Case Study: Design and Validation of the L6 Block Peggy Jones, Ph.D GM Powertrain Materials Engineering-CDVC, Saginaw, MI, USA Dean Weed, Paul Crepeau, Ph.D. GM Powertrain, Pontiac, MI, USA The design and validation process used for the L6 block is reviewed from both the product and materials engineering viewpoints. Products are designed with 3-D Unigraphics models. These models are used to perform thermal and stress analysis, as well as casting solidification analysis. Concurrent engineering of the product and tool design is necessary to take full advantage of the complex geometric capabilities of the process.In the structural design, assembly as well as operational thermal and mechanical loads must be accounted for. In particular, a thorough understanding of the fatigue properties of the casting is required. Verification and validation of the design is accomplished via Finite Klement Analysis, component testing, engine dynamometer testing, and detailed metallurgical testing. |