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Quest for the 200-mpg Car A ev ti na y inte na c mb sti n engine gives ise t a s pe mi eagevehic e with the p tentia t t ansf m a t m tive design.By Heinz-Gustav Reisser, CEO, Niama-Reisser, LLC, Coshocton, U.S.A.

The N-r 1 s pe mi eage vehic e isexpected t pe f m at an ext eme yhigh eve f efficiency: t ansp tingf ad ts 200 mi es at 70 mi espe h n n y ne ga n f f e .This vehic e and its engine, pa t fthe ev ti na y fami y f high- efficiency Cent if ga Heinz B xe(CHB) engines, a e being deve ped

by Niama-reisse , l lC, in theu ited st te .

Niama-reisse is a vehic e andp p si n se vice c mpany with adedicated enginee ing depa tmentspecia izing in c ns ting, esea ch anddeve pment f inte na c mb sti nengine design, maj s bsystemsand enti e vehic es. uti izing ANSYSFluENT s ftwa e f f id f w and

ANSYS Mechan ica techn gy f

st ct a and the ma sim ati ns,

the c mpany ffe s a wide ange fse vices f c st m enginee ingp jects. It a s c nd cts ng ing

esea ch and deve pment p jectsn inn vative c ncepts.

In deve ping the s pe mi eagevehic e, enginee s sed ANSYSFluENT s ftwa e t dete mine d agc efficient f m tip e ve si ns f

the N-r 1 vehic e b dy she , savings ign i f i can t t ime and expensec mpa ed t b i ding and testingn me s physica p t types.Expe imenta wind-t nne es tsc se y va idated ana ysis tp t andenab ed enginee s t a ive at anae dynamica y ptimized design.using the s ftwa e, the deve pmentteam we ed the d ag c efficientf m 0.33 f the initia vehic e b dy

she design t ess than 0.28 f thec ent ptimized design.The CHB engine bea s i t t e

simi a ity t t aditi na inte nac mb sti n engines, in which

pist ns m ve p and d wnin a ecip cating inea

m ti n. In c nt ast, aset f pp sing t s-

shaped pist ns in theCHB sc i a t e in

ro t r mo t io .Inc eased efficiency is

attained sing tw c m-p essi n st kes pe c mb sti nchambe t tate the c ank shaft. Inadditi n, a patented kinematic c ntmechanism and inkage a te the

Prototype CHB engine attains high efficiencywith on-the-fly adaptive compression ratio,engineered composite material componentsand fewer parts.

Stress distribution of the CHB engine housingoverlaid on the geometry and mesh of the

ANSYS Mechanical model

engines c mp essi n ati n the f ywhi e in pe ati n. Pe f mance isf the b sted th gh the se fenginee ed c mp site mate ia s that

eq i e n b icati n iq id c antt maintain p pe pe ating tempe -at es. Fewe m ving pa ts, s ch asw ist pins, va ves, wate p mp and ip mp, ead t a 30 pe cent ed cedpa t c nt and an inc eased enginep we -t -weight ati .

Fluid flow analysis helped engineers toreduce drag coefficients on the prototypeN-R 1 body shell.

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T st dy the c mb sti n andthe ma behavi f the CHB, engi-nee s sed p edefined defa ts tc eate a m ving and def ming mesh(MDM) t set p in-cy inde gas f wcha acte istics f m tip e f idst ct e inte acti n (FSI) ana yses. Inthese st dies, mass ai f w wasdete mined efficient y sing c mp ex

ANSYS FluENT ana ysis f m ethan 12 mi i n e ements. With this f idm de , enginee s c d effective yana yze in-cy inde c mb sti n tachieve a h m gene s mixt e and

ptima b n. This, in t n, yie ded thehighest-p ssib e efficiency f a givenf e mixt e.

AN SYS Mecha ni ca s f twa ewas a s an integ a pa t f the CHBdeve pment eff t. In ne stage fthe p ject, the enginee ing team

sed the s ftwa e t ana yze pist nst esses whi e app ying ea istic

ads nt the pist n face and

In-cylinder gas flow characteristics simulated with CFD

Mass air flow represented in cylinder linersfor heat distribution purposes

Engineers used ANSYS Mechanical software to determine stress distribution in engineeredcomposite material pistons, which oscillate in a rotary motion.

inc p ating f icti na c efficientsbetween the cy inde b e and thepist n mante . In pa tic a , enginee sf c sed n enginee ed c mp sitemate ia c mp nents t dete minethe feasibi ity f va i s designs andt identify imminent st ct a fai e.In these cases, when c mp sitemate ia c mp nents a e st died in

e ati n t adjacent meta pa ts,c ntact e ements we e sef inm de ing t ching pa ts f dissimi amate ia s. A s , pa amete izati n fsim ati n m de s and bidi ecti nac nnectivity with CAD s ftwa e we eimp tant t ef ect changes inc mp nents dimensi ns s thatsensitivity st dies c d dete minethe best design in te ms f pe f -mance, e iabi ity and mate ia c sts.This app ach saves c nside ab etime in physica p t type testing and

eads t ptima designs that a e imp actica t exp e with m ck ps.

In this ana ysis, the enginee simp ted c mp nent ge met y f m

the CAD system sing the ANSYSDesignM de e t . This techn gywas fast, seam ess and he pf intasks s ch as s face sp itting tp epa e the ge met y f meshing.The sim ati n m de was c eated

sing m tip e settings s ch astet ahed a hex-d minant meshesmade with the ANSYS W kbenchmeshing app icati n. B nda yc nditi ns (c nst aints, c ntacts,

j ints, ads, etc.) we e then definedsing ANSYS Mechanica techn gy.

F wing the st ct a ana ysisstage, enginee s sed the enginee edc mp site mate ia c mp nentsm d e g e n e a t e d b y A N S Y SW kbench f an ANSYS Mechanicathe ma ana ysis. D e t the diffe encein expansi n c efficients, this is ve yimp tant f app icati ns in whichcy inde ine s a e c mp sed fc mm n meta a ys. The sim ati nis pe f med t ens e p pe pist nb e gapping d ing n ma pe atingtempe at es, which ange f m 450deg ees t 1,100 deg ees C.

Eng inee s f nd the se -f iend iness and speed f ANSYSMechanica t be tw f the m stimp tant advantages f p d ctsf m ANSYS. The es ting efficiencyin s ftwa e se a wed the Niama-reisse enginee ing depa tment t

eadi y c nd ct a se ies f ite ative

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sim ati ns t efine the design, th sav iding n me s t ia -and-e

p t type test cyc es. Indeed, p t -typing c sts p ima i y in thedeve pment f the CHB enginefami y have been ed ced60 pe cent since the int d cti n f

ANSYS p d cts at the c mpany.Niama-reisse has emp yed

ANSYS Mechanica capabi ities f awide ange f the p jects withsignificant advantages ve thep evi s y sed st ct a ana ysis

s ftwa e. In st ct a beam app i-cati ns, s ti n times have beentypica y ed ced 70 pe cent t 100pe cent with ANSYS Mechanica ,which a s p vides m ch faste andm e stab e p b em c nfig ati ns.

These advantages we e evident inyet an the app icati n, an inn vativetw -in- ne t ai e design that se vesas a g seneck t ai e c nnected t

a t ck bed an attchment t adead-weight b mpe t ai e hitch.The p evi s ana ysis s ftwa e p at-f m had diffic ties in c eating the3-mm fine mesh needed f detai edana ysis; the p g am c ashed ften

Structural beam analysis of two-in-one trailer design

beca se f ng c mp te timesand meshing diffic ties. M e ve ,m tip e sepa ate steps had t bepe f med t set p a cy ind ica

c dinate system necessa y fthe ana ysis. In c nt ast, ANSYSMechanica s ftwa e p vided thec ean, st aightf wa d se inte face

eq i ed t easi y set p s chp b ems with the c ick f a m se. n

Selecting the Right Software for the Job

Niama-reisse an s bstantia benchma king tc mpa e c mp tati na f id dynamics (CFD)s ftwa e ffe ings and se ected the ANSYS FluENTp g am f w k s ch as dete mining d agc efficients f vehic e ae dynamics and ana yzingf id f w inside engine cy inde s f pist nc ing st dies.

Fluid dynamics studies helped lower drag coefficientsfor vehicle body shell.

o tstanding c st me s pp t f m ANSYStechnica s pp t staff in these c mp ex app icati nsand s bseq ent excepti na f id f w sim ati n

es ts gave enginee s high c nfidence in p d ctsf m ANSYS. The s ccesses with f id f w app i- cati ns p mpted Niama-reisse t switch f m aCAD-based finite e ement package t ANSYSMechanica s ftwa e f st ct a and the maana ysis. The p -ANSYS decisi n was based nseve a c mpe ing eas ns, inc ding:

S bstantia y dec eased p cessing times with ANSYS s ftwa e, typica y bey nd 50 pe cent

Bette meshing capabi ities ega ding imp vede ement t ansiti ning and highe meshdensities in detai ed egi ns f the m de

Abi ity t hand e a ge assemb ies efficient ywith high-pe f mance c mp ting

B ad base f integ ated s ti ns in the ANSYS p d ct p tf i

St aightf wa d inte face and ease f se inapp ying feat es f c mp ex p b ems