Page 8 of catalogue Cylinder head covers of Reinz-Dichtungs-GmbH

The virtual test bench 2: 3D analyses for optimum cylinder head cover design In this analysis, the results of the 2D computer testing (characteristics of cylinder head cover gasket and isolating elements) are combined with the cover module’s CAD data to obtain a complete 3D model of cylinder head cover, gasket, Bolts, isolating elements, and cylinder head. This model provides very precise information on the mechanical stresses in the cylinder head cover, especially the deflection between the bolts that could create leak locations. In this way, the ideal working range of the cover gasket and the rigidity of the cylinder head cover module can be determined in several cycles for different cylinder head cover designs, including different wall thicknesses or additional ribbing. The analyses are carried out both at room temperature and at extreme temperatures (-30° C/ -22° F and +150° C/+302° F).

The virtual test bench 3: Modal analysis combats noise To prevent a cylinder head cover module from vibrating at undesirable resonant frequencies, it can be examined with time-consuming shaker tests and subsequent step-by-step optimization. VICTOR REINZ employs fast and sophisticated modal analysis. First, material and structural properties are determined with FEA simulations. Based on a 3D model of the CAD data that takes the mounting points into account, we generate a grid network with vibration characteristics that deliver precise information on resonant frequencies – and the intrinsic stiffness of the cylinder head cover module. In this way, every cylinder head cover module can be constantly improved, speeding up development significantly. If the model exhibits areas that would oscillate at a critical frequency – such as 200 Hz, a typical limiting frequency for four-cylinder Diesel engines – this behavior can be eliminated by defined stiffening ribs, modifying reinforcements, or adding mounting points. This ensures that the first prototype absorbs noise reliably without producing any noise of its own.

The virtual test bench 4: Mold-filling simulations for even better process reliability Mold-filling simulations are rheological, thermal, and structural-mechanical analyses that ensure both the cylinder head cover module design and manufacturing process are as efficient as possible. Filling analyses simulate the injection process even before the first injection mold is built, to ensure it will be filled completely. As a result, the gate point, necessary filling pressure, mold temperature, and other process parameters can be optimized. Evaluation of mold tempering, also known as cooling analysis, allows precise evaluation of the solidification process from mold to demolding. With technical thermoplastics, a balance must be found between uniform cooling and an adequate but not excessive injection cycle time. This helps to minimize cycle times, so time and cost savings can be realized at a very early stage in development.

Detecting component stresses: 3D-analysis of the composite system of cylinder head cover, gasket, bolts, isolating elements, and cylinder head reveals critical areas.

Modal analysis combats noise: Determination of resonant frequencies and the oscillation curves of a cylinder head cover module.

Filling analysis delivers improved process reliability, shorter cycle times, better quality, and reduced costs.

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