Design Analysis

Analysis at MAHLE Powertrain

In an industry where time to market is so important and reducing the number of prototype engines and development phases is vital, use of virtual prototypes is a necessity.
Early in the engineering programme, predictive analysis provides a means of optimising the design with regard to fluid flow, mechanical and thermal stresses, stiffness, weight and material choice.

Our Approach

MAHLE Powertrain's team of engineers have extensive experience in conducting Computer Aided Engineering (CAE) analysis of many powertrain systems and components, and have access to the worlds leading simulation tools and high performance computing resources.

The main systems routinely analysed are:
  • Engine performance
  • Cranktrain
  • Base engine
  • Valvetrain
  • Cooling system
  • Intake system
  • In-cylinder and combustion systems
  • Exhaust system
  • Ancillaries
  • Powertrain
  • Whole vehicle (drive cycle)

Our Tools, Facilities and Services

A wide variety of tools and analysis methods are used to carry out the simulations. The different methods employed at MAHLE Powertrain are:

  • 1D drive cycle simulation for modelling the fuel consumption, and hence carbon emissions, of vehicles over various drive-cycles
  • 1D cycle simulation for prediction of engine torque, power and brake mean effective pressure (BMEP) and optimisation of intake and exhaust runners, valve timing and turbo matching
  • 1D fluid flow for analysis and optimisation of oil, cooling and breather circuits
  • Computational Fluid Dynamics (CFD) to analyse and reduce pressure losses in the intake, exhaust and cooling system, to predict coolant heat transfer and to model in-cylinder charge motion for optimisation of the combustion system
  • Multi-body Dynamics for the prediction of the dynamic behaviour of cranktrain, valvetrain and timing drive systems
  • Finite Element Analysis (FEA) for the calculation of component and assembly stiffness, stress and natural frequency
  • Fatigue Analysis for the prediction of component durability
  • Noise Vibration and Harshness (NVH) analyses for the prediction of vibration levels by means of forced response analyses and radiated noise using Boundary Element (BE) techniques


AVI Files

Below are some small avi files that demonstrate some of our analysis techniques.

This animation graphically shows the inside of a working engine showing air flow, fuel injection, combustion and exhaust. This is a purely graphical representation and not from an analysis.

This animation shows the exhaust gas flow through a turbocharger. The small balls give a visual aid to the flow and are colour coded by gas velocity.

This animation shows fuel being sprayed into the cylinder of an engine. The fuel is colour coded by velocity and the particle size represents the fuel droplet size. As the fuel evaporates and mixes with the air the droplets get smaller.

This animation shows the stress in an exhaust manifold as it heats up and cools down.

This animation shows the stresses and exaggerated deformations of a crankshaft during an engine cycle. The rotation of the crank is removed.

This animation shows the stresses in a cylinder head as the cylinder head bolts are tightened up and the valve guides are seats are inserted.

This animation shows the temperatures in a cylinder head as it heats up and cools down