This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Overall Approach to the Validation of Charge Air Coolers
Technical Paper
2005-01-2064
ISSN: 0148-7191, e-ISSN: 2688-3627
Annotation ability available
Sector:
Language:
English
Abstract
This paper gives a brief overview of the Behr reliability management system, including, as an integral element, the validation process. It describes the application of test methods as well as simulation tools and associated coupling strategies which are used to validate charge air coolers.
Simulation of the main validation tests for charge air coolers are performed. For this study a CFD simulation is carried out to predict surface temperature distribution. The results are evaluated and compared with temperature measurements from an infrared camera. By mapping these temperature distributions, obtained either from computations or measurements, onto an FE model as boundary conditions, structural analyses are performed for the thermal cycle test. The stresses computed are compared with strain gage measurements from the test rig.
Due to the very high temperature values and varying boost pressures involved, pressure cycle fatigue tests, in which the component is pressurized with hot air, have to be performed. The stress results from the simulation can be compared with cycles-to-failure from the test rig. In a double logarithmic scale this leads to an s-n-curve with constant slope valid for a specific failure mode.
With the aid of a global FEA modeling standard the results of different simulations and tests can be compared. With this s-n-curve new design variants can be evaluated and necessary improvements can be implemented without prior testing.
Recommended Content
Authors
Topic
Citation
Knaus, H., Weise, S., Kühnel, W., and Krüger, U., "Overall Approach to the Validation of Charge Air Coolers," SAE Technical Paper 2005-01-2064, 2005, https://doi.org/10.4271/2005-01-2064.Also In
References
- Aubele, P House of Reliability - Zuverlässig-keitsmanagement für eine neue Zuverlässigkeit. 2004
- Zuverlässigkeitssicherung bei Automobil-herstellern und Lieferanten. VDA-Verlag Frankfurt a. Main 2000
- Haibach, E Betriebsfestigkeit: Verfahren und Daten zur Bauteilberechnung. VDI-Verlag Düsseldorf 1989
- FKM Richtlinie Rechnerischer Festigkeitsnachweis für Maschinenbauteile. VDMA Verlag Frankfurt a. Main 2002