Ten-cylinder engines breathe easy

May 10, 2007
German automotive systems supplier Mahle Filtersysteme GmbH has designed one of the largest polyamide (PA) intake modules ever made for passenger cars.

Ten-cylinder engines breathe easy

Mahle designers also spec'd Ultramid B3WG6 GP for BMW four and six-cylinder engines: The eight-cylinder intake module, with its complex shape (top) and the large, two-part 10-cylinder intake manifold for the M5 and M6 models feature a special designer surface.


The module weighs more than 7 kg (15.4 lb) and goes into BMW 10-cylinder engines for M5 and M6 sports cars. The two-piece module is made from Ultramid B3WG6 GP, a 30% glass-fiber-reinforced PA6. The material comes from BASF Corp., Florham Park, N.J. The dimensionally stable PA6-GF30 features a bursting strength almost twice that of conventional PA grades. High-burst-strength materials create smooth, highly structured surfaces, says Nicole Berg, production engineer at the Mahle Co. in Öhringen. It also features a flame-retardant UL 94 HB rating (at 1.6 mm), an Izod-notched-impact strength of18 kJ/m2, a heat-deflection temperature (1.8 MPa) of 210°C (410°F), and a maximum service temperature (short-cycle operation) of 200°C (392°F).

Mahle designers also spec'd Ultramid B3WG6 GP for BMW four and six-cylinder engines. Intake manifolds for eight-cylinder engines posed a major challenge for designers because they have a variable length. Secure joining of the seven individual parts calls for five welding procedures. Manifold material mustn't warp much, important because individual parts are stored for different lengths of time. An accurate fit is also crucial for the 10-cylinder module because the two part halves must affix to the engine close to each other during final assembly.

Injection-molding cycles for each side of the intake module are about 4.5 sec at temperatures of about 280°C. The modules feature wall thickness of between 1 mm for small ribs and 3.5 mm at the "wings," to better resist inside pressure.

MAKE CONTACT
BASF Corp., (800) 669-2273,
www.plasticsportal.com
Mahle Filtersysteme, +49 (0) 79 41-67-0, www.mahle.com

 

Sponsored Recommendations

The entire spectrum of drive technology

June 5, 2024
Read exciting stories about all aspects of maxon drive technology in our magazine.

MONITORING RELAYS — TYPES AND APPLICATIONS

May 15, 2024
Production equipment is expensive and needs to be protected against input abnormalities such as voltage, current, frequency, and phase to stay online and in operation for the ...

Solenoid Valve Mechanics: Understanding Force Balance Equations

May 13, 2024
When evaluating a solenoid valve for a particular application, it is important to ensure that the valve can both remain in state and transition between its de-energized and fully...

Solenoid Valve Basics: What They Are, What They Do, and How They Work

May 13, 2024
A solenoid valve is an electromechanical device used to control the flow of a liquid or gas. It is comprised of two features: a solenoid and a valve. The solenoid is an electric...

Voice your opinion!

To join the conversation, and become an exclusive member of Machine Design, create an account today!