Today's power train applications have increased dynamics and temperatures while power train packaging offers less space for shielding components to protect surrounding parts.
Short development timing requires the use off FE analysis to determine stiffness & durability based on CAD models in the early design phases.
While these tools are already very common in metal sheet forming components, it is still unusual to simulate this on conventional heat shield designs made from steel and composite layer combinations - so called Sandwich material. Even CAE-software providers do not have much experience in modeling this composite material. The construction and assembly of the different layers in a heat shield component form is an important aspect to the simulation. This in return also makes it very difficult for modeling.
The largest contradiction between normal metal sheet formed parts and sandwich components is finding accurate comparable results in analytical analysis compared to real experimental testing and operation.
This publication describes the modern research and development process designed by ElringKlinger in creating concepts made from sandwich components and using the existing CAE-tools to generate a analytical model and correlating the results with actual physical part testing.