOAD)
� *SURFACE for *PRE-TENSION SECTION
Injecting Innovation in Performance Engine Design
19MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh - ABAQUS Support
� Extensive keyword support
� *CONTACT INTERFERENCE, *CLEARANCE, *PHYSICAL CONSTANTS, *AMPLITUDE, *HEADING, *RESTART, ….
� Some Keywords missing: *FILM PROPERTY, *GAP CONDUCTANCE, dynamics…
Injecting Innovation in Performance Engine Design
20MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
HyperMesh- ABAQUS Support
� STEP MANAGER
� Initial conditions
� *STATIC, *HEAT TRANSFER
� Restraints
� Loads, bolt loads (incl FIXED)
� *MODEL CHANGE
� Output requests
� *NSET, *ELSET (Set Manager)
Bore distortion
Injecting Innovation in Performance Engine Design
21MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
Injecting Innovation in Performance Engine Design
HyperView - Temperature Solutions
Low Temperature
High Temperature
22MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
Injecting Innovation in Performance Engine Design
HyperView - Structural solutions
� ODB upgrade
� Multiple ODBs
� Very large ODBs ( > 30Gb)
� Load step manipulation
� Signed Von Mises
� High quality images & animations
� Node history tracking
23MAHLE Powertrain Ltd., Predictive Analysis, Mehrdad Ghanbari, 1 - October - 2008 © MAHLE
Conclusions
� No need for separate geometry clean-up software (I.e. CADFIX)
� Comprehensive ABAQUS Keyword support
� Increased productivity
� Good technical support
Injecting Innovation in Performance Engine Design