Efficient simulation process for the optimization of conrods in internal combustion engines

C. Ortmann VI-grade In cooperation with

Motormechanik

Agenda
General CAE Process
Data Availability Modelling Refinements

EHD Bearing in FEV VirtualEngine Process Reliability

Automation

Conrod Application Example Tool Transfer

22.01.2011 W.Kujawski, Tel. 35041
Motormechanik

Konzept

Typical CAE-Process in Engine Development

Definition phase Confirmation phase
System

Concept

Design

Subsystem

Detailed Design

Part

Model Refinement

low
22.01.2011

high
3

Motormechanik

Flexible Refinement Level

level 4: 3D FEM Model Refinement level 3: beam level 2: torsional flexible level 1: rigid crankshaft

Torsionelement Part Marker Beam

Starre Verbindung

Implementation EHD-bearing ADAMS-TOWER

Beam

Data Availability
4

Motormechanik

Bearing Modelling Methods

1
(Impedanz-Chart)

2
(E)HD

3
EHD

hmin hmin hmin

pmax pmax
Motormechanik

pmax

Stand: 09.11.2007

1st VI-grade User's Conference, Marburg Germany

ADAMS-TOWER interface
TOWER - Working Principal FEV VirtualEngine
Time integration of the Newton equation of motion input parameter: part data kinematics and constains external loads boundary conditions

EHD Bearing -TOWER

Time integration of the Reynolds equation

interface
t t + t
u = * q
position, velocity

input parameter: bearing geometry bearing clearance oil viscosity hydro mesh

User-Subroutine

MFOSUB2
output parameter: displacement velocity acceleration hydrodynamic force output parameter: bearing force oil film gap pressure (oil, contakt)

f = *T F

Motormechanik

1st VI-grade User's Conference, Marburg Germany

Stand: 09.11.2007

ADAMS-TOWER interface
TOWER - microhydrodynamics Extended Reynoldssche-DE
p h3 p ij = xi 12 x j s ( h ) ( ij ) ( h ) ui + ui + xi xj t

Flow calculation
ui1

p1
ui2

p2

q*

throttling effect p 1
pressure flow factor

Supply effect s
shear flow factor
flow X flow Y smooth

flow X flow Y smooth

Oil film gap

Oil film gap

Stand: 09.11.2007

Motormechanik

1st VI-grade User's Conference, Marburg Germany

ADAMS-TOWER interface
TOWER contact model Greenwood/Tripp:
h* 5 pc = K c 4,4086 10 4
2 E1 E2 Kc = K E 1 2 + E 1 2 1 2 2 1
6 ,804

rouhgness contact pressure from the flow calculation (local):

3 10 4 < K < 3 10 3

Contact pressure (integral)

pc

range of variation Greenwood/Tripp flow calculation

Oil film gap

Motormechanik

ADAMS-TOWER interface
TOWER modelling of the bearing geometry
bz
b,a

bz

b,e

r a

zb,e zb,a

f3,e f3,a
tf3

lf3

m 360e

vo

rb

rs

source: IST

Stand: 09.11.2007

Motormechanik

1st VI-grade User's Conference, Marburg Germany

Calculation model
conrod bearing (VirtualEngine-TOWER)
rigid body:
Piston Piston pin

flex body:
Con rod: reduced FE-model with 1040 Nodes within con rod bearing, 300 DoF dummy cranktrain: reduced FE-model with 50 DoF

External Loads:
ind. Cylinder pressure as gas force at the piston

attachment:
Con rod cranktrain : EHD-bearing with 1040 bore nodes of the con rod Dummy cranktrain cylinder head: revolute joint, zero-clearance Piston - liner: translation joint, zero-clearance Piston - piston pin: revolute joint, zero-clearance Piston pin - con rod: revolute joint, zero-clearance

drive:
Dummy cranktrain, kinematical

10

Motormechanik

1st VI-grade User's Conference, Marburg Germany

Stand: 09.11.2007

Calculation model
animation, 2000rpm, full load
MBS- conrod model total pressure Contact pressure

11

Motormechanik

1st VI-grade User's Conference, Marburg Germany

Stand: 09.11.2007

Calculation model
animation, 6000rpm, full load
MBS- conrod model total pressure Contact pressure

Motormechanik

Process Reliability & Efficiency

Limit manual model data preparation New methods converted in new modelling element
Guarantee consistent modelling approach

Automation in GUI
Avoid error prone manual steps Increase productivity

22.01.2011

W.Kujawski, Tel. 35041

Motormechanik

13

Process Reliability
GUI EHD-Bearing

Step 1 of 2: select bearing model refinement level

22.01.2011

W.Kujawski, Tel. 35041 Motormechanik

14

Process Reliability
GUI EHD-Bearing

Step 2 of 2: bearing data input

22.01.2011

W.Kujawski, Tel. 35041 Motormechanik

15

Application Example
Position of the oil flow bore at conrod bearing
2000prm 6000rpm

60
circumferential dir. [deg] 180 120 60 0 -60 -120 -180

X Y

Circumferential dir. [deg] BDC ITDC BDC GTDC Combustion cycle

GTDC

180 120 60

-60 -120 -180

Combustion cycle

Motormechanik

Application Example
Position of the oil flow bore at con rod bearing: animation, 6000rpm
MBS con rod model Total pressure

17

Motormechanik

1st VI-grade User's Conference, Marburg Germany

Stand: 09.11.2007

Application Example
study of the Position of the oil flow bore at con rod bearing
contact pressure, 2000rpm 600 500 pressure [bar] 400 300 200 100
40 60 80

oil flow rate , 6000rpm 0.25 0.20 oil flow [l/min] 0.15 0.10 0.05 0.00 -0.05 -0.10 0 180 360 540 crank train angle [deg] average oil flow rate 0.07 2000 6000 oil flow [l/min] 0.06 0.05 0.04 0.03 0.02 0.01 0 2000 6000 720
40 60 80

60 40
X Y

0 0 180 360 540 cranktrain angle [deg] max. contact pressure 600 500 pressure [bar] 400 300 200 100 0 40 50 60 70 position of oil supply bore [deg] 80 720

80

40

50 60 70 position of oil supply bore [deg]

80

Motormechanik

Tooltransfer
ADAMS-ABAQUS-Translator
ADAMS 2 ABAQUS-Translator
MKS-Modell ADAMS-TOWER FEM-Modell ABAQUS

Automatisch Automatically generated Includefile for FE-Analysis in ABAQUS

Motormechanik

Conclusion
A process oriented tool chain is required to support the CAE development process with different refinement levels according to simulation task and data availability EHD Bearing integrated in FEV VirtualEngine represents highest refinement level for detailed studies: i.e. conrod Automatic connection to Abaqus increases productivity and process reliability.
Motormechanik