INTEGRATED APPROACH TO AN OPTIMAL AUTOMOTIVE TIMING CHAIN SYSTEM DESIGN

Ensuring engine efficiency is a crucial issue for automotive manufacturers. Several manufacturers focus on reducing the time taken to develop and introduce brand new vehicles to the market. Thus, a synergic approach including various simulations is generally adopted to achieve a development schedule and to reduce the cost of physical tests. This study involved proposing a design process that is very useful in the preliminary development stage through effective support from simulations. This type of simulation-based design process is effective in developing timing chain drives; the use of this process, based on results from multiple trials, showed improvements in performance including low friction and vibration, improved durability, and cost-effective part design when compared to conventional processes. This study proposes an integrated approach to the preliminary design of an automotive timing chain system. The approach involves structural and dynamic analyses. The details of the design process are described by using the case of a virtual engine. This study conducted and summarized a dynamic and structural analysis as well as topological optimization to describe a process to obtain optimal results. The results of this study indicated the following improvements in overall performance factors: 12.1 % improvement in transmission error, 10.1 % reduction in chain tension, 46 % reduction in tensioner arm weight, and 11 % reduction in transversal displacement.