The Audi 2.0 l R4 TFSI Race Engine for the DTM – Victory for Efficiency

Authors

Dipl.-Ing. H. Diel, Dipl.-Ing. W. Kotauschek, Dipl.-Ing. (FH) S. Dreyer, Dipl.-Ing. U. Baretzky,  AUDI AG, Neckarsulm / Ingolstadt:

Year

2021

Print Info

Production/Publication ÖVK

Summary

The introduction of the energy based regulation for the DTM in 2019 made it possible to demonstrate the complete efficiency of Audi´s newly developed 2.0 R4 TFSI engine. Based on the methodical development of Audi’s Le Mans engines, it was possible to transfer the knowledge from diesel to modern gasoline engines. The engine was designed in accordance with the DTM Class One regulations. The cylinder head incorporates a sophisticated combustion chamber. It consists of the narrow angled but inclined valves, a centrally positioned injector and sparkplug, and a highly developed piston crown. High tumble inlet port design and injector-spray-layout are key features to attain the highest combustion efficiency. The combustion process was developed for the given parameters of fuel quality and fuel flow. A key factor is lean combustion. The cylinder-head cooling manages the high thermal load on the combustion chamber side. Piston and crank train were optimized to cope with high combustion pressures. Severe knocking phenomena needed to be understood and mastered. High mechanical and thermal loads led to several mechanical challenges: dynamic vibration in crankshaft, gear- and valve train and in the transaxle drive combined with 2^nd order vibrations. Reduction of friction and minimizing the oil flow reduced the mechanical losses of the engine. Extensive endurance testing was made to enable a full season’s mileage from the beginning of the first season. The engine´s transient behaviour was optimized using an anti-lag-system. Due to limited track testing time, driveability was tested on a simulator in combination with a powertrain test bench. The overall development is the result of a very intensive cooperation between design, calculation and testing on single cylinder and complete engine test benches. The following article explains the items in more detail.

Number of pages

43 Order