Lu Tong, CAE Department,
Great Wall Motor Powertrain Research Institute
China User Conference 2026

This case study systematically evaluates the two core functions of the FEARCE-Vulcan software — "empirical thermal boundaries" and the "boiling module" — to address the engineering need for accurate thermal load prediction in high-power-density gasoline engines. The study shows that by using the software's built-in empirical thermal boundaries for in-cylinder and exhaust port simulations, the predicted results compared to bench test data exhibit an average error of less than 5% in key areas, with a maximum point error below 10%. This fully meets engineering accuracy requirements and validates the feasibility of "replacing high-cost CFD with semi-empirical models." Furthermore, after enabling the boiling module, simulation accuracy in high-risk boiling regions of the cylinder head is significantly improved, with the average error further reduced to 2.6%. This work demonstrates that the combined "empirical boundaries + boiling module" approach in FEARCE-Vulcan can drastically shorten the simulation cycle for full-engine temperature fields from "weeks" to "hours" while maintaining prediction accuracy. It provides an efficient and reliable tool for engine conceptual design and thermal optimisation.

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This was presented by Lu Tong, CAE Department, Great Wall Motor Powertrain Research Institute at the 2026 China User Conference on 20 May 2026.