Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Computer simulates thermal stress

13.08.2008
A new simulation method has made it possible to predict in record time when and where heavily stressed engine components are likely to fail. Car manufacturers can thereby significantly reduce the time for developing new engine components

Exhaust fumes come hissing out of car engines at up to 1050 degrees Celsius – and that’s pretty hot! It exposes the engine components to tremendous stress, for they expand heavily in the heat.

On frosty days, by contrast, the material contracts. There can be no doubt about it: In the long run, such temperature fluctuations put the material under enormous pressure. The manufacturers therefore test particularly stressed components on a test rig while the vehicle is still under development. However, these investigations cost time and money. Component prototypes have to be built and modified in a time-consuming trial-and-error process until the manufacturer has finally produced a reliable component with no weak points.

These investigations have to be repeated for each new material. For certain car manufacturers and suppliers, however, time-consuming component tests are now a thing of the past. A new simulation method developed at the Fraunhofer Institute for Mechanics of Materials IWM in Freiburg enables companies to significantly reduce the time taken to develop exhaust manifolds. Exhaust manifolds collect the hot exhaust fumes from the engine and pass them on to the catalytic converter. They are exposed to particularly high temperatures and therefore under very great stress.

The new simulation method enables the researchers to work out the places in which a component will wear out and fail after a certain number of heating and cooling cycles. Thanks to this, the manufacturer can optimize the shape of the workpiece on the computer and greatly reduce the number of real test runs. The Freiburg scientists take a very close look at the material.

Starting by testing the material in the laboratory, they heat, squeeze and pull the metal, repeatedly checking under the microscope when and where tiny cracks begin to form. The researchers then feed these insights into their simulation software. From now on, car manufacturers can use it to calculate how the material will behave and when it will fail, for each new component shape. “It goes without saying that our simulation models can also be applied to all kinds of materials and used in other sectors of industry,” says IWM project manager Dr. Thomas Seifert. At present, Seifert and his colleagues are engaged in a joint project with RWE Power and Thyssen-Krupp to investigate heat-resistant nickel alloys for a new generation of power stations.

These will be built to operate at particularly high temperatures and achieve a higher degree of efficiency than today’s facilities.

Dr.-Ing. Thomas Peter Seifert | alfa
Further information:
http://www.fraunhofer.de/
http://www.fraunhofer.de/EN/press/pi/2008/08/ResearchNews082008Topic4.jsp
http://www.fraunhofer.de/EN/bigimg/2008/rn08fo4g.jsp

More articles from Automotive Engineering:

nachricht 3D scans for the automotive industry
16.01.2017 | Julius-Maximilians-Universität Würzburg

nachricht Improvement of the operating range and increasing of the reliability of integrated circuits
09.11.2016 | Technologie Lizenz-Büro (TLB) der Baden-Württembergischen Hochschulen GmbH

All articles from Automotive Engineering >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: Making lightweight construction suitable for series production

More and more automobile companies are focusing on body parts made of carbon fiber reinforced plastics (CFRP). However, manufacturing and repair costs must be further reduced in order to make CFRP more economical in use. Together with the Volkswagen AG and five other partners in the project HolQueSt 3D, the Laser Zentrum Hannover e.V. (LZH) has developed laser processes for the automatic trimming, drilling and repair of three-dimensional components.

Automated manufacturing processes are the basis for ultimately establishing the series production of CFRP components. In the project HolQueSt 3D, the LZH has...

Im Focus: Wonder material? Novel nanotube structure strengthens thin films for flexible electronics

Reflecting the structure of composites found in nature and the ancient world, researchers at the University of Illinois at Urbana-Champaign have synthesized thin carbon nanotube (CNT) textiles that exhibit both high electrical conductivity and a level of toughness that is about fifty times higher than copper films, currently used in electronics.

"The structural robustness of thin metal films has significant importance for the reliable operation of smart skin and flexible electronics including...

Im Focus: Deep inside Galaxy M87

The nearby, giant radio galaxy M87 hosts a supermassive black hole (BH) and is well-known for its bright jet dominating the spectrum over ten orders of magnitude in frequency. Due to its proximity, jet prominence, and the large black hole mass, M87 is the best laboratory for investigating the formation, acceleration, and collimation of relativistic jets. A research team led by Silke Britzen from the Max Planck Institute for Radio Astronomy in Bonn, Germany, has found strong indication for turbulent processes connecting the accretion disk and the jet of that galaxy providing insights into the longstanding problem of the origin of astrophysical jets.

Supermassive black holes form some of the most enigmatic phenomena in astrophysics. Their enormous energy output is supposed to be generated by the...

Im Focus: A Quantum Low Pass for Photons

Physicists in Garching observe novel quantum effect that limits the number of emitted photons.

The probability to find a certain number of photons inside a laser pulse usually corresponds to a classical distribution of independent events, the so-called...

Im Focus: Microprocessors based on a layer of just three atoms

Microprocessors based on atomically thin materials hold the promise of the evolution of traditional processors as well as new applications in the field of flexible electronics. Now, a TU Wien research team led by Thomas Müller has made a breakthrough in this field as part of an ongoing research project.

Two-dimensional materials, or 2D materials for short, are extremely versatile, although – or often more precisely because – they are made up of just one or a...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Fighting drug resistant tuberculosis – InfectoGnostics meets MYCO-NET² partners in Peru

28.04.2017 | Event News

Expert meeting “Health Business Connect” will connect international medical technology companies

20.04.2017 | Event News

Wenn der Computer das Gehirn austrickst

18.04.2017 | Event News

 
Latest News

Wireless power can drive tiny electronic devices in the GI tract

28.04.2017 | Medical Engineering

Ice cave in Transylvania yields window into region's past

28.04.2017 | Earth Sciences

Nose2Brain – Better Therapy for Multiple Sclerosis

28.04.2017 | Life Sciences

VideoLinks
B2B-VideoLinks
More VideoLinks >>>