Blue Room - Session 3

1:00 to 2:00 p.m. Tuesday April 21, 2015

Reliability Study of Engine Cooling Radiators Undergoing Pressure Pulsation Fatigue Loadings

The high level of competitiveness of the automotive industry requires new product development to be faster and cheaper; the capability to predict in-service durability assumes therefore a fundamental importance during the design validation phase. A first general design of reliability is achieved both theoretically (structural simulation) and experimentally (bench tests). This procedure enables us to quickly detect the weak parts of the component, to highlight the areas of probable failure and to predict the mechanical endurance. Moreover, it is possible to adapt the component robustness to the customer specification and avoid the risk of an oversized design.

In the framework of improving the reliability of its components, Valeo Thermal Systems has recently established a procedure that permits us to determine, for any given product: a) the estimated fatigue life, b) the response to in-usage stress loadings and c) the correlation between simulation predictions and endurance test results. Focusing on one particular in-service damage loading (pressure pulsation), this presentation illustrates how the above mentioned procedure has been applied in order to define the reliability of three engine cooling radiators (including new innovative technology).

Key Words: Design for Reliability, Experiment Design and Analysis (DOE), Automotive, Test & Simulation Correlation, Engine Cooling Components

Marco Bonato, Philippe Goge, David Delaux and Arnaud Maire

Valeo Thermal Systems