In this paper, a simulation method based on an orthogonal anisotropic material is proposed. A numerical example using a simple plate is presented to show the difference in the static performance between the orthogonal anisotropic and the isotropic models. Comparing with the tested modal data of a diesel engine oil cooler cover made by glass fiber reinforced polyamide 66 (PA66), the proposed simulation method was confirmed to be much closer to reality than the general isotropic model. After that, a comprehensive performance comparison between the plastic oil cooler covers with the orthogonal anisotropic and the isotropic fiber orientations was carried out including a static deformation and stress analysis under a pressure-temperature coupled load, a forced response analysis, and an acoustic analysis under real operating conditions. The results show that the stress, the deformation, the peak vibration velocity, and the overall sound power level of the orthogonal anisotropic model are different from that obtained with the isotropic model. More importantly, the proposed method can provide a much more detailed frequency content compared to the isotropic model.
Keywords: diesel engine oil cooler cover; finite element method; glass fiber reinforced PA66; lightweight; orthogonal anisotropic.