Simulation by order of HENN GmbH & Co. KG

Sector: Automotive supplierSpecialist field: Acoustics, Multiphysics, Structural mechanics

Summary
Project Details
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Summary

Task

For the optimization of a muffler connected between a turbo charger and an automotive pipe, three key applications involving miscellaneous physics had been selected:
1. strength and tightness of the closing mechanism,
2. flow induced deformations, pressure loss,
3. customization of the acoustic transmission loss.

Solution

As a consulting project CADEM analyses were performed with Ansys FEM, Ansys CFD and a parametric model structure and fluid behavior as well as acoustic transmissions. This was followed with a know-how transfer that allowed HENN engineers to run further simulations and perform virtual prototyping on their own.

Customer benefits

Dramatically reduced number of prototypes, thus ensuring a short development cycle while reducing the R&D costs and increasing product quality while reducing production costs.

Project Details

Task

HENN is producing innovative connection technology including mufflers for the automotive industry. Numerical prototyping was being considered in order to accelerate the development process while increasing product quality. Key applications involving miscellaneous physics had been selected:
1. strength and tightness of the closing mechanism,
2. flow induced deformations, pressure loss,
3. customization of the acoustic transmission loss.
These cases were given to CADFEM in order to allow for a progressive, safe and robust entry into numerical prototyping including pilot projects, know how transfer and software support.

Fig. 2: Structural stresses and deformations of connector mechanism and muffler.

Customer Benefit

In house virtual prototyping:

ability to automatically generate custom muffler designs to address specific transmission loss requirements in a few days instead of a few weeks
dramatically reduced number of prototypes, thus ensuring a short development cycle while reducing the R&D costs
increased product quality while reducing production costs
safe and progressive introduction of state of the art simulation technologies thanks to a dynamic trade-off between the use of CADFEM and in-house resources.

Courtesy of HENN GmbH & Co. KG

Fig. 1: Composite image from fluid, structure and acoustic analyses of a muffler connected between a turbo charger and an automotive pipe. Streamlines colored with velocity, walls with pressure or deformation and iso-surfaces from sound pressure level.

Solution

Ansys FEM structural analyses involving non-linear frictional contacts, hardening and hyper-elastic material laws were used to compute structural deformations, stresses and contact pressures under realistic conditions for the connecting mechanism (Fig. 2). An Ansys CFD analysis was used to compute pressure losses. The resulting pressure field was applied on a structural model in order to obtain structural deformations and stresses (Fig. 1). Optimizations based on a parametric model of the acoustic transmission loss measurement setup allowed the generation of custom designs automatically according to target transmission loss profiles (Fig. 3) and size reduction objectives. Consulting projects were followed by know-how transfer that allowed engineers at HENN to run further simulations and perform virtual prototyping on their own.