Profile

The analysis engineers at Delphi work with 3D, 2D and 1D models to simulate the fuel flow through the pumps and injectors using Computational Fluid Dynamics (CFD) and also assess the structural integrity of each of our components using Finite Element Analysis (FEA).

Personally, I work in the Fluids and Systems team, meaning that I work primarily with the fluid simulation.  Being able to simulate and predict how a product will work and respond before any manufacturing is done is important to the business as it saves money on buying multiple prototypes, and saves time having them produced.  Simulations also allow us to see detail which would otherwise be unmeasurable in a test rig or on engine tests and predict where products might fail, allowing us to change or optimise a design before it’s ever made.

Simulations vary in size and detail:

3D – Large three dimensional simulations use the CAD (Computer Aided Design) models to create geometry where we set the fluid inlets and outlets so we can assess what happens between them.  This means that we can look at parts of the product which we wouldn’t be able to see or measure if they were manufactured and tested.

2D – Sometimes, when geometry is symmetrical, we can run 2D simulations that will let us predict a cross section of the product.  These often give a similar result as a 3D model but take much less time to set up and run, sometimes saving us weeks at a time.

1D – One dimensional simulations are quite different.  Though they use the geometry of the components, they don’t use the CAD models.  1D models are essentially a system of equations which solve together to simulate full pumps or injectors.  Though not as detailed as the 2D or 3D models, they can run whole fuel systems in under 30 seconds, making them very beneficial to us.

A lot of the time during school and even my degree, I struggled to see why I was learning particular things without being given a practical example; I’ve always found it easier to remember an equation if I understand why I need it and what it does.  I’m under the assumption I’m not the only one.

It’d be great if I (maybe with a little help) could create a set of models or demonstrations which use some of the things commonly taught in the curriculum in real-world applications, hopefully helping other curious minds understand why they need particular information or skills as it’s not always obvious at the time.