Cylinder head test bench

Cylinder head test bench

Task

Our cylinder head test benches can be used to perform time-lapse simulations
of the thermo-mechanical fatigue (TMF) cycles for cylinder heads
in the lab in order to verify the TMF strength of test items.

Test stand

The test facilities employ burner units which run on a propane-oxygen
mixture. Each one contains six separately adjustable burners on which
cylinder heads of various dimensions can be continuously tested at a high
performance level.
The test item is mounted on a dummy crankcase, which has been designed
and optimised using computational fluid dynamics (CFD) to create
flow conditions in the cooling channels of the cylinder head identical to
those which exist in the running engine.
The test items can be quickly brought to operating temperature and be
cooled using tempered glycol-water mixtures in user-defined and selectable
cycles. There are two separate coolant circuits, each set to a
different inlet temperature so that the cooling curves can be adapted to
the required conditions. All facility components are designed for automated,
continuous operation.
The open structure permits inspection during continuous tests with interruptions
of just minutes. A digital camera system is also employed to
detect and document fractures. The test bench can be controlled automatically
via a user interface. The test chamber is connected to a control
room, a separate assembly zone and a storage room.
IAGB provides these testing services, including the design and CFD-optimisation
of adaptation parts for clients in the automotive, power engineering
and shipbuilding industries.

Benefits

The cylinder heads can be tested at very early stages of development
without the need for the entire engine.
Both the duration as well as the costs of the tests are significantly lower
than those for tests using common engine test benches.
During the test phase, an automated digital camera system can be used
to detect and document cracks and fracture development. This leads to
faster and more precise test results with regard to service life and fracture
development, allows for multiple tests with different parameters and
provides statistical proof of test results based on a high number of test
runs. This opens up new options for validation and optimization of mathematical
methods.
The test stands may be used for passenger car and commercial vehicle
engines, ship engines or heavy-duty gas engines used in the power generation
industry.
IAGB‘s innovative test methodology can help shorten development cycles
and significantly reduce the amount of time and cost intensive engine
endurance tests. Using the new quasi continuous crack inspection, simulation
models can be validatet and optimised significantly. So, the quality
of both simulation and test resluts can be improved significantly. This
gets more and more important as as the power output per liter increases.