Integration of CAE Tools in the Engine Design and Development Process - NAUC2010 (1)

Keynote Address:Integration of CAE Tools in the Engine Design & Development Process

Dr. Warren SeeleyFord Motor Company9th September 20102010 North American Ricardo Software User Conference

9th September 20102010 North American Ricardo Software User ConferencePage 2

Contents

Ford of Europe Powertrain CAE Team CAE Trends The Way Forward Integration of CAE tools and Disciplines Outlook


Ford of Europe Powertrain CAE TeamSplit across two sites, Dunton & DagenhamCovers five component/system areas

Performance and Economy Durability Intake & Exhaust Systems Powertrain NVH Calibration

Teams aligned to customer vs. a single CAE teamData sharing between teams is critical to an integrated working environmentMethodology development allows for a consistent modelling approachTeam consists of 25+ CAE analysts consisting of 4 teams covering gasoline and diesel engine developmentSplit 25:25:50% CFD:1D:FEBig interaction with FNA CAE team, particularly with method development leading to Global best practises


CAE trends

HPC capacity

Attribute tradeoffs

Managing & exchanging data

Reduced product development time


CAE trends - HPC Capacity

Growth in High Performance Computing capacity has increased by 50% YOY within FordLarge capacity Linux cluster used by all CAE disciplinesManagement of analyses through highly effective queuing systemLicenses shared Globally allowing for maximum and efficient usage around the clockInteraction with cluster via Web interface for ease of use for all type of analysesBatch post processing routines and data returned to local host automatically


CAE trends Cross Attribute Tradeoffs

0%

50%

100%P&E

Durability

PackageCost

NVH

Target CurrentExample Only

$


Design & Release Engineers

CAE Analyst

Where is my data ???

Supplier

Dept. Website

NIC

Release Info

PDL

Test Data

CAD DataLegacy Programs

Best Practices, CETPs

Loading / BCs Data

Requirements

CAE trends Managing & Exchanging data


Preliminary development

Mainstream vehicledevelopment

Productplanning

Manufacturing:Planning, realisation, verification

Supplier developmentand manufacturing

Traditional Approach:

New approach:

Compressed timingCompressed timing

CAE trends Reduced product development time


DEFINEREQTS.

CASCADE TARGETS VERI

FY D

ESIG

NCONFIRM

OPTIMISE

Vehicle Level

System/Level 1 Subsystem

Level 2 Subsystem

Component Level

CAE is the GPDS backbone CAE is the GPDS backbone

targetsrequirements

developmentoptimisation

verificationmanufacturing

GPDS: Global Product Development System

The Way Forward The GPDS Development Process


Integration of CAE analyses


INPUT

SOLUTION

OUTPUT

Combustion Simulation

WaterjacketSimulation

Structural Modelling

Life Prediction

(Residual Stress Modelling)

Durability analysis overview

StressesTemperatures


Valvetrain & Timing Belt Systems Timing Chain Systems

Drive layout assessment and optimisation. Drive durability assessment chain loads,

tensioner movement, chain contact loads Drive robustness assessment component

variability, input variability (Crank Tvs, FIP / Cam torque etc).

NVH optimisation and investigation. Hub loads camshafts, cranks and FIP.

Timing Belt Systems Drive layout assessment and optimisation. Drive durability assessment belt loads, tensioner

movement, belt flap, crank to cam transmission errors.

Drive robustness assessment component variability, input variability (Crank Tvs, FIP / Cam torque etc).

Hub loads camshafts, cranks and FIP.

Gear Drive Systems Durability assessment tooth loads. NVH optimisation tooth profile optimisation.

Valvetrain Systems Cam profile assessment for valve lift, closing

velocity / closing force, spring durability. Valvetrain system dynamics


1D performance analysis

Full systems models of each engine family both gasoline and dieselProvide engine performance analysis i.e. Torque, Power, Fuel Economy etc.Flow coefficients are required to define the ports characteristics which are taken from test data of CFD analysisOutputs include gas side boundary conditions for FE & in-cylinder analysisUsed throughout the GPDS process from early concepts to vehicle calibrationUsed extensively to drive transient CFD model through coupled analysis


Intake manifold analysisTypical CFD analyses undertaken are:

Pressure drop simulation using steady state CFD.

Predicts mass flow variation through each runner.

Engine cycle simulation using transient CFD. EGR and PCV distribution within the manifold.

Initial concept studies used to conduct quick design evaluations reducing the need for expensive rapid prototypesMore complex coupled analyses allowing for more accurate predictions including the real dynamics of the engineCoupled analysis used extensively for both manifold development for Engine Performance as well as AFR/PCV/EGR Distribution CFD analysis applied solidly throughout the process as a design tool within the constraints


Port flow analysisIntake port designs are currently optimised using 3DCFD.Automatic process using developed design rules to analyses intake and exhaust ports.Steady state analyses performed at different valve lifts to mirror traditional bench testing.Typical engine flow metrics such as swirl, tumble & flow coefficients are used to evaluate port performance.The analyses are conducted early in the development process and can be used to support the 1D modelling or to investigate other phenomena such as the effect of carbon deposit on flow

80 16.482 98.352 6.15

23.122

6000

ProfileGulp Factor

Rs/LDSWIRL Ratio

Reduced SWIRLRs @ 0.3 L/DRs @ max L

Mean CfCf @ 0.3 L/DCf @ max L/D

Cycle CfMean k

L/D Cf Cd Cf (lift) k Swirl Valve Lift [mm] +ve Rig SWIRL Cf0.0433 0.1105 0.6781 0.6382 0.0184 0.0033 1 0.0033 0.11050.0866 0.2629 0.7948 0.7591 0.0438 0.001 2 0.001 0.26290.1299 0.3553 0.7058 0.6839 0.0592 0.0017 3 0.0017 0.35530.1732 0.422 0.6199 0.6093 0.0704 0.0014 4 0.0014 0.4220.2165 0.4701 0.5446 0.5429 0.0784 0.0015 5 0.0015 0.47010.2597 0.5078 0.4835 0.4887 0.0847 0.0015 6 0.0015 0.50780.303 0.5368 0.4321 0.4428 0.0895 0.0001 7 0.0001 0.53680.3463 0.558 0.3878 0.4028 0.093 0.002 8 0.002 0.5580.3896 0.5722 0.3488 0.3671 0.0954 0.0027 9 0.0027 0.57220.4329 0.5826 0.3155 0.3365 0.0972 0.0001 10 0.0001 0.58260.4762 0.5944 0.2888 0.3121 0.0991 0.0004 11 0.0004 0.59440.5195 0.6018 0.2646 0.2896 0.1004 0.0013 12 0.0013 0.6018

Shape FactorNumber of ValvesInner Seat Diameter [mm]

Valve Seat Angle []Rated Engine Speed [rpm]

Test Detail

Test Summary

EXHAUSTFORWARD

Valve TypeFlow Direction

SWIRLTumble/Swirl

Cam 2

0.53470.5636

0.0044

0.00070.989

Cam 1

0.00020.00130.2898

0.0046

Ford Dunton AirFlow Rig

Engine DetailMean Piston SpeedMean Gas Velocity

Cylinder Bore [mm]Engine Stroke [mm]

0.94970.00080.00510.0049

0.05030.04831.69930.5501

1.8117

0.00020.00230.30180.5347 0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 0.1 0.2 0.3 0.4 0.5 0.6

L/D (-)

C

f

(

-

)

-0.0005

0

0.0005

0.001

0.0015

0.002

0.0025

0.003

0.0035

S

w

i

r

l

R

a

t

i

o

(

-

)

Cf Swirl


In-cylinder air motion & mixture preparationIn-cylinder air motion and mixture preparations conducted using es-ice to develop combustions chambers and ports.Used to understand the influence of different geometry features;

Port & valve angles Piston bowl Shapes Spray patterns Spark plug location and

orientation

Provides boundary conditions for FE analysis and supports understanding of flow phenomena for 1D analysis i.e. blow through during high valve overlapCombustion analysis applied to Diesel engines, being developed on Gasoline engines


Water jacket coolant analysis

CFD methodology applied to calculate flow and thermal characteristics of cooling jacketsHeat transfer coefficients, pressure drop and flow rate over critical flow passages i.e. hot spots, stagnation areas etcHTCs are used for FE thermal analysis and provide boundary conditions for 1D analysisAnalysis conducted very early in the process before hardware is available for test. This allows the design to be optimised using CFD techniques

Water in

Water out

Cylinder block

Cylinder head

Possible problematic areas

Predicted HTCs are used for FE thermal analysis


Exhaust Manifold, Catalyst & HEGO AnalysisTypical CFD analysis undertaken are:

Gas flow distribution onto the catalyst brick to assess performance

Optimisation of manifold/catalyst design

Optimising oxygen sensor location

CFD methodology for exhaust systems have been established over a number of years and proved to very effective in the design processTransient analysis with scalars used to generate a suitable sensor locationInternal heat flow analyses used to predict HTC which is turn are applied to FE thermal based calculations


Aftertreatment

Emissions prediction CO, HC, NOx, soot Conversion over 1D, 2D or 3D

DOC, SCR, LNT 1D, 2D or 3D DPF model for

soot loading and regeneration scenarios

Temperatures Transient heat up and cool

down Exotherm generation Including pipes, cones, wall flow

(1D), Flow through substrates,

vaporiser Urea injector

System back pressureVisualisation


Transient Analysis Hil/Sil


Outlook

The CFD tools exist to allow the design and development of engines within Ford but we have to work smarter and apply them in an integrated fashion

Computing resources have become a thing of the past with analysis times being significantly reduced, but at the same time the product development cycle time has also be reduced

Data sharing between the different CAE model types needs to be efficient to reduce waste during the development process

CAE experts develop the rules and processes but the experience of the engineer conducting the CAE analysis is changing with some early concept analyses already being carried out by CAD designers, component engineer etc.

The ultimate goal is to have a fully analytical engine before any hardware is available, we are not there yet, but we are getting closer!


Acknowledgements

I would like to thank a number of members of the CAE team at Ford for providing picture, animations and data to make the presentation come together.

Mark MarshAlex LeongElvir AvdicKevin MaileAlastair GilmourAndrew EmtageFang Haung


Q&A

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Integration of CAE Tools in the Engine Design and Development Process - NAUC2010 (1)