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Today, detailed up-front theoretical analysis is essential to shorten development time and decrease costs. Multi-Layer Steel (MLS) cylinder head gaskets we use are coated with a very thin rubber-like coating plus featuring other complicated geometric features, which makes the analysis a difficult task. With the Proteus® software package we define a project, which consists of the manufacturing process of the main elements (like embossments or wave stopper) up to the functional parameters (like loading behaviour and durability). This paper presents how we start with the single layer element simulation and transfer the information into the multi-layer analysis. Both of those cases are 2D-axis-symmetrical. Further the developed information will be used for 3D simulations in other software packages Besides the project approach in Proteus® we will briefly explain the theoretical basis. For that we start with the Method of the Local Functionals (MLF), a modification of the traditional FEM.

Today, Computer Aided Engineering (CAE) is standard in the up-front gasket development. As presented three years ago, it helps to reduce the development cycle and at the same time the development costs. With the success in using this approach, we received new requirements from the customer requesting for more and better details so that the project can be completed within the same time frame. The theoretical advancement and the drastic changes in the computer hardware technology along with lower costs aided in fine tuning our previously developed approach and adding new features. So we upgraded our specialized Proteus® software for the element study and extended it into the multi-layer 2D case. Further, more we detailed and improved the simplified 3D-model module as well as the whole bank 3D-model. A very important addition is the flow/thermal analysis to create the thermal map with our models.

MLS (Multi-layer steel) CHG ( Cylinder Head gasket) designs play a major role in today's sealing approach for internal combustion engine. However, as a member between cylinder block and cylinder head, it not only has a sealing function, but also influences the hardware structure. The knowledge of their interaction is critical to fulfill all necessary requirements. This paper discusses different MLS CHG designs and how they influence the hardware's structure while maintaining the seal of the assembly. Therefore, we investigate major parameters like sealing stress, sealing gap lift-off, bore distortion and etc. A comparison is made between different designs, using experimental data as well as finite element analysis. Because of the vast number of designs and their interactions between the hardware and gasket, the focus is on basic trends of their influences.