Escolar Documentos
Profissional Documentos
Cultura Documentos
2010-01-0420
MAHLE
Contents
Connecting Rod Weight Optimization
Selection Criteria Critical Connecting Rod Zones Pin End Features Shank and I-beam Crank End Features Advanced Numerical Simulation Engine Validation Conclusions & Future Work
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MAHLE
Selection Criteria
Selection Criteria
Current Production Rod 36MnVS4BY Forged Steel Stepped Pin End Bushing-less Bushing less Pin End MJ8 vs. MJ9
Current Production
Optimized Design
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Crank End
Crank Bore Deformation Bolted Joint Optimization
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Structural FEA
Fatigue F ti S Safety f t Factor F t Stress Results Criteria 95% Survival Rate 10 Million Cycle Pin Bore Profile
Piston pin p
Results
Pressure @ Beginning of Profile Too Aggressive Profile Safety Factors Above MAHLE Min. Standards
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Engine Validation
Tests
Successfully y Completed p 50 Hours Transient City y Cycle y Test Pin End Deformation Crank Bore Roundness Passed Buckling Bench Testing @ 1.4 x Max. Compression Load
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Conclusions
Results
27% Mass Reduction Meets MAHLE Min. Safety Factor Mass Production Valid Ideal for Range Extender/Hybrid Applications Light Weight Engine Applications
Future Work
Advanced Numerical Simulation Full Engine Dynamometer Durability Test
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2010-01-0420
MAHLE