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The first proposal for an engine component usually is based on the supplier technical expertise, previous cases and/or selection manuals. Occasionally, this first proposal is also validated by numerical simulation; however, the main purpose is to satisfy a desirable target, not to assure an optimized nor robust proposal. The objective of the developed work is to present a proposed sequence for selection of one or as many as possible optimized and feasible proposals as well as the expected robustness in terms of performance for each proposal. This selection sequence is based massively on numerical simulation and on the advantageous expertise about the product. The example presented in this work is a ring dynamics simulation using an optimization method to select solutions that simultaneously reduce the blow-by and lube oil consumption (LOC). It is also presented the robustness calculation of the selected proposals.

Nowadays, due to the high competitiveness in the automotive market, the car manufacturers and the engine developers are concentrating as many efforts as possible in order to diminish the lead-time to production and to promote cost reductions of their engine developments. As a consequence, many systems and component tests are being substituted by numerical simulations, allowing a significant reduction in the amount of engine and bench tests. The integration of individual numerical simulation tools generates the philosophy of Virtual Engine Development, which is based on the concept of simulating as much as possible the entire engine as well as its components behaviors. This paper presents the application of Virtual Engine Development (VED) in a PSA 1.4l SI engine development. Theoretical results of engine performance as well as powercell components behavior such as piston, rings, conrod, bearings, liner, engine block and cylinder head, among others, are presented and discussed.