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8/6/2019 Mechanical Testing Web

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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 [email protected]

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


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


Internet http://www.fev.com

chanicalTesting/I/2005

and

areregistredTradeMarksofFEVMotorentechnikGmbHintheStatesoftheEuropeanCommunityandtheUnitedStatesofAmerica.

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