Post on 07-Apr-2018
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MECHANICAL TESTING
hot
cold
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Mechanical Testing
still necessary?
Todays product engineering and development
market demands rapid analysis, advanced
development capabilities and high levels of
precision. Computer-aided design (CAD) and
engineering (CAE) has become the standard
approach in an industry where development
costs and time to market has become a driving
factor.
Where e.g. many mechanical items were
traditionally verified just through empirical
testing, todays engineers and analysts
increasingly apply state-of-the-art analytical
tools such as FEA, MBS or CFD in their work.
FEV has a long term experience in those CAx
applications.
In automotive development practice, the
benefit in engine safety against failure gained
from these CAE tools will be used up by rising
product utilization (i.e. forced specific engine
values, e.g. power density or power-to-mass
ratio). Todays engines are increasingly
designed much closer to their mechanical
limits since ever!
The character of Mechanical Testing haschanged: to further satisfy product quality
demands mechanical validation testing is
absolutely necessary for product release.
Modern mechanical development strategies
are characterized by an intensive model-based
optimization of a virtual prototype followed
by validation testing on the physically high-
level prototypes concentrating on advanced
product-life-related test procedures.
This brochure focuses on those test
procedures gathered in the comprehensive
FEV Test Catalogue with special attention to
modern component-, function- and durability-
testing for successful developments of high
quality mass production engines.
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AachenDetroit
Dalian
Three Mechanical Development Centers worldwide
with multiple simulation and testing resources
Comprehensive FEV Test Catalogue with detailed test procedures
for successfull component-, function- and durability-testing
Large database of over 200 modern engines
for detailed benchmark assessments
Comprehensive know-how in mechanical development
of high quality mass production engines
North American Technical
Center, Auburn Hills,
Michigan, USA
FEV Headquarters,
Aachen, Germany
Engineering Center,
Dalian, China
Mechanical Development Center
Prototype Assembly Shop
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Quality Assurance
Test Facilities
Component RatingDurability Testing
Stage 1 Stage 2 SOP Production
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Component Testing
Appropriate component testing allows a cost-
effective verification of calculation results as
well as a capable validation of engine sub sys-
tems. One significant advantage of component
testing is its share on time reduction of the
development process due to the possible start
without the complete engine to be available.
FEV distinguishes between: static component tests pulse testing dynamic rig tests
One example for the first mentioned group is
the static cylinder liner bore distortion meas-
urement, which is performed under cold and
hot conditions. The detailed procedure for this
test as for all other investigations - is predi-
fined in the FEV Test Catalogue.
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Liner Bore Distortion Measurement
Static Component Tests:
Fuji paper
Liner bore distortion Nitrogen gasket leakage Bolt preload measurement Bolt residual load measurement Lubricant level investigation Bearing distortion Fax film measurement Piston cooling jet test Surface roughness measurement
FEV Acyclism Generator
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Whereas component tests as e.g. the pulse
testing on the one hand are an essential part
of the entire engine development process, FEV
also offers these investigations as stand-alone
activity in terms of fundamental analysis or
trouble shooting.
The early comparison between calculation and
measurement e.g. concerning valve train
dynamics requires specific test rigs if ready
to run engines are not yet available. FEV is well
prepared for this case regarding human as well
as technical resources, such as laboratories
and work shops.
The FEV acyclism generator is one example
for a unique solution which allows to act upon
the early specimen with the typical angular
vibration of a combustion engine without
firing. Different numbers of cylinders can be
simulated. Depending on the current speed, the
angular deviation is adjusted automatically.
Pulse Testing
Valve Train Dynamics
Pulse Testing:
Cylinder head pulsing Crankcase pulsing Con rod pulsing Crankshaft pulsing Exhaust manifold thermo pulsing
Dynamic Rig Testing:
Valve train Timing drive Accessory drive Cooling flow distribution Friction test
crank angle []
spring
force
[N]
Calculation
Measurement
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Functional Testing
All relevant engines sub-systems have to pass
the functionality tests under fired conditions.
FEV is able to conduct these investigations on
test benches as well as in vehicle. To ensure a
high quality level, all details of the mentioned
tests are defined in the "FEV Test Catalogue".
Beside the definition of the boundary condi-
tions for installation and execution of the test,also targets and limits are given. These values
are well known from FEVs benchmark data
base and calculation results.
According to the requirements of the specific
project, an individual test program is selected
from the "FEV Test Catalogue" and accomplis-
hed according to the FEV Quality Standards.
In variance to this procedure, FEV is also
well experienced in carrying out
costumer specific test programs.
Client
L
FEV Test Cataloque (extract)
Coolant/Lubrication functional test Oil aeration test Crankcase ventilation test Hot/Cold piston scuff test Hot idle test Engine inclination test Piston/Valve temperature test General temperature test Valve train and chain drive dynamics Overspeed test Oil dilution test Deep thermo shock
Test Procedures
FEV Test Catalogue
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Inclination Test Bench
Telemetric Data
Transfer
ont / Left Low
Low
Rear / Left Low
Rear Low
Rear / Right Low
Right Low
Front Low
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Distance
Rating
icle Testing
Test Bench Days
DurabilityHours
0 10 20 30 40
800
600
400
200
0 800 Hours in 40 Days
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Customer satisfaction is a primary operating
principle for an engineering service provider.
Attention to quality and customer satisfaction
through process control are key factors in the
success and performance of a company.
Recently, FEV Motorentechnik was certified to the
ISO 14001 Environmetal Management System
Standard. Re-certification to the ISO 9001:2000Quality Management System Standard was ob-
tained by FEV in the summer of 2003. These
certifications were granted for FEVs total service
and product spectrum (e.g. engine - powertrain,
vehicle application, electronics - mechatronics
and measurement - test systems). FEV now has
an integrated quality and environmental manage-
ment system.
Evidence of customer satisfaction has be-
en demonstrated by the receipt of one of our
customers own certifications. In November,
Ford of Europe updated FEVs Q1-2003 status
for powertrain development. The Q1 require-
ments exceed those of the ISO-standards. The
Q1 global standard is a highly esteemed quality
mark that also stands for proof of FEVs syste-
matic quality assurance.
The strategic determination of measurable qua-
lity metrics as well as the continuous pursuit
of improvement measures are required for this
standard.
FEV has established a QM-system in preparation
for future quality requirements.
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Quality Assurance
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The chain cracks due to its weakest link!
To avoid this, FEV has established a con-tinuous process of high quality throughoutthe whole mechanical testing. The devel-opment procedure with defined respon-sibilities is a comprehensive example. Toguarantee its functionality, different stand-
ardized tools are installed.
The above mentioned FEV Test Cataloguedefines reproducible boundaries for thefollowing details:
types of measurement technology number and position of sensors operating points boundary conditions such like ambient
temperature, pressure, strategy of data evaluation incl.
visualisation targets and limit
This is done in terms of a single stand-ard for each test within the whole TestCatalogue.
Not only regular events are covered: Ifsome unexpected incident occurs while
test run, a damage failure report has tobe generated. The consequent usage ofthis tool allows an effective quality controlwithin the development process in termsof improvement check from stage to stage,based on statistic evaluation.
Furthermore, the high number of con-ducted standardized engine developments
leads to a capable correlation between testbench results and field experiences, as it isdocumented in the FEV Wear Catalogue.
To fulfil the Test Catalogue requirements,FEV has installed all necessary technicalresources, such as e.g. a state-of-the-artmeasurement machine.
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Measuring Machine
Damage Failure Report
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Benchmarking
FEV Engine Mechanics Database
An important pre-condition to create innovative
engine designs is the knowledge of the current
state-of-the-art.
FEV collects a various number of data from of
all mentioned disciplines of mechanical testing
component, functional and durability testing.By name, these are:
friction results
wear behaviour temperatures of: lubricants
coolants
gases components mass flow of: lubricants
coolants
gases pressures of: lubricants
coolants
gases component dynamics: timing error torsional vibration
valve closing velocity endurance
The high capability of the benchmark hardly
is driven by the pre-mentioned quality ensure
tools which lead to comparable results. Source
of the information is both, series production as
well as prototype investigation.
Beside the numerical values, some input data
are suitable to be evaluated graphically, which
allows a visual comparison between the cus-
tomers product and the field of its competi-
tors.
Each and every project increases FEVs know-
how we are prepared to share it with you!
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FMEP Scatter Ranges Design Parameters
50 cc Natural AspiratedGasoline Engine
Scatter Bands
FEV Engine Mechanics Database
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References
Further Examples:
1.8 L I4 Gasoline Engine 2.2 L I4 Gasoline Engine 2.5 L I6 Gasoline Engine 1.6 2.0 L Gasoline Engine Family 3.3 3.8 L V6 Gasoline Engine Family 1.4 L I4 DI Diesel Engine 3.0 L I4 DI Diesel Engine 3.0 L I6 DI Diesel Engine 3.6 L V8 DI Diesel Engine 4.4 L V8 DI Diesel Engine 7.0 L V8 DI Diesel Engine
7.2 L I6 Medium Duty Diesel Engine 9.6 L I6 Heavy Duty Diesel Engine 12.6 L I6 Heavy Duty Diesel Engine 2.7 L Gasoline Engine 3.2 L Gasoline Engine 3.4 L Gasoline Engine 3.6 L Gasoline Engine 1.05 L Gasoline Engine
1.8 L Turbo Gasoline Engine 1.15 L Diesel Engine 0.7 L Diesel Engine 1.7 L Diesel Engine 3.7 L Diesel Engine
1.7 L I4 SuperchargedGasoline Outboard Engine
1.8 L I4 Gasoline Turbo Engine
2.0 L / Cylinder V6 / V8Heavy Duty Diesel Engine Family
16 L / Cylinder V12 / V16Locomotive Engine Family
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CONTACT
FEV Motorentechnik GmbHNeuenhofstrae 181
52078 Aachen GermanyPhone +49 (0) 241/56 89 - 0Fax +49 (0) 241/ 56 89 -119
E-Mail marketing@fev.com
FEV Engine Technology, Inc.
4554 Glenmeade Lane
Auburn Hills, MI 48326-1766 USA
Phone +1 (0) (248) 373- 60 00Fax +1 (0) (248) 373- 80 84
E-Mail marketing@fev-et.com
FEV China Co., Ltd.
No.35 Xinda Street Qixianling
High Tech Zone 116023 Dalian China
Phone +86 (0) 411 / 84 82 - 16 88Fax +86 (0) 411 / 84 82 - 16 00
E-Mail fev-china@fev.com
Internet http://www.fev.com
chanicalTesting/I/2005
and
areregistredTradeMarksofFEVMotorentechnikGmbHintheStatesoftheEuropeanCommunityandtheUnitedStatesofAmerica.