Fretting Analysis of an Engine Bearing Cap Using Computer Simulation

Satô, Kenji; Hamakawa, Takeru; Yamasaki, Takeyuki; Ishihara, Yoshimichi; Hashimoto, Hisashi; Shi, Chen; Haneda, Hiroaki; Takahashi, Shinichi; Iida, Yoshiyuki

doi:10.4271/2016-01-1083

Cited by 2 publications

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“…Fretting fatigue phenomena has been researched a lot but not yet thoroughly understood. Sato et al [16] studied the engine main bearing cap fretting. Their model predicts fretting fracture correctly.…”

Section: Introductionmentioning

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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Section: Introductionmentioning

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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Development of an Evaluation Method for Fretting Fatigue at the Mating Surface between a Cylinder Block and Main Bearing Cap with Temperature Fluctuations

Otsuka

2024

SAE Technical Paper Series

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<div class="section abstract"><div class="htmlview paragraph">Fretting is a phenomenon in which a fatigue crack is initiated by a small relative slip between two objects, resulting in crack propagation and fracture at stresses far below the fatigue limit [<span class="xref">1</span>, <span class="xref">2</span>]. Since the mechanism behind fretting is complex and covers multiple disciplines, it is not easy to develop a consistent evaluation method. In the field of engine development, fretting events can also pose an issue due to the complexity of the mechanism [<span class="xref">3</span>]. In particular, it has been a challenge to help predict changes in the presence and severity of fretting events, as the engine temperature fluctuates with operating conditions. As one method for evaluating fretting, Sato, et al. have made predictions using analytical models based on the finite element method (FEM) [<span class="xref">4</span>, <span class="xref">5</span>]. However, their predictions did not take into account temperature fluctuations in the system, and they were unable to predict events in which the occurrence of fretting fatigue changed with temperature fluctuations.</div><div class="htmlview paragraph">In this study, first, tests were conducted on an actual engine to examine the effect of temperature on the occurrence of fretting. In addition, the mating surface was observed in detail after the tests. Specifically, the microcracks on the mating surface were measured, and the damaged areas were analyzed for their composition. As a result, it was found that the main factors influencing the occurrence of fretting were the relative slip velocity caused by thermal expansion and the relative slip rate and stress amplitude caused by the crank load. Traditionally, fretting has been evaluated based on the stress amplitude at the mating surface and the relative slip caused by the crank load [<span class="xref">4</span>]. In this study, the relative slip caused by thermal expansion due to the difference in thermal expansion coefficients between the two objects was incorporated into the evaluation, making it possible to evaluate fretting while taking the effect of temperature into account. The influence of each factor was quantified using a three-dimensional nonlinear FEM. Simulations included bolt-tightening force, cyclic crankshaft force, and temperature variation. The simulation results were combined with test results from various engine types to develop experimental criteria.</div></div>

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Fretting Analysis of an Engine Bearing Cap Using Computer Simulation

Cited by 2 publications

References 0 publications

Simulation-Driven Development of Combustion Engines: Theory and Examples

Simulation-Driven Development of Combustion Engines: Theory and Examples

Development of an Evaluation Method for Fretting Fatigue at the Mating Surface between a Cylinder Block and Main Bearing Cap with Temperature Fluctuations

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