Manufactring Design Porcess

Engine Design and Analysis
Southwest Research Institute®(SwRI®) has more than
three decades of experience in engine design and
analysis that includes:
• “Clean sheet” engine design from concept to
production release
• Engine upgrades or conversions for increased power,
improved fuel economy, and reduced emissions
• Vehicle integration
• Design reviews
• Product and process troubleshooting
• Technology transfer
• On-road, off-road, light-duty through high horsepower
SwRI engineers use a variety of sophisticated tools and
techniques in a production-centered approach to evaluation
and development of unique engine concepts, analyses of
engines and engine components, and problem-solving.
SwRI’s engine design team has specialized expertise gained
through work for more than a dozen engine manufacturers.
The results are robust, low-friction engine designs based
on experience with support from simulation and analysis
software, produced with very short cycle times.
The team has extensive expertise in applying computeraided
engineering (CAE) tools for production intent as
well as research-oriented designs. The following CAE
analysis techniques are applied in the design process for
components, engines, drivetrains, and vehicle subsystems:
• Solid modeling/computer-aided design (CAD)
• Engine performance simulation
• Finite element analysis (FEA)
• Classical analysis
• Dynamic system simulation
• Computational fluid dynamics (CFD)
• Fluid flow system simulation
• Probabilistic reliability
• Fatigue and life prediction
• Noise, vibration, and harshness (NVH)
• Rapid prototyping and tooling
SwRI engineers
use 3-D parametric CAD
modeling and an experience-based analysis
approach to design production-quality clean sheet engines.
SwRI maintains a specialized facility for noise source and signal analysis, modelbased
simulation, structural dynamics, and sound quality evaluation.
SwRI engineers use computational fluid dynamics to analyze coolant flow through a cylinder head
water jacket to predict temperatures in solid models. Combined with FEA, relative analysis, and
proprietary design guidelines, this technique is used to ensure structural durability.
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Southwest Research Institute technology data sheet

Mechanical Simulation
Simulation is performed by experienced staff with an understanding of constraints
often imposed by manufacturing parameters. To simulate the kinematic
and dynamic performance of engine mechanisms, SwRI engineers balance
technological solutions with practical experience in their approach to client projects.
Analyses can be performed independently or coupled with parametric solid
modeling, finite element analysis, tribology, and cycle simulation software.
Noise, Vibration, and Harshness
SwRI engineers use established and evolving techniques to design quiet
engines. Our globally recognized staff has extensive experience in engine noise
evaluation and assessment, source and path evaluation, as well as component
design and remedial action to suppress noise.
Probabilistic Reliability
In an effort to develop faster, better, and more cost-effective ways to design,
manufacture, and maintain engine systems, SwRI engineers have pioneered the
integration of advanced reliability methods and failure models.
Rapid Prototyping
Rapid prototyping (RP) is used to create production-intent hardware suitable for
engine development testing while production tooling is being developed. This can
substantially improve total time to market and reduce product development costs.
SwRI’s in-house RP capabilities include direct computer numerically controlled
(CNC) machining and a fused deposition modeler (FDM) machine that builds
models in ABS plastic. A selective laser sintering (SLS) machine is also available
to model in different materials at higher speeds.
SwRI has designed multiple prototype research engines
including this customizable single-cylinder engine used for
combustion and friction research.
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We welcome your inquiries.
For additional information, please contact:
Douglas C. Eberle
Manager, Engine Design & Analysis
(210) 522-5260
douglas.eberle@swri.org
Engine, Emissions & Vehicle Research Division
Southwest Research Institute
6220 Culebra Road • PO Drawer 28510
San Antonio, Texas 78228-0510
swri.org
enginedesign.swri.org
SwRI and Grainger & Worrall (GW) received a 2012
R&D100 award for a patented casting technology that
enables manufacturing of cylinder heads with much higher
peak pressure capability for high efficiency.
enginedesign.swri.org
Find us on
Southwest Research Institute is an independent, nonprofit, applied engineering and physical sciences research and
development organization using multidisciplinary approaches to problem solving. The Institute occupies 1,200 acres
in San Antonio, Texas, and provides more than 2 million square feet of laboratories, test facilities, workshops,
and offices for nearly 3,000 employees who perform contract work for industry and government clients.
SwRI Business Development • San Antonio, Texas • (210) 522-2122 • bd@swri.org
© 2015 Southwest Research Institute. All rights reserved.
An Equal Opportunity/Affirmative Action Employer • Minority/Female/Disabled/Veteran • Committed to Diversity in the Workplace
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