Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

1Diesel Development Department

Volkswagen Diesel Engine Development -Experimental Engine Testing

Dr.-Ing. Jens Hadler (Head of Department)Dr.-Ing. Christian Heikel (Lecturer)

Technical University of LiberecLecture 21.11.2005

For internal university use only!

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

2Diesel Development Department

0

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20

30

40

50

60

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1950 1960 1970 1980 1990 2000 2010

Pow

er o

utpu

t per

litre

[kW

/l]

Power output per litreDiesel passenger car segment

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

3Diesel Development Department

dynamische Beanspruchbarkeit (High-Cycle-Fatigue)

derzeitige Zylinderköpfezukünftige Zylinderköpfe

thermische Beanspruchbarkeit (Low-Cycle-Fatigue)

geringes Bauteilgewicht

niedriger Bauraum

prozesssichere Fertigung

geringe Herstellungskosten

hohe Funktionssicherheit

gute Recyclingfähigkeit

Dynamic load range (high-cycle-fatigue) Thermomechanical load range

(low-cycle-fatigue)

Low component weight

Low component space

Steady quality of manufacture

Low cost of production

High operativeness

Easy to recycle

Present cylinder heads

Future cylinder heads

Future development trends for motoric casting componentsCylinder heads / crankcases

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

4Diesel Development Department

Motoric test bench testing Important test bench tests

Usual engine bench tests

Endurance tests Function tests

�Screening� tests �Detail� tests

� Polycyclic short

endurance test (PZD)

� Endurance test (DL1,

DL2)

� �

� Piston seizing test (KFT)

� Oil-Consumption test run (ÖVL)

� Thermal shock test (THS)

� Exhaust manifold crack test

� Resonance endurance test

� �

� Power output test

� Emissions test

� Temperature determination

� Pressure measurement

� Resonance analysis

� Acoustic investigation

� �

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

5Diesel Development Department

Special engine engineering testing methods Important special engine engineering tests from Volkswagen

Special testing methods

Overall motor Motor components

� Engine slew test

� Climatic chamber

� High-altitude chamber

� Radiotracer technique

wear measurement

� �

� Stress number test (for

instance: Wöhler Curve)

� Computer tomography

� Resonance test

� �

� Corrosion test

� High Cycle Fatigue test

(HCF-Test)

� Low Cycle Fatigue test

(LCF)

� �

Material specimens

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

6Diesel Development Department

The overall vehicle test The most expensive durability run

Diesel engine overall vehicle durability test

Vehicle endurance run Roller test bench

� Defined test courses

� High-altitude testing

� Cold-climate testing

� Hot-climate testing

� Deep wade through

� �

� Emissions test

� Endurance run

� �

� Motor damage analysis

� Safety investigation

� �

Collision test

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

7Diesel Development Department

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, temperature-

measurement

Material specimen:microstructure, hardness,

strength test

Overall vehicle test: e.g. hot-climate test

Release for series production

Component testing:endurance tests,

computer tomography flow distribution

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

8Diesel Development Department

aktivierte Maschinenteile in laufender Maschine,hier: Plasmaspritzschicht und oberster Kolbenring

Durchfluß-meßkopf

Filtermeßkopfmit Ölfilter

Detektor

Detektor

AusgangÖlwanne

AusgangÖlfiltermodul

Zeit [h]

Vers

chle

iß [n

m]

Zylinderwand

Kolbenring

aktivierterZwickelbereich

aktivierte Chrom-beschichtung

V

Plasmaspritz-schicht Blei = Bleiabschirmung gegen

Umgebungsstrahlung

Blei

Öl

Ölfilm

Pumpe

AbriebAuswertung

V

Turnaround point

Piston ring

Radiating chrome layer

Plasma sprayed layer

Cylinder bore

SensorTime

Wea

r

Sensor

Oil

Oil film

Exit oil filter

Exit oil mulde

Radiateing tribotechnical system (plasma sprayed layer and first piston ring)

interpretationInterpretation

Marginal layer abrasion in the turnaround point: 4 � 6 nm / h

Properties of plasma-sprayed cylinder bore surfacesRadiotracer technique wear measurement (RNT)

Dr.-Ing. Jens HadlerDr.-Ing. Christian Heikel

9Diesel Development Department

Specimen location in cylinder head casting

ε

σ

σm

σο

σu

εm εoεu

εat

εap

σ a

∆εat

∆εap

∆σa

E

Thermomechanical hysteresis loop

Numerical calculation:

Thermomechanical durability

Manson-Coffin(plastic extension amplitude)Basquin(total extention amplitude)Smith Watson Topper

Current material casting variant studiesFrom LCF specimen production to cylinder head service life prognosis