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Air quenching is a common manufacturing process in automotive industry to produce high strength metal component by cooling heated parts rapidly in a short period of time. With the advancement of finite element analysis (FEA) methods, it has been possible to predict thermal residual stress by computer simulation. Previous research has shown that heat transfer coefficient (HTC) for steady air quenching process is time and temperature independent but strongly flow and geometry dependent. These findings lead to the development of enhanced HTC method by performing CFD simulation and extracting HTC information from flow field. The HTC obtained in this fashion is a continuous function over the entire surface. In current part of the research, two patching algorithms are developed to divide entire surface into patches according to HTC profile and each patch is assigned a discrete HTC value.

The integration of CAD/CAM/CAE in product development is the key to realize concurrent engineering. Generally, different systems are employed in product development department. These different systems create a lot of troubles such as difficult communication, misunderstanding and so on. A new approach to integrate CAD/CAM/CAE in one system based on CATIA for the end-to-end process in cylinder head development is presented. Multi-Model Technology (MMT) is used to create consistent and associated CAD models for the end-to-end process in cylinder head development. The concept and method to create and organize multi- models are discussed. A typically four-layer structure of MMT for mechanical products is defined. The multi-level structure of the cylinder head models based on MMT is provided. The CAD models of cylinder head created based on MMT can be used as the consistent model.

Cylinder head design is a highly challenging task for modern engines, especially for the proliferation of boosted, gasoline direct injection engines (branded EcoBoost® engines by Ford Motor Company). The high power density of these engines results in higher cylinder firing pressures and higher operating temperatures throughout the engine. In addition to the high operating stresses, cylinder heads are normally heat treated to optimize their mechanical properties; residual stresses are generated during heat treatment, which can be detrimental for high-cycle fatigue performance. In this paper, a complete cylinder head high cycle fatigue CAE analysis procedure is demonstrated. First, the heat treatment process is simulated. The transient temperature histories during the quenching process are used to calculate the distribution of the residual stresses, followed by machining simulation, which results in a redistribution of stress.

The monolithic DPF made of cordierite ceramic has unsatisfactory on his fatigue or long-term strength. A new design of configuration of plugs combined with the hexagonal channels shows a transversally isotropic property, and can remove the anisotropy of monoliths with square channels. This anisotropy is assumed to be one of main reasons for the failure of monoliths with square channels regarding the experimental results. Considering the honeycomb structure as a homogeneous material based on the Boltzmann continuum can't give the correct behaviour of this structure in a FEM simulation. Another homogenization procedure using the Cosserat theory has been discussed. The FEM stress analyses with structural detail-models show that the maximal tensile stresses in the monolith with square channels exist in the diagonal (i.e. 45°-) direction, or on the edges of channels. This feature is identical with what the theory has predicted and the experimental results have shown.