Brief review on high-cycle fatigue with focus on non-metallic inclusions and forming

Vaara, Joona; Mäntylä, Antti; Frondelius, Tero

doi:10.23998/rm.65048

Cited by 16 publications

(11 citation statements)

References 31 publications

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“…Fracture mechanics is also used for crankshaft fatigue analysis. A good description of the application of Zcrack in crankshaft fatigue analysis is shown in [12].…”

Section: Crankshaft Fatigue Analysismentioning

confidence: 99%

Medium Speed Engine Crankshaft Analysis

Väisänen¹,

Mäntylä²,

Korpela³

et al. 2017

RakMek

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“…Fracture mechanics is also used for crankshaft fatigue analysis. A good description of the application of Zcrack in crankshaft fatigue analysis is shown in [12].…”

Section: Crankshaft Fatigue Analysismentioning

confidence: 99%

Medium Speed Engine Crankshaft Analysis

Väisänen¹,

Mäntylä²,

Korpela³

et al. 2017

RakMek

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“…The challenge in the fretting is that the phenomenon itself is a complex interaction of friction, wear and fatigue [3,13]. Propagation of fretting-induced cracks can be predicted by using fracture mechanics [2,12], but there is no generalized theory to predict surface damage. The energy-based Ruiz fretting damage parameter (FDP) [11] and its enhancement [14] can be used to predict potential locations of the fretting damage, but these theories are sensitive to COF, which makes it difficult to define any damage thresholds.…”

Section: Introductionmentioning

confidence: 99%

Large bore engine connecting rod fretting analysis

Mäntylä

Göös²,

Leppänen³

et al. 2017

RakMek

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Summary.A detailed contact analysis of a large connecting rod was performed to evaluate the fretting risk in the big end. Simulation was carried out in Abaqus considering all relevant boundary conditions, such as assembly loads, housing machining and dynamics from a flexible multibody simulation with elastohydrodynamic bearings. Being one of the most important variables, the local coefficient of friction (COF) and its evolution is calculated during the solution by using a subroutine in Abaqus. The model is validated by strain gauge measurements in a running engine. The resulted friction coefficient distribution matches well with the findings from a laboratory engine. The described methodology increases the accuracy of the fretting damage prediction by using a more realistic friction coefficient definition.

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“…Without understanding the fundamentals of fretting fatigue, it is nearly impossible to design reliable medium-speed connecting rods. Fatigue [54,64,65,66] and fretting [67,68] still demand basic research to utilize the latest methodology to the engine design.…”

Section: Detailed Designmentioning

confidence: 99%

Simulation-Driven Development of Combustion Engines: Theory and Examples

Frondelius

Tienhaara

Kömi

et al. 2018

SAE Technical Paper Series

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T his paper describes the simulation-driven design process used in engines technology. The research question is "how to use research in the structural analysis and dynamics field to ensure world-class product development?" This paper describes research on simulation methodologies from the design process perspective, demonstrating the need for research in various steps of product development. Each section of the paper includes one or two practical examples in which research was needed to increase product design quality. In the product definition section, the Digital Design Platform (DDP) shows the coupling between product requirements and simulation tasks. At the concept design stage, it is shown that computational methods can optimize the placement of material in the case of the main bearing cap topology. The second example is JuliaFEM, an open-source finite element method (FEM) platform, which is suitable for heavy-duty method development, where the internals of the FE solver is needed to make new calculation methodologies available. The next section is about detailed design, where an example of an oil sump welds fatigue illustrates the continuous improvement of the simulation methodology. The second example is connecting rod fretting calculation, which illustrates the full complexity of the structural analysis and dynamics simulations. The second last process step is the virtual validation, where first the cylinder head simulation methodology shows the internal connections between different disciplines' simulations. Another example here is the crankshaft virtual validation process, which describes the complexity of the "simple" component calculation as well as illustrates the number of needed competencies. Finally, in the validation process step, Big Data analyses describe the internals and complexity of the methodologies. Lastly, counterweight measurement device development illustrates that validation of the simulation models and methods sometimes leads toward a measurement device development project. As a conclusion, all the previous methodologies are used to build the Wärtsilä 31 engine, which is the most efficient four-stroke engine in the world. It is, of course, a performance achievement, but a lot of research in simulation methodologies, as explained, was needed to make a reliable product with such a high cylinder peak pressure.

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Brief review on high-cycle fatigue with focus on non-metallic inclusions and forming

Cited by 16 publications

References 31 publications

Medium Speed Engine Crankshaft Analysis

Medium Speed Engine Crankshaft Analysis

Large bore engine connecting rod fretting analysis

Simulation-Driven Development of Combustion Engines: Theory and Examples

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