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In a mechanical complex system like the gear box of a power train the friction is responsible for the heat released and thus also responsible for the high temperatures. Therefore the various parts have to be cooled. The “ideal” gear box has minimized oil capacity with good lubrication of the rotating parts and a minimized heat release. The paper describes a simulation method and the models applied to compute the oil flow in gear box housing. The simulation methods are validated with various measurement techniques (High Speed Camera, Laser Doppler Anemometry, Particle Image Velocimetry). Theses measurements are performed on modified gear box housing with optical access. The paper shows the actual status of the simulation method developed and gives and outlook on the ongoing work. The results look very promising so that we are confident that the models and methods applied are able to depict the complex processes when looking on the oil flow in gear box housing.

The increasing packing and power density in vehicles makes the thermal environment in the engine compartment more and more severe. A critical area in terms of radiation are the components facing the exhaust system. This paper shows the simulation methods applied at MAGNA STEYR finding hot spots and endangered parts when looking on the effects of radiation. The simulation runs in parallel to design, gives a reliable rating of variants and helps the designer to optimize his system. The influence of an exhaust manifold design change from double-walled to a single-walled on the steering system in a right hand drive vehicle is shown. This change was done due to cost reduction, but also resulted in additional costs for heat protection. The methods are applied in advance of the physical prototypes and help to find good measurement positions for the physical testing also.