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The real cycle simulation is an important tool to predict the engine efficiency. To evaluate Extended Expansion SI-engines with a multi-link cranktrain, the challenge is to consider all concept specific effects as best as possible by using appropriate submodels. Due to the multi-link cranktrain, the choice of a suitable heat transfer model is of great importance since the cranktrain kinematics is changed. Therefore, the usage of the mean piston speed to calculate a heat-transfer-related velocity for heat transfer equations is not sufficient. The heat transfer equation according to Bargende combines for its calculation the actual piston speed with a simplified k-ε model. In this paper it is assessed, whether the Bargende model is valid for Extended Expansion engines. Therefore a single-cylinder engine is equipped with fast-response surface-thermocouples in the cylinder head. The surface heat flux is calculated by solving the unsteady heat conduction equation.

Engine valve flow coefficients are used to describe the flow throughput performance of engine valve/port designs, and to model gas exchange in 0D/1D engine simulation. Valve flow coefficients are normally determined at a stationary flow test bench, separately for intake and exhaust side, in the absence of the piston. However, engine operation differs from this setup; i. a. the piston might interact with valve flow around scavenging top dead center, and instead of steady boundary conditions, valve flow is nearly always subjected to pressure pulsations, due to pressure wave reflections within the gas exchange ports. In this work the influences of piston position and flow pulsation on valve flow coefficients are investigated for different SI engine geometries by means of 3D CFD and measurements at an enhanced flow test bench.

A simulation approach to predict the amount of snow which is penetrating into the air filter of the vehicle’s engine is important for the automotive industry. The objective of our work was to predict the snow ingress based on an Eulerian/Lagrangian approach within a commercial CFD-software and to compare the simulation results to measurements in order to confirm our simulation approach. An additional objective was to use the simulation approach to improve the air intake system of an automobile. The measurements were performed on two test sites. On the one hand we made measurements on a natural test area in Sweden to reproduce real driving scenarios and thereby confirm our simulation approach. On the other hand the simulation results of the improved air intake system were compared to measurements, which were carried out in a climatic wind tunnel in Stuttgart.

For basic research on the piston group a new simulation technique is developed using the contact algorithm of a commercial FE-code (MARC). Several improvements were made in order to adapt the MARC solver to the problem of sliding and dynamic contact. The first computations, a real transient analysis simulating the piston group, of both a two-stroke engine and a modern direct injected four-stroke Diesel engine for passenger cars, show that the new method is able to calculate the movements, velocities and accelerations of the piston. The quality of the results is mainly influenced by the hydrodynamic effects.

Thixoforming is another word for Semi-Solid-Metalforming (SSM) which means that metal will be formed between solid and liquid temperature. In this state the material behavior is thixotropic. Aluminum alloys can be formed in this thixotropic state when 30 to 40% of the material is liquid. In this case it is possible to form the aluminum in a process that is located between the die-casting and the forging technology. The thixoforming process allows it to produce Near Net Shape aluminum-parts with high quality for the automotive industry. This paper is intended to give the reader some examples about and some insights into the possible applications of the thixoforming process.

For the gasoline engine, the isochoric process is the ideal limit of the ideal processes. During the project, a combustion engine with real isochoric boundary conditions is built. A “resting time” of the piston for several degrees crank angle in the top dead center (TDC) can be realized with a special crank drive. This crank drive consists of two crankshafts with different strokes, which are combined. The two crankshafts rotate with a ratio of two to one in opposite directions. The total stroke corresponds to the amount of the first crankshaft, so it is possible to investigate different strokes of the second crankshaft in the same crankcase. Different “resting times” can be achieved by different strokes of the second crankshaft. A specific combination of both crankshafts make a stroke possible which corresponds to that of a conventional combustion engine.

The noise emission of cruising vehicles essentially consists of tire/road noise, drivetrain noise (engine with intake and exhaust system, transmission and driving axle) and aerodynamic noise due to the flow around bodywork, chassis, wheels and cooling air flow (fan). Engines and drivetrains have become quieter due to many man-years of engineering attention and tire noise has also been reduced - at least the noise reaching the passenger compartment. Consequently, the aerodynamic noise of ground vehicles has become dominant at driving speeds above 100 kph both in interior and exterior noise. In order to determine the contribution of aerodynamic noise to the overall noise, measurements are carried out more and more in specially equipped automotive wind tunnels.

More than 20 years after the first presentation of the heat transfer equation according to Bargende [1,2], it is time to introduce some useful additions and enhancements, with respect to new and advanced combustion principles like diesel- and gasoline- homogeneous charge compression ignition (HCCI). In the existing heat transfer equation according to Bargende the calculation of the actual combustion chamber surface area is formulated in accordance with the work of Hohenberg. Hohenberg found experimentally that in the piston top land only about 20-30% of the wall heat flux values from the combustion chamber are transferred to the liner and piston wall. Hohenberg explained this phenomenon that is caused by lower gas temperature and convection level in charge within the piston top land volume. The formulation just adds the existing piston top land surface area multiplied by a specified factor to the surface of the combustion chamber.

The fluorescence characteristics of different carbonyl compounds were investigated in a pressurized bomb using an excimer laser (308 nm) for excitation. The partial pressure of the carbonyl compounds and air was varied between 0 - saturation pressure and 0 - 5 bar, respectively. The fluorescence signal of different ketones increased almost linearly with vapour pressure. It was found to be almost independent of air pressure indicating only a weak quenching influence of oxygen. Ethylmethylketone (EMK) has a boiling temperature and vapour pressure similar to gasoline. Therefore, the applicability of EMK for measuring 2-D fuel distributions in a combustion chamber was tested in a transparent SI square piston engine. EMK was injected into the intake manifold by a conventional injector for studying the fuel/air mixing during the intake and compression stroke at 1.000 rpm. From the 2-D fluorescence signals 2-D air/fuel ratios were calculated using calibration data from bomb experiments.

In this paper the effects of pulsating blankholder forces in deep draw processes for sheet metal parts are discussed. Areas with and without tangential compressive stresses in the flanges, which are located between the binders, are discussed separately. Areas without tangential compressive stresses can be simulated by a special friction strip-draw test using a pulsating normal force ( representing the blankholder force ). Investigations using this equipment show that by pulsating blankholder forces it is possible to avoid galling and to reduce the friction force. Areas with tangential compressive stresses can be simulated by deep drawing axissymmetric cups using a pulsating blankholder force. Investigations with this equipment show that without increasing the danger of wrinkling the friction forces can be reduced by pulsating blankholder forces, when a certain frequency limit is reached.

In sheet metal stamping some industrial applications have shown that it is possible to achieve larger drawn depth by using a pulsating blankholder force. In deep drawing, areas with and without tangential stresses have to be distinguished. Areas without tangential stresses can be described by the strip drawing test. Areas with tangential stresses are described by using a deep drawing die for the production of cups which are axisymmetric. With the strip drawing test it could be shown that it is possible to reduce the increase of the friction force, caused by adhesion. Another effect is the reduction of the peak of the transition of static to dynamic friction. It was shown by experimental research, that the wrinkle height of parts, produced with pulsating blankholder force is in the range of the wrinkle height of parts produced with a constant blankholder force which is equal to the maximum force of the pulsation.

Longitudinal models are used to evaluate different vehicle-engine concepts with respect to driving behavior and emissions. The engine is generally map-based. An explicit calculation of both fluid dynamics inside the engine air path and cylinder combustion is not considered due to long computing times. Particularly for dynamic certification cycles (WLTC, US06 etc.), dynamic engine effects severely influence the quality of results. Hence, an evaluation of transient engine behavior with map-based engine models is restricted to a certain extent. The coupling of detailed 1D-engine models is an alternative, which rapidly increases the model computation time to approximately 300 times higher than that of real time. In many technical areas, the Fourier transformation (FT) method is applied, which makes it possible to represent superimposed oscillations by their sinusoidal harmonic oscillations of different orders.

In order to meet increasingly stringent exhaust emission regulations, new engine concepts need to be developed. Lean combustion systems for stationary running large gas engines can reduce raw NOx-emissions to a very low level and enable the compliance with the exhaust emission standards without using a cost-intensive SCR-aftertreatment system. Experimental investigations in the past have already confirmed that a strong reduction of the charge air temperature even below ambient conditions by using an absorption chiller can significantly reduce NOx emissions. However, test bench operation of large gas engines is costly and time-consuming. To increase the efficiency of the engine development process, the possibility to use 0D/1D engine simulation prior to test bench studies of new concepts is investigated using the example of low temperature charge air cooling. In this context, a reliable prediction of engine efficiency and NOx-emissions is important.

In recent years, driving simulators have become a valuable tool in the automotive design and testing process. Yet, in the field of vehicle dynamics, most decisions are still based on test drives in real cars. One reason for this situation can be found in the fact that many driving simulators do not allow the driver to evaluate the handling qualities of a simulated vehicle. In a driving simulator, the motion cueing algorithm tries to represent the vehicle motion within the constrained motion envelope of the motion platform. By nature, this process leads to so called false cues where the motion of the platform is not in phase or moving in a different direction with respect to the vehicle motion. In a driving simulator with classical filter-based motion cueing, false cues make it considerably more difficult for the driver to rate vehicle dynamics.

In cooperation with industrial companies at the Institute for Metal Forming Technology (IFU) of the University of Stuttgart, Germany, a new press concept specially for hydroforming tubes and extrusions was developed. The press has a capacity of 3500 tons closing force and a press table size of 2500 mm × 900 mm. A great reduction in costs can be achieved by integrating spacers between the frame of the press and the ram. This paper introduces this new press.

A physically based model to predict the amount of snow which is entering the air intake of an automobile is extremely important for the automotive industry. It allows to improve the air intake system in the development state so that new vehicles can be developed in a shorter time. Using an Eulerian/Lagrangian approach within a commercial CFD-software we set up a model and calculated the snow ingress into an air intake of an automobile. In our numerical investigations we considered different particle shapes when calculating the drag coefficient, different coefficients of restitution and different particle sizes. Furthermore two-way coupling was considered. To obtain key parameters for the simulation, we measured the size of snow particles in the Daimler climatic wind tunnel in Sindelfingen by using a microscope and a measuring device from Malvern. Besides we used mechanical snow traps to determine the snow mass flux in the climatic wind tunnel and on a test area in Sweden.

In automotive open-jet wind tunnels reference velocity is usually measured in terms of a static pressure difference between two different cross-sectional areas of the tunnel. Most commonly used are two sections within the nozzle (Method 1: ΔP-Nozzle). Sometimes, the reference velocity is deduced from the static pressure difference between settling chamber and plenum (Method 2: ΔP-Plenum). Investigations in three full-scale open-jet automotive wind tunnels have clearly shown that determination of reference dynamic pressure according to ΔP-Plenum is physically incorrect. Basically, all aerodynamic coefficients, including drag coefficient, obtained by this method are too low. For test objects like cars and vans it was found that the error ΔcD depends on the test object's drag blockage in an open-jet wind tunnel.

For the NOx removal from diesel exhaust, the selective catalytic reduction (SCR) and lean NOx traps are established technologies. However, these procedures lack efficiency below 200 °C, which is of importance for city driving and cold start phases. Thus, the present paper deals with the development of a novel low-temperature deNOx strategy implying the catalytic NOx reduction by hydrogen. For the investigations, a highly active H2-deNOx catalyst, originally engineered for lean H2 combustion engines, was employed. This Pt-based catalyst reached peak NOx conversion of 95 % in synthetic diesel exhaust with N2 selectivities up to 80 %. Additionally, driving cycle tests on a diesel engine test bench were also performed to evaluate the H2-deNOx performance under practical conditions. For this purpose, a diesel oxidation catalyst, a diesel particulate filter and a H2 injection nozzle with mixing unit were placed upstream to the full size H2-deNOx catalyst.

Cars cause a lot of pollutants during the utilization phase. Within the last years environmental legislation tried to reduce the emissions by the introduction of very tight laws. The results are impressive: Most of the car exhaust emissions like carbonmonoxid and nitrous oxides have been reduced. At this stage new emission reduction limits in Europe as well as in the United States can only be achieved if the formulation of the catalyst system is significantly changed. An increased use of precious metals and rare earth materials is the result of such a modification which succeeds in a more expensive design of the total catalyst systems. More expensive means not only cost aspects but also the environmental burdens related to the increased production of precious metals and other catalyst components. The Life Cycle Engineering (LCE) of the catalyst system which achieves the new legislation is demonstrated as well as the effects to the usage phase.

There is a growing need for low-emissions concepts due to stricter emission regulations, more stringent homologation cycles, and the possibility of a ban on new engines by 2035. Of particular concern are the conditions during a cold start, when the Three-Way Catalyst is not yet heated to its light-off temperature. During this period, the catalyst remains inactive, thereby failing to convert pollutants. Reducing the time needed to reach this temperature is crucial to comply with the more stringent emissions standards. The post oxidation by means of secondary air injection, illustrated in this work, is a possible solution to reduce the time needed to reach the above-mentioned temperature. The strategy consists of injecting air into the exhaust manifold via secondary air injectors to oxidize unburned fuel that comes from a rich combustion within the cylinder.