Comparative Evaluation of Fatigue Assessment Techniques on a Forged Steel Crankshaft of a Single Cylinder Diesel Engine

2012 ◽  
Author(s):  
Rajesh M. Metkar ◽  
Vivek K. Sunnapwar ◽  
Subhash Deo Hiwase
Keyword(s):  
Diesel Engine ◽  
Fracture Mechanics ◽  
Early Stage ◽  
Life Assessment ◽  
Growth Time ◽  
Connecting Rod ◽  
Rotating System ◽  
Element Analysis ◽  
Ic Engine ◽  
Single Cylinder

Crankshaft is one of the critical components of an IC engine, failure of which may result in disaster and makes engine useless unless costly repair performed. It possesses intricate geometry and while operation experiences complex loading pattern. In IC engines, the transient load of cylinder gas pressure is transmitted to crankshaft through connecting rod, which is dynamic in nature with respect to magnitude and direction. However, the piston along with connecting rod and crankshaft illustrate respective reciprocating and rotating system of components. the dynamic load and rotating system exerts repeated bending and shear stress due to torsion, which are common stresses acting on crankshaft and mostly responsible for crankshaft fatigue failure. Hence, fatigue strength and life assessment plays an important role in crankshaft development considering its safety and reliable operation. The present paper is based on comparative studies of two methods of fatigue life assessment of a single cylinder diesel engine crankshaft by using fracture mechanics approach viz. linear elastic fracture mechanics (LEFM) and recently developed critical distance approach (CDA). These methods predict crack growth, time required for failure and other parameters essential in life assessment. LEFM is an analytical method based on stress intensity factor which characteristics the stress distribution in the vicinity of crack tip, where as CDA is a group of methods predicts failure using stress distance plot. The maximum stress value required for both the methods are obtained using finite element analysis. The present paper provides an insight of LEFM and CDA methods along with its benefits to the designers to correctly assess the life of crankshaft at early stage of design. This paper also gives a detailed overview of failure analysis process including theoretical methods and result integration for predicting life of components as compared to life estimation by means of software.

Application of Advanced Probabilistic Fracture Mechanics to Life Evaluation of Turbine Rotor Blade Attachments

1995 ◽  
Author(s):  
H. R. Millwater ◽  
Y.-T. Wu ◽  
J. W. Cardinal ◽  
G. G. Chell
Keyword(s):  
Fracture Mechanics ◽  
Computational Algorithm ◽  
Operating Time ◽  
Turbine Rotor ◽  
Life Assessment ◽  
Inspection Planning ◽  
Element Analysis ◽  
Turbine Rotor Blade ◽  
Probabilistic Fracture Mechanics ◽  
Life Evaluation

This paper describes the application of an advanced probabilistic fracture mechanics computational algorithm with inspection simulation to the probabilistic life assessment of a turbine blade attachment, sometimes referred to as a steeple or fir tree. The life of the steeple is limited by high cycle fatigue. The methodology utilized combines structural finite element analysis, stochastic fatigue crack growth, and crack inspection and repair. The resulting information provides the engineer with an assessment of the probability of failure of the structure as a function of operating time and the effect of the inspection procedure. This information can form the basis of inspection planning and retirement-for-cause decisions.

Dynamic Analysis of the Crank Train in a Single Cylinder Diesel Engine Using a Lumped Parameter Method

2016 ◽  
Author(s):  
X. Y. Zhang ◽  
J. Guo ◽  
Zhang Wenping
Keyword(s):  
Diesel Engine ◽  
Dynamic Analysis ◽  
Internal Force ◽  
Parameter Method ◽  
Cylinder Pressure ◽  
Connecting Rod ◽  
Single Cylinder ◽  
Rotating Speed ◽  
Lumped Parameter ◽  
Lumped Parameter Method

The kinematic and dynamic behaviors of the crank train in a single cylinder diesel engine are analyzed in the paper. The crank train mechanism consists of four parts: a crank without counterweight, a connecting rod, a piston associated with a cylinder and two stops at both ends of a stroke. The dynamic model is developed using a lumped parameter method. The inertia of mass or moment are considered by an equivalent treatment in the centers of the piston pin, the crank pin, the main journal, respectively. The longitudinal deformations of the connecting rod are simulated by spring-damping elements, as well as the angular and bending deformations of the crank. As a result, it was possible to predict the effects of the component inertia of mass or moment and stiffness on the internal force and rotating speed of the crank under the cylinder pressure.

scholarly journals Design optimization of a diesel engine connecting rod

2019 ◽  
Vol 6 (1) ◽  
pp. 24-40 ◽  
Author(s):  
Aisha Muhammad ◽  
Ibrahim Haruna Shanono
Keyword(s):  
Finite Element ◽  
Diesel Engine ◽  
Material Selection ◽  
Reduction Rate ◽  
Weight Optimization ◽  
Connecting Rod ◽  
Roller Conveyor ◽  
Engineering Structures ◽  
Ic Engine ◽  
Static And Dynamic Analysis

Rotary motion is generated from a crankshaft’s piston alternating motion using a connecting rod. The engine combustion gases and components motion of inertia exert pressures that induces compressive and tensile stress in the connecting rod respectively [1], [2]. Connecting rods fail due to its overloading, bearing failure, irregular adjustments of the bolts and faulty assembly or fatigue [3]. It is important for connecting rods to be able to withstand the complex high tensile loads that acts on them. As a result, numerous design technology, material selection, working and fatigue test of a connecting rod have been studied and presented [4]. Mechanical properties (such as hardness, tensile strength, rigidity and fatigue resistivity) of the materials used in the manufacture of a connecting rod need vehicles depends on the design of the connecting rod. Failure of connecting rod is attributed to the in availability of much strength needed to hold the load. This can be overcome with the life cycle extended by increasing the strength [5]. Finite element analysis of connecting rod have been conducted and presented by a lot of researchers. In [6], theoretical and FEA of an IC engine connecting rod was conducted. The result of the analysis obtained shows the causes of failure at the fillet of both ends due to the induced stress. In [7] static FEA for fatigue, deformation and weight optimization of a connecting rod using ANSYS workbench is carried out and presented. From the suggested design changes obtained from the weight optimization result, the failure result is further updated to achieve a better result. In a paper by Bansal, dynamic stress analysis was carried out on a single cylinder four stroke diesel engine connecting rod of Aluminum material using FEA. The optimization was also done under dynamic loading with the boundary conditions and inputs determined from the pressure-volume diagram and engine specification chart respectively are carried out with different meshing size for an accurate result. [8]. FEA is the commonly employed computational tool for testing and modifying engineering structures within certain design limit.  It involves diving in to small units known as ‘elements’ for static and dynamic analysis of simple to complex model under different design constraints. Further investigation can also be done to improve the design for optimal performance and lifespan with regards to design failure [9]. Many kinds of literature have worked on weight optimization. Gaikwad in his paper modifies a roller conveyor by performing weight optimization after carrying out static analysis on the roller conveyor [10] In another paper by [10] the weight of a roller conveyor was reduced thereby saving the materials under specific load constraints using finite element method. In this paper shape optimization with target weight reduction rate of 20 to 60% with an interval of 10 under a static loading of 100N. Further analysis for structural optimization is also done to determine a new optimized structure with new deformation and stress values respectively. The analysis is carried out in ANSYS static structural, mechanical solver with a tensile force of 100N acting on its larger end.

scholarly journals Study of the Piston Secondary Movement on the Tribological Performance of a Single Cylinder Low-Displacement Diesel Engine

Lubricants ◽  
2020 ◽  
Vol 8 (11) ◽  
pp. 97
Author(s):  
Jorge Duarte Forero ◽  
Guillermo Valencia Ochoa ◽  
Wlamyr Palacios Alvarado
Keyword(s):  
Mathematical Model ◽  
Diesel Engine ◽  
Hydrodynamic Lubrication ◽  
Lateral Displacement ◽  
Cylinder Liner ◽  
Deformation Model ◽  
Analysis Tool ◽  
Connecting Rod ◽  
Single Cylinder ◽  
Piston Skirt

The present study aims to analyze the secondary movement of the piston considering the deformations present in the piston skirt, the hydrodynamic lubrication, and the effects of the clearances in the connecting rod bearings. The analysis of the piston movement is performed by developing a mathematical model, which was used to evaluate the dynamic characteristics of the piston movement, the slap force on the piston skirt, the effect of the secondary piston movement on the connecting rod, and the influence of clearances in the connecting rod bearings and in the piston. For the study, the geometric of the crankshaft-connecting rod–piston system of a single-cylinder diesel engine is taken as a reference. The deformation model of the piston was carried out by means of a symmetric finite element model (FEM), which was integrated into the mathematical model of the piston. MATLAB® software (The MathWorks Inc., Natick, MA, USA) is used for the development of model simulations. The obtained results show that during the combustion cycle, there are six changes of direction in the secondary movement of the piston with lateral and angular velocities that can reach a magnitude of 0.13 m/s and 4 rad/s. The lateral and angular movement of the piston during its travel causes the appearance of impacts on the piston skirt with the cylinder liner, which produces an increase of approximately 500 N in the hydrodynamic forces in the connecting rod bearings. The force analysis shows that the range of the maximum magnitudes of these forces is between 1900 N and 3480 N. The increase in clearance between the cylinder liner and the piston skirt (Cpc) causes a greater lateral displacement and an increase in the angle of inclination of the piston. Analysis of the change in connecting rod bearing clearance shows that there are critical values in relation to clearance Cpc. The model presented allows us to analyze the different characteristics of the secondary movement of the piston, which involve the interaction between the piston skirt and the cylinder liner. Additionally, the influence of this movement on the connecting rod bearings is considered. The foregoing can be used as an analysis tool for the study of designs and/or modifications in the engine in such a way that greater durability of the components, reductions in acoustic emissions, and reduction in friction losses are achieved.

The Finite Element Analysis of Tension and Compression Condition of Diesel Engine Connecting Rod

2014 ◽  
Vol 722 ◽  
pp. 120-124 ◽  
Author(s):  
Gang Chen ◽  
Lei Wu ◽  
Long Wu ◽  
Pei Qing Xie
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Diesel Engine ◽  
Reference Value ◽  
Production Cycle ◽  
Connecting Rod ◽  
Analysis Software ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Tension And Compression

In this paper, through the finite element analysis software ANSYS, analysis and research on the part drawing of the diesel engine connecting rod. Using pro/e modeling, introduce it into the finite element analysis software ANSYS for the finite element static analysis of the state of load on the connecting rod. Setting correct model, partitioning appropriate mesh, and setting a reasonable process solution, it can generate visual stress nephogram to facilitate access to important data and intuitive understanding. There is a certain reference value to guide the practical production and shorten the production cycle of the product.

scholarly journals Finite Element Analysis of Connecting Rod of IC Engine

2015 ◽  
Vol 34 ◽  
pp. 02004 ◽  
Author(s):  
Prasanta Kumar Samal ◽  
B Murali ◽  
Abhilash ◽  
Tajmul Pasha
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Connecting Rod ◽  
Element Analysis ◽  
Ic Engine

scholarly journals Stress and Factor of Safety for Connecting Rod using Ansys

2019 ◽  
Vol 8 (6) ◽  
pp. 3463-3466
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Factor Of Safety ◽  
Stress Test ◽  
Von Mises Stress ◽  
Loading Conditions ◽  
Connecting Rod ◽  
Element Analysis ◽  
Ic Engine ◽  
Von Mises

The primary link of an IC engine is a connecting rod. Its position is in-between the crankshaft and the piston whose key function is to convert the piston motion which is reciprocating in nature into rotary motion of the crank by transmitting the piston thrust to the crankshaft. This has entailed performing a detailed load analysis. In this paper, connecting rod's finite element analysis was done using Finite Element techniques. So firstly by using the schematic diagram the solid model of the connecting rod was created using Solid works software. Then using the Ansys R17.1 software the meshing was done and then the Finite element analysis is done to find the Equivalent (Von-Mises) stresses and the Factor of Safety under the loading conditions. Structural Steel is the material which is used for connecting rod and the loading conditions are assumed to be static. In Equivalent (Von-Mises) stress test maximum stress is found to be 1.504x108 Pa and the minimum factor of safety is 1.20765 for the connecting rod

scholarly journals Implementation of a 3.5 kW resistive load bank for a single-cylinder diesel engine test bench

2020 ◽  
Vol 25 (4) ◽  
pp. 598-505
Author(s):  
Jorge Eliécer Duarte Forero ◽  
Miguel Celis Quintero ◽  
Gabriel Hernandez Acosta
Keyword(s):  
Diesel Engine ◽  
Internal Combustion Engines ◽  
Test Bench ◽  
Thermal Design ◽  
Power Measurement ◽  
Resistive Load ◽  
Engine Test ◽  
Engine Test Bench ◽  
Element Analysis ◽  
Single Cylinder

This article presents the implementation of a 3.5 kW resistive load bank applied to a four-stroke single-cylinder diesel engine test bench that operates with an alternator.   With this experimental test bench, it is possible to perform mechanical, thermodynamic, and polluting emissions studies in compression-ignited or induced internal combustion engines.   Applying the quantitative research methodology, the design of the electric charging system is carried out. Power control circuits and safety elements are designed for the load back. CAD software is used to design the structure and casing considering anthropometric measurements. Also, finite element analysis (FEA) is incorporated to verify the structural and thermal design criteria.   he implementation of an electrical and instrumentation acceleration system for sensing power and torque in low-displacement engines showed a measurement error of less than 1%. Similarly, the FEA allowed to quantify the maximum efforts and guarantee a safety factor above 5.   With the characterization of the implemented sensors, a correlation coefficient of up to 99.97% was achieved. The power measurement displayed an error lower than 3%, which leads to a high characterization capacity of any thermal machine with equal power or less than the designed one.

Fatigue Analysis of Diesel Engine Connecting Rod Based on Finite Element Method

2010 ◽  
Vol 39 ◽  
pp. 550-554 ◽  
Author(s):  
Xin Fan ◽  
Mao Hui Pan ◽  
Cheng Song Zhang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Diesel Engine ◽  
Three Dimensional ◽  
Work Load ◽  
Connecting Rod ◽  
Three Dimensional Model ◽  
Element Analysis ◽  
Body Contact ◽  
Element Method

Connecting rod fatigue in a certain type of diesel engine is analyzed by using finite element analysis method and the FEM software ANSYS. According the actual working conditions, the three-dimensional model with multi-body contact is established to simulate the contact between the connecting rod parts; By using APDL language programming, the work load on the connecting rod, calculated according all the link work loads, is applied to the connecting rod bearing and bushing through the oil film pressure distribution. By finite element method structural strength of the connecting rod was calculated, that can effectively guide the connecting rod design, which has been proved by practice.

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