Verification and Analysis

Applying world-class simulation tools and techniques to build high confidence in the earliest project phases.

Our Value Add

  • State-of-the-art Computer Aided Engineering (CAE) software packages
  • World leading simulation tools and high performance computing resources
  • Extensive experience in the detailed analysis and correlation to measurement data of major powertrain systems 

Our Tools, Facilities and Services

  • 1D drive cycle simulation (GT-Drive) of fuel consumption and carbon emissions
  • 1D cycle simulation (GT-Power) of engine performance and fuel economy
  • 1D fluid flow for analysis of oil and cooling systems: GT-Suite, Flowmaster

  • Computational Fluid Dynamics (CFD) for analysis of heat transfer, pressure loss, flow and in-cylinder charge motion: CD-Adapco Star-CD / CCM+
  • Multi-body Dynamics for analysis of dynamic behaviour: GT-Vtrain, AVL Excite, Abaqus, MSC Nastran
  • Finite Element Analysis (FEA) for stress / strain calculations: Abaqus, Altair Hyperworks, ECS FEMFAT, MSC Patran, MSC Nastran, PERMAS
  • Fatigue Analysis for structural and component durability
  • Noise Vibration and Harshness (NVH) analysis

Customer Benefits

  • Sophisticated software tools for accurate, repeatable results
  • Proven correlation with physical tests
  • Opportunities for virtual prototyping to delete physical builds
  • Significant time and cost savings potential

 Project Examples

  • Dynamic analysis of cranktrain / valvetrain / timing drive
  • Fluid network analysis of oil / cooling circuits and complete engine thermal model
  • Structural analysis (FEA) for design guidance and verification
  • CFD analysis for airpath optimization, cooling jacket design and complete combustion system development

Our Value Add

  • Applying 1D simulation for the investigation of new engine concepts
  • Achieving optimal solutions regarding cost, packaging and project timing
  • Correlating models to initial test data for enhanced accuracy

 Our Tools, Facilities and Services

  • ‘GT-Power’ from Gamma Technologies for 1D cycle simulation
    • Gamma Technologies is the developer of GT-SUITE, a Model-Based Systems Engineering (MBSE) CAE system simulation tool. It provides a broad set of validated 0D/1D/3D multi-physics component libraries simulating the physics of fluid flow, thermal, mechanical, multi-body, structural, electrical, magnetic, chemistry, and controls.  Utilizing these libraries, models can be built of practically any engineering system. MAHLE Powertrain and Gamma Technologies have joined forces to offer their customers reliable advanced simulation services based on the experience that MAHLE Powertrain has developed over many years of providing consulting support to the industry.
  • Design of Experiments (DoE) techniques for complex, multi-dimensional tasks
  • GEM3D to construct detailed 1D analysis models from CAD data
  • GT-Power coupled to CFD models for flow investigation in key areas
  • GT-Drive to generate fuel consumption maps for use in drive cycle simulations
  • Simulation of intake / exhaust pressure pulses for predicting acoustic behaviour
  • GT-Power coupled to Simulink® models for ‘Software in the Loop’ calibration studies

Customer Benefits

  • Fast and effective investigation and optimisation of new engine concepts
  • Access to detailed information on gas dynamic effects within the engine
  • Gain an in-depth understanding of all engine functions
  • Rapid investigation of changes to improve engine performance
  • Generate key performance parameters to support first prototype build 

Download here our brochure for more information. [PDF; 269 KB]

Our Value Add

 A complete service for engine mechanical development and validation including:

  • Design and carrying out of complete engine development programs, on dyno and in vehicle
  • In-depth investigation into identified problems
  • Determination of test quantity and specification to achieve target reliability level
  • Specific component measurement techniques

 Our Tools, Facilities and Services

  • Test schedules of previous development programs used in conjunction with design critiques and FMEA methodology
  • Engine dynamometers, rig and vehicle tests
  • Recommendations based on functional test results to generate improvements
  • Durability and validation tests with engines assembled to specific design limits and with a high degree of component measurement
  • Assessment of wear levels after durability testing
  • Determination of engine health

 Customer Benefits

  • Improved understanding of root cause and conditions of failure
  • Integration of test plans in early design phases of new powertrains