Thermo-Mechanical Analysis of the Exhaust Manifold of a High Performance Turbocharged Engine

2018 ◽  
Vol 774 ◽  
pp. 307-312 ◽  
Author(s):  
Mariano Lorenzini ◽  
Matteo Giacopini ◽  
Saverio Giulio Barbieri
Keyword(s):  
Finite Element ◽  
Thermal Fatigue ◽  
Thermal Loading ◽  
Complex Geometry ◽  
Combustion Engine ◽  
Equivalent Plastic Strain ◽  
Operating Conditions ◽  
Exhaust Manifold ◽  
Element Analysis ◽  
Damage Criterion

This contribution presents a methodology for the structural analysis of the exhaust manifold of an internal combustion engine. In particular, the thermal loading and the related thermal fatigue damage mechanism are addressed. The component investigated is a melted exhaust manifold which includes the turbine involute. The complex geometry of the component derives from the project constrains in terms of engine performance and sound targets. Finite Element simulations are performed to obtain a virtual approval of the component geometry, in advance with respect to the component manufacturing. The Finite Element analysis accurately follow the experimental approval procedure which considers different warming and rapid cooling cycles to mimic typical engine operating conditions. Two particular aspects of the developed numerical methodology are described in details: a) the elasto-plastic behaviour of the material at high temperatures; b) a damage criterion for thermal fatigue. Following the Ferrari expertise derived by previous experimental and numerical analysis of other exhaust manifolds, the increase of the equivalent plastic strain registered for a single thermal cycle (delta PEEQ) is firstly adopted as a damage criterion. The methodology reveals itself to be well correlated with the experimental evidences thus limiting the number of tests necessary for the component approval.

Analysis on Thermal Fatigue Fracture on Engine Exhaust Manifold Based on ANSYS

2011 ◽  
Vol 217-218 ◽  
pp. 1531-1535
Author(s):  
Chao Lu
Keyword(s):  
Finite Element ◽  
Thermal Stress ◽  
Fatigue Fracture ◽  
Thermal Fatigue ◽  
Element Model ◽  
Exhaust Manifold ◽  
Element Analysis ◽  
Engine Exhaust ◽  
Existing Problems ◽  
Structure Improvement

The thermal fatigue fracture of engine exhaust manifold will affect its service life and engine work, to prevent and resolve this problem, finite element analysis software ANSYS was used to establish a finite element model for exhaust manifold work environment, and calculate the steady-state temperature distribution under the thermal field. Through the thermal stress analysis of manifold, identified the region most prone to the generate thermal stress and fracture, conducted failure analysis, for the existing problems analyzed the reason of thermal fatigue fracture on exhaust manifold, and provided a reliable basis for the optimization of the exhaust manifold. The thermal fatigue failure of exhaust manifold got good improvement after the structure improvement.

Thermal Fatigue Analysis of the Engine Exhaust Manifold

2012 ◽  
Vol 482-484 ◽  
pp. 214-219
Author(s):  
Da Lei Li ◽  
Yue Feng Yin ◽  
Guang Fei Chen ◽  
Chao Cui ◽  
Bo Han
Keyword(s):  
Finite Element ◽  
Thermal Fatigue ◽  
High Speed ◽  
Failure Process ◽  
Element Model ◽  
Working Environment ◽  
Exhaust Manifold ◽  
Element Analysis ◽  
High Speed Rotation ◽  
Prediction And Control

Exhaust manifold is the main heated part of the engine, which bears the alternating heat loads and vibration loads in the process of high speed rotation in the extremely bad working environment. According to the method of fluid-solid coupling, the temperature, stress, strain and failure process of the exhaust manifold is reproduced through Abaqus finite element analysis and practical fatigue failure analysis. Comparing the simulation results with the real situation, it is proved that the finite element model is reasonable and the solving conditions are accurate. The further study of the problem will provide theoretical basis for the subsequent materials and structure optimization of the exhaust manifold, which will have important reference for the thermal fatigue damage, life prediction and control under the high temperature and thermal shock.

Elastic Core Concept in Shakedown Analysis

2008 ◽  
Author(s):  
Janek Porowski ◽  
Tom O’Donnell
Keyword(s):  
Finite Element ◽  
Cyclic Loading ◽  
Thermal Loading ◽  
Evaluation Method ◽  
Complex Geometry ◽  
Core Concept ◽  
Element Analysis ◽  
Inelastic Analysis ◽  
Elastic Core ◽  
Thermal Bending

Use of an Elastic Core concept in finite element inelastic analysis of shakedown for components subjected to cyclic loading is described. The Elastic Core is defined as the portion of the wall which remains elastic during the entire history of cyclic loading. If it can be shown that the Elastic Core continues to exist in the wall of a component during consecutive cycles, there is no ratchet. It is shown how elastic-plastic cyclic analysis conducted only for a limited number of cycles can be used to confirm the presence of the Elastic Core. The Elastic Core concept was introduced to bound the accumulated strain for structures in elevated temperature service including plasticity and creep (1974, 1979). The resulting evaluation method is included in the ASME Code. The ASME Boiler and Pressure Vessel Code, Section III and Section VIII, Division 2 provide rules for the evaluation of plastic ratcheting in components subjected to cyclic loading. These evaluations use results of elastic analysis for components subjected to mechanical and thermal loading below the creep regime. Equations defining the onset of plastic ratchet in the Code are based on a simplified one-dimensional model including sustained membrane stress and cyclic thermal bending stress. Therefore, they only provide approximate results. The proposed use of finite element analysis extends the application of the Elastic Core for redundant structures of complex geometry and loading conditions. The results obtained herein also show the usefulness of the Code method in predicting the behavior of these structures.

scholarly journals Driving forces on dislocations: finite element analysis in the context of the non-singular dislocation theory

2021 ◽  
Author(s):  
Xiandong Zhou ◽  
Christoph Reimuth ◽  
Peter Stein ◽  
Bai-Xiang Xu
Keyword(s):  
Finite Element ◽  
Dislocation Loop ◽  
Driving Force ◽  
Complex Geometry ◽  
Driving Forces ◽  
Singular Solutions ◽  
Dislocation Model ◽  
Configurational Force ◽  
Element Analysis ◽  
Dislocation Configuration

AbstractThis work presents a regularized eigenstrain formulation around the slip plane of dislocations and the resultant non-singular solutions for various dislocation configurations. Moreover, we derive the generalized Eshelby stress tensor of the configurational force theory in the context of the proposed dislocation model. Based on the non-singular finite element solutions and the generalized configurational force formulation, we calculate the driving force on dislocations of various configurations, including single edge/screw dislocation, dislocation loop, interaction between a vacancy dislocation loop and an edge dislocation, as well as a dislocation cluster. The non-singular solutions and the driving force results are well benchmarked for different cases. The proposed formulation and the numerical scheme can be applied to any general dislocation configuration with complex geometry and loading conditions.

scholarly journals Prediction of Thermal Fatigue Life of Lead-Free BGA Solder Joints by Finite Element Analysis

2001 ◽  
Vol 42 (5) ◽  
pp. 809-813 ◽  
Author(s):  
Young-Eui Shin ◽  
Kyung-Woo Lee ◽  
Kyong-Ho Chang ◽  
Seung-Boo Jung ◽  
Jae Pil Jung
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fatigue Life ◽  
Thermal Fatigue ◽  
Solder Joints ◽  
Lead Free ◽  
Element Analysis ◽  
Thermal Fatigue Life

Research on the Structural Performance of Large-Tonnage Gantry Crane

2013 ◽  
Vol 823 ◽  
pp. 247-250
Author(s):  
Jie Dong ◽  
Wen Ming Cheng ◽  
Yang Zhi Ren ◽  
Yu Pu Wang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Theoretical Calculations ◽  
Complex Structure ◽  
Early Period ◽  
Operating Conditions ◽  
Structural Performance ◽  
Gantry Crane ◽  
Element Analysis ◽  
Design And Manufacture

Because of the huge lifting weight and complex structure of large-tonnage gantry crane and in order to effectively design and review it, this paper aims to carry out a research on its structural performance based on the method of theoretical calculation and finite element analysis. During the early period of design, the method of theoretical calculations is adopted, and after specific design it comes the finite element analysis, so as to get the results of analysis under a variety of operating conditions, which illustrates that the structural design and review of large-tonnage gantry crane based on theoretical calculations and finite element are feasible, and also verifies that the method of finite element is an effective way to find a real dangerous cross-section, thus providing the basis for the design and manufacture of the crane structure.

An Experimental and Numerical Methodology to Investigate Crack Growth in a 304L Austenitic Stainless Steel Pipe Under Thermal Fatigue

2010 ◽  
Author(s):  
Pauline Bouin ◽  
Antoine Fissolo ◽  
Ce´dric Gourdin
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Austenitic Stainless Steel ◽  
Crack Growth ◽  
Thermal Fatigue ◽  
Thermal Loading ◽  
Steel Pipe ◽  
Design Stage ◽  
Inner Surface ◽  
Stainless Steel Pipe

This paper covers work carried out by the French Atomic Energy Commission (CEA) to investigate on mechanisms leading to cracking of piping as a result of thermal loading existing in flow mixing zones. The main purpose of this work is to analyse, with a new experiment and its numerical interpretation, and to understand the mechanism of propagation of cracks in such components. To address this issue, a new specimen has been developed on the basis of the Fat3D experiment. This thermal fatigue test consists in heating a 304L steel pre-cracked tube while cyclically injecting ambient water onto its inner surface. The tube is regularly removed from the furnace for a crack characterisation. Finally, the crack growth is evaluated from the crack length differences between two stops. In parallel, a finite element analysis is developed using the finite element Cast3M code. A pipe with a semi-elliptical crack on its inner surface is modelled. A cyclic thermal loading is imposed on the tube. This loading is in agreement with experimental data. The crack propagates through the thickness. A prediction of the velocity of the crack is finally assessed using a Paris’ law type criteria. Finally, this combined experimental and numerical work on 304L austenitic stainless steel pipes will enable to improve existing methods to accurately predict the crack growth under cyclic thermal loadings in austenitic stainless steel pipe at the design stage.

Pipeline Dent Management Program

2002 ◽  
Author(s):  
Scott D. Ironside ◽  
L. Blair Carroll
Keyword(s):  
Finite Element ◽  
Oil And Gas ◽  
Selection Process ◽  
Element Model ◽  
Field Trials ◽  
Management Program ◽  
Operating Conditions ◽  
Published Data ◽  
Element Analysis ◽  
The Past

Enbridge Pipelines Inc. operates the world’s longest and most complex liquids pipeline network. As part of Enbridge’s Integrity Management Program In-Line Inspections have been and will continue to be conducted on more than 15,000 km of pipeline. The Inspection Programs have included using the most technologically advanced geometry tools in the world to detect geometrical discontinuities such as ovality, dents, and buckles. During the past number of years, Enbridge Pipelines Inc. has been involved in developing a method of evaluating the suitability of dents in pipelines for continued service. The majority of the work involved the development of a method of modeling the stresses within a dent using Finite Element Analysis (FEA). The development and validation of this model was completed by Fleet Technology Limited (FTL) through several projects sponsored by Enbridge, which included field trials and comparisons to previously published data. This model combined with proven fracture mechanics theory provides a method of determining a predicted life of a dent based on either the past or future operating conditions of the pipeline. CSA Standard Z662 – Oil and Gas Pipeline Systems provides criteria for the acceptability of dents for continued service. There have been occurrences, however, where dents that meet the CSA acceptability criteria have experienced failure. The dent model is being used to help define shape characteristics in addition to dent depth, the only shape factor considered by CSA, which contribute to dent failure. The dent model has also been utilized to validate the accuracy of current In-Line Inspection techniques. Typically a dent will lose some of its shape as the overburden is lifted from the pipeline and after the indentor is removed. Often there can be a dramatic “re-rounding” that will occur. The work included comparing the re-rounded dent shapes from a Finite Element model simulating the removal of the constraint on the pipe to the measured dent profile from a mold of the dent taken in the field after it has been excavated. This provided a measure of the accuracy of the tool. This paper will provide an overview of Enbridge’s dent management program, a description of the dent selection process for the excavation program, and a detailed review of the ILI validation work.

Incorporating Neural Network Material Models Within Finite Element Analysis for Rheological Behavior Prediction

2006 ◽  
Vol 129 (1) ◽  
pp. 58-65 ◽  
Author(s):  
B. Scott Kessler ◽  
A. Sherif El-Gizawy ◽  
Douglas E. Smith
Keyword(s):  
Finite Element ◽  
Effective Means ◽  
Element Model ◽  
Operating Conditions ◽  
Behavior Prediction ◽  
Element Analysis ◽  
Material Models ◽  
Rheological Models ◽  
Wide Range ◽  
Novel Method

The accuracy of a finite element model for design and analysis of a metal forging operation is limited by the incorporated material model’s ability to predict deformation behavior over a wide range of operating conditions. Current rheological models prove deficient in several respects due to the difficulty in establishing complicated relations between many parameters. More recently, artificial neural networks (ANN) have been suggested as an effective means to overcome these difficulties. To this end, a robust ANN with the ability to determine flow stresses based on strain, strain rate, and temperature is developed and linked with finite element code. Comparisons of this novel method with conventional means are carried out to demonstrate the advantages of this approach.

The Finite Element Analysis and Optimization of Micro Free Piston Swing Engine’s Strain Interference

2010 ◽  
Vol 139-141 ◽  
pp. 938-942
Author(s):  
Ji Jing Lin ◽  
Yan Hong Chen
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Internal Combustion Engine ◽  
Combustion Engine ◽  
Internal Combustion ◽  
Computation Method ◽  
Element Analysis ◽  
Free Piston ◽  
New Type ◽  
Swing Engine

MFPSE, Micro Free Piston Swing Engine, is a new type of miniature internal combustion engine based on the working principle of two-stroke swing engine. The successful development and operation of this type of miniature internal combustion engine provide important significance for the miniaturization of the internal combustion engine, and provide a number of important research theory, computation method and experimental data. In this article, according to the work characteristics and co-ordination requirements of MFPSE (Micro Free Piston Swing Engine), whose strain interference is analyzed using finite element analysis software, the problems and interference of the center pendulum and cylinder is found evidently. The data of analysis provides theory basis for the MFPSE’s structural optimization, and is critical to improve the performance of MFPSE.

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