Volkswagen Diesel Engine Development , Experimental Engine

Technical University of Liberec
Lecture 21.11.2005
Volkswagen Diesel Engine Development Experimental Engine Testing
Dr.-Ing. Jens Hadler (Head of Department)
Dr.-Ing. Christian Heikel (Lecturer)
For internal university use only!
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
Diesel Development Department
1
Power output per litre
Diesel passenger car segment
80
Power output per litre [kW/l]
70
60
50
40
30
20
10
0
1950
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
1960
1970
1980
1990
2000
Diesel Development Department
2010
2
Future development trends for motoric casting components
Cylinder heads / crankcases
Dynamic load range
dynamische Beanspruchbarkeit
(high-cycle-fatigue)
Thermomechanical load range
(High-Cycle-Fatigue)
thermische Beanspruchbarkeit
(low-cycle-fatigue)
Easy
to
recycle
(Low-Cycle-Fatigue)
gute Recyclingfähigkeit
High operativeness
hohe Funktionssicherheit
Low component
weight
geringes
Bauteilgewicht
Present cylinder heads
derzeitige
Future Zylinderköpfe
cylinder heads
zukünftige Zylinderköpfe
Low
costHerstellungskosten
of production
geringe
Low
component
space
niedriger
Bauraum
Fertigung
Steadyprozesssichere
quality of manufacture
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
Diesel Development Department
3
Motoric test bench testing
Important test bench tests
Usual engine bench tests
Endurance tests
„Detail“ tests
„Screening“ tests
• Polycyclic short
endurance test (PZD)
• Endurance test (DL1,
DL2)
•…
Function tests
• Piston seizing test (KFT)
• Power output test
• Oil-Consumption test run (ÖVL)
• Emissions test
• Thermal shock test (THS)
• Temperature determination
• Exhaust manifold crack test
• Pressure measurement
• Resonance endurance test
• Resonance analysis
•…
• Acoustic investigation
•…
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
Diesel Development Department
4
Special engine engineering testing methods
Important special engine engineering tests from Volkswagen
Special testing methods
Overall motor
• Engine slew test
• Climatic chamber
Motor components
• Stress number test (for
instance: Wöhler Curve)
• High-altitude chamber
• Computer tomography
• Radiotracer technique
• Resonance test
wear measurement
•…
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
•…
Material specimens
• Corrosion test
• High Cycle Fatigue test
(HCF-Test)
• Low Cycle Fatigue test
(LCF)
•…
Diesel Development Department
5
The overall vehicle test
The most expensive durability run
Diesel engine overall vehicle
durability test
Collision test
Roller test bench
Vehicle endurance run
• Defined test courses
• Emissions test
• Motor damage analysis
• High-altitude testing
• Endurance run
• Safety investigation
• Cold-climate testing
•…
•…
• Hot-climate testing
• Deep wade through
•…
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
Diesel Development Department
6
Development example of an high stressed Diesel cylinder head
Schematic drawing
Product description of the
projected cylinder head
Digital blueprint of the
new cylinder head
Numerical calculations:
CFD, LCF, HCF
Motoric test bench:
PZD,THS, temperaturemeasurement
Material specimen:
microstructure, hardness,
strength test
Component testing:
endurance tests,
computer tomography
flow distribution
Overall vehicle test:
e.g. hot-climate test
Release for series
production
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
Diesel Development Department
7
Properties of plasma-sprayed cylinder bore surfaces
Radiotracer technique wear measurement (RNT)
Turnaround
aktivierter
Zwickelbereich
point
Oil film
Ölfilm
V
V
Sensor
Detektor
Abrieb
Oil
Öl
Pumpe
Exit
Ausgang
DurchflußÖlfiltermodul
oil filter
Blei
meßkopf
aktivierte
Radiating
Chromchrome
layer
beschichtung
Plasma sprayed
layer
Plasmaspritzschicht
Exit
Ausgang
oil
mulde
Ölwanne
interpretation
Interpretation
Auswertung
Verschleiß
[nm]
Wear
Piston ring
Kolbenring
aktivierte
Maschinenteile
in laufender
Radiateing
tribotechnical
system Maschine,
hier:
Plasmaspritzschicht
und
oberster
Kolbenring
(plasma sprayed layer and first
piston
ring)
Zeit [h]
Sensor
Detektor
Zylinderwand
Cylinder
bore
Filtermeßkopf
mit Ölfilter
Time
Blei = Bleiabschirmung gegen
Umgebungsstrahlung
Marginal layer abrasion in the turnaround point: 4 … 6 nm / h
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
Diesel Development Department
8
Current material casting variant studies
From LCF specimen production to cylinder head service life prognosis
Numerical calculation:
Manson-Coffin
(plastic extension amplitude)
Basquin
(total extention amplitude)
Smith Watson Topper
σ
E
εap
σm
∆σa
Specimen location
in cylinder head
casting
σa
σο
εu
σu
εo
εm
∆εap
ε
εat
∆εat
Thermomechanical
hysteresis loop
Dr.-Ing. Jens Hadler
Dr.-Ing. Christian Heikel
Thermomechanical
durability
Diesel Development Department
9