Enhancing the Durability of Connecting Rod of a Heavy-Duty Diesel Engine

This paper investigates the mechanical loads resulting from the combustion pressure and dynamic inertia and their effects on the connecting rod of a direct injection turbocharged diesel engine. The main purpose is to enhance the durability of the connecting rod in order to withstand more engine power increase. The distribution of the axial (compressive/tensile) stress, deformation, and safety factors are calculated in order to predict any possible mechanical failure. The finite element routine is used by ANSYS Workbench to analyse the loading on the connecting rod model. The current study is applied to the connecting rod of a 300 hp diesel engine in order to increase the engine power by 17%. The connecting rod operates safely and withstands the applied loads until the power increase reaches 72%. The most stressed points are at the connecting rod shank, while less stressed are experienced at the big end. Calculations show that introducing some changes to the connecting rod geometry may result in decreasing the excessive stresses. These changes include increasing the thickness of the shank cross-section, increasing the fillets radii and slightly reducing the dimensions of the big end in order to maintain the same mass. The new geometry could significantly reduce the maximum stress by 25.5% with an insignificant reduction in the total mass of the connecting rod.

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Relation between hydroxyl and formaldehyde in a direct-injection heavy-duty diesel engine

Combustion and Flame ◽

10.1016/j.combustflame.2010.09.024 ◽

2011 ◽

Vol 158 (3) ◽

pp. 564-572 ◽

Cited By ~ 20

Author(s):

A.J. Donkerbroek ◽

A.P. van Vliet ◽

L.M.T. Somers ◽

N.J. Dam ◽

J.J. ter Meulen

Keyword(s):

Diesel Engine ◽

Direct Injection ◽

Heavy Duty ◽

Heavy Duty Diesel Engine ◽

Heavy Duty Diesel

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Thermo Mechanical Analysis of a Direct Injection Heavy Duty Diesel Engine Piston Using FEA

Volume 6A: Energy ◽

10.1115/imece2016-66160 ◽

2016 ◽

Author(s):

Islam Ismail ◽

Ahmed Emara ◽

El Sayed Abdel Razek

Keyword(s):

Heat Transfer ◽

Finite Element Analysis ◽

Direct Injection ◽

Heavy Duty ◽

Element Analysis ◽

Engine Piston ◽

Heavy Duty Diesel Engine ◽

Heavy Duty Diesel ◽

Cylinder Bore ◽

Engine Power

This paper involves simulation of a 4-stroke direct injection heavy duty diesel engine piston made of aluminum silicon alloy to determine its temperature field, stress distribution and deformation at the conditions of upgrading the engine power from 300 HP to 350 HP. Turbocharger is the way used to enhance the engine power from 300 HP to 350 HP beside improving the fuel injection system. When the engine power is upgraded, high temperature and pressure will be developed because the engine will run at high loads. The piston is subjected to the coupled action of the thermal effect due to the transfer of heat from the head to the body and the mechanical effect represented by the combustion pressure and the inertial load due to the important change of direction of the piston in the cylinder bore. This results in producing stresses in the piston and if these stresses exceed the designed values, the failure of the piston is the result. Finite element analysis (FEA) is considered as one of the best numerical tools to model and analyze the physical systems. The three dimensional piston model was developed in Solid-Works and imported into ANSYS software. Finite element analysis is considered Code for preprocessing, loading and post processing. The simulation parameters used in this paper were combustion pressure, inertial effects and temperature. Diesel RK software is used to simulate the thermal analysis of engine cycle at each case of engine power 300 HP and 350 HP. Also, this model included the effect of the heat flow on the piston to overcome the whole area of the piston is used to illustrate the temperature distribution on the total area of the piston. This area divided into piston surface area and sidle area of piston which included the groves of rings (pressure and oil). The heat transfer coefficient is determined in each area of the piston according to the mechanism of heat transfer. Finally, the results of two different piston conditions are compared with each other. The highest temperature appeared at the combustion chamber side which occurred at the edges of the piston top face in direct contact with the hot gases in the radial. The piston deformation value is within a safe margin and below the gap between the piston and the cylinder bore in case of engine power of 350 HP. The highest calculated value of stresses was below the yield stress of the piston material at elevated temperatures and engine brake power of 350 HP. Hence the piston would withstand the induced stresses during work cycles.

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Nox. reduction from a heavy-duty diesel engine with direct injection of natural gas and cooled exhaust gas recirculation

International Journal of Engine Research ◽

10.1243/146808704773564578 ◽

2004 ◽

Vol 5 (2) ◽

pp. 175-191 ◽

Cited By ~ 16

Author(s):

G McTaggart-Cowan ◽

W. K. Bushe ◽

P. G. Hill ◽

S. R. Munshi

Keyword(s):

Diesel Engine ◽

Natural Gas ◽

Direct Injection ◽

Nox Reduction ◽

Exhaust Gas Recirculation ◽

Exhaust Gas ◽

Heavy Duty ◽

Heavy Duty Diesel Engine ◽

Heavy Duty Diesel ◽

Gas Recirculation

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Direct Injection of Natural Gas in a Heavy-Duty Diesel Engine

10.4271/2002-01-1630 ◽

2002 ◽

Cited By ~ 45

Author(s):

James Harrington ◽

Sandeep Munshi ◽

Costi Nedelcu ◽

Patric Ouellette ◽

Jeff Thompson ◽

...

Keyword(s):

Diesel Engine ◽

Natural Gas ◽

Direct Injection ◽

Heavy Duty ◽

Heavy Duty Diesel Engine ◽

Heavy Duty Diesel

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Study of Cavitation and Wear Damages in Conrod Big End Bearing of a Heavy Duty Diesel Engine by Using Elasto-Hydrodynamic Method

ASME 2009 Internal Combustion Engine Division Fall Technical Conference ◽

10.1115/icef2009-14091 ◽

2009 ◽

Cited By ~ 2

Author(s):

Hadiseh Karimaei ◽

Hamidreza Chamani

Keyword(s):

Diesel Engine ◽

Heavy Duty ◽

Connecting Rod ◽

Cavitation Damage ◽

Oil Film ◽

Heavy Duty Diesel Engine ◽

Hydrodynamic Method ◽

Heavy Duty Diesel ◽

Wear Damage ◽

Oil Film Pressure

Wear and cavitation erosion are the common damages in engine bearing shells. In the case of cavitation damage, the generation and immediate collapse of small gas bubbles cause high pressure pulses and the bearing surface is being locally damaged. Cavitation damage is observed in heavy duty diesel engine due to highly dynamic loading, oscillation of pins, turbulence of oil flow and other factors. Wear damage induces adjustment in the bearing geometry and affects the oil film pressure and the durability of bearing shell. In this paper, wear and cavitation damages in connecting rod big end bearing have been studied. In order to compute the bearing lubrication characteristic such as minimum oil film thickness and maximum oil film pressure, Elasto-Hydrodynamic method that incorporates mass conserving algorithm has been utilized. Wear and cavitation damages in two different designs of connecting rod structure in a heavy duty diesel engine have been assessed and the results have been presented. Furthermore, the effect of connecting rod structure on wear damage has been investigated.

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Turbocharging of a Heavy Duty Diesel Engine for a Specific Power and Performance Enhancement

Volume 6A: Energy ◽

10.1115/imece2015-53635 ◽

2015 ◽

Cited By ~ 1

Author(s):

Kareem Emara ◽

Ahmed Emara ◽

Elsayed Abdel Razek

Keyword(s):

Diesel Engine ◽

Direct Injection ◽

Combustion Characteristics ◽

Specific Power ◽

Heavy Duty ◽

Direct Injection Diesel Engine ◽

Engine Simulation ◽

Brake Power ◽

Heavy Duty Diesel Engine ◽

Heavy Duty Diesel

Increase of the capacity of heavy duty diesel engines is of great interest in the way of power enhancement in many engine applications. Turbocharger is one of the most important ways used to increase the engine specific power. The present study aimed to develop an analytical model to simulate the performance and combustion characteristics of a direct injection diesel engine. This model depends on the basic conservation equations of continuity, momentum and energy as well as equation of state, these equations are solved together numerically by using two steps Lax-Wendroff scheme. To address this, a comprehensive computer “FORTRAN” code was developed and applied to study the performance and combustion characteristics of a six-cylinder, four stroke, direct injection, heavy duty diesel engine as a base engine and when its power upgraded by 15% using a turbocharger. This code is open source, preprocessor is user-friendly and very easy in work and will used at any time. The computed results are compared with the results obtained by applying the engine simulation DIESEL-RK software. But the DIESEL-RK solver may be run under the control of an external code. In that case the interface of the program includes input & output text files. Templates of these files are generated automatically. The developed model provides reasonable estimates and the experimental validation of the model show that an appropriate agreement between mathematical model, DIESEL-RK software, and the real measurements, in addition the capability of the model to predict satisfactorily the performance, and combustion characteristics of the direct injection diesel engine. Simulation study was also performed to compare the turbocharged engine with the naturally aspirated direct injection diesel engine. This study examined the engines for operating parameters like brake power and brake specific fuel consumption over the entire speed range and revealed that turbocharging offers higher brake power and lower brake specific fuel consumption values for most of the operating range. The results indicated that turbocharging offers marginally higher brake thermal efficiency and enhancing the engine performance.

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