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Today, Computer Aided Engineering (CAE) has become an essential part in the development of Thermal-Acoustical Protective Shields (TAPS). As presented three years ago, such a theoretical approach has been able to reduce the development cycle of TAPS while simultaneously reducing costs. Using the approach as previously presented gave us an opportunity to learn more and upgrade the approach with more modules. These modules are focused not only on obtaining better accuracy but also adding information about processes and function of the TAPS. Besides those parameters we are now able to look up-front into the visual appearance of the product using simulation techniques. This paper will describe this updated CAE approach, with a main focus on the new added techniques and modules. This paper will also describe how the results of the approach are used in the development of new TAPS and how we verify the theoretical results by the means of experimental techniques.

Thermal Acoustic Protective Shields (TAPS) serves dual purpose. They provide a thermal barrier, which protects sensitive components from the exhaust manifold radiated energy. They also act as an acoustic insulator, which reduces the amount of sound power transmitted from the engine to the environment. The design of multi layered TAPS has, until recently, relied on trial and error or simplified numerical analyses. The following work describes efforts to develop a comprehensive numerical methodology for the initial forming of the components, which accounts for most of the physics of the problem. The simulation accounts for the complete forming operations of the part, i.e. edge folding, multi layer assembly, edge crimping, beading, and final forming. Non-linear effects are accounted for such as interlayer frictional dissipation, plastic anisotropy and self-contact.

Today, Computer Aided Engineering (CAE) is standard in the up-front gasket development. As presented three years ago, it helps to reduce the development cycle and at the same time the development costs. With the success in using this approach, we received new requirements from the customer requesting for more and better details so that the project can be completed within the same time frame. The theoretical advancement and the drastic changes in the computer hardware technology along with lower costs aided in fine tuning our previously developed approach and adding new features. So we upgraded our specialized Proteus® software for the element study and extended it into the multi-layer 2D case. Further, more we detailed and improved the simplified 3D-model module as well as the whole bank 3D-model. A very important addition is the flow/thermal analysis to create the thermal map with our models.