Expo Engine 2011 Analysis of crankshaft under virtual engine operation using Ansys APDL ...

22 Pages·2011·5.64 MB·English

Expo(cid:5)Engine(cid:5)2011
Analysis(cid:5)of(cid:5)crankshaft(cid:5)under(cid:5)virtual(cid:5)engine(cid:5)operation(cid:5)using(cid:5)Ansys APDL(cid:5)
routines(cid:5)and(cid:5)Ansys WB(cid:5)software
Alex de Souza Rodrigues
Development Engineering
ThyssenKrupp MetalúrgicaCampo Limpo- Brazil
E-mail: [email protected]
Phone: [phone] Mobile: [phone]
ThyssenKrupp(cid:11)Forging(cid:11)Group
1.(cid:5)Agenda
11.. CCoonnvveennttiioonnaall BBeennddiinngg aanndd TToorrssiioonn TTeessttss;;
2. Under virtual Engine Operation
3. Super Crank
Page(cid:11)#2/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
2.(cid:5)Development(cid:5)cycle
Page(cid:11)#3/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
3.(cid:5)Finished(cid:5)Part(cid:5)Development
Page(cid:11)#4/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
4.(cid:5)Technical(cid:5)Nomenclature
Pin Journal
Crank Nose
OOiill HHoollee
Main Journal
Flange
Counter-weights
Crankshaft Throw
Main Fillet Web
Pin Fillet
Page(cid:11)#5/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
5.(cid:5)Bench(cid:5)Test
(cid:1) Bench(cid:5)Bending(cid:5)Test (cid:1) Virtual(cid:5)Bending(cid:5)Test
Material Properties identification
based on experimental tests with
crankshafts under bending load
•Stair Case Method is applied for
endurance limit evaluation
•10 million cycles
•The stresses are measured directly
in the bearings fillets by strain gauges
((ppoossiittiioonnss 11,, 22,, 33 aanndd 44))
-F +F •Endurance limit is calculated for
Remote(cid:8)Force bearings fillets based on measured
data and statistical treatment
Material Properties
•SR: ultimate tensile strength
•SE: yield tensile strength
•E: Young’s modulus
•Poisson
•NC and NL: number of load cycles
•SC and SL: endurance limits
SN Methodology
•PUC Criteria
Strain(cid:5)gauge
Page(cid:11)#6/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
5.(cid:5)Bench(cid:5)Test Fatigue(cid:8)Safety(cid:8)Factor
Stair(cid:8)Case(cid:8)Method(cid:8)for(cid:8)Bending
Minimum(cid:8)SF=1(cid:8)for(cid:8)
infinite(cid:8)life
107.1
Endurance(cid:8)Limit(cid:8)(SL)(cid:8)for(cid:8)10(cid:8)
million(cid:8)cycles(cid:8)(NL)
738(cid:5)MPa
Endurance(cid:8)Limit(cid:8)(SC)(cid:8)for(cid:8)1(cid:8)million(cid:8)cycles(cid:8)(NC)
Page(cid:11)#7/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
5.(cid:5)Bench(cid:5)Test
Material Properties identification
(cid:1) Bench(cid:5)Torsion(cid:5)Test (cid:1) Virtual(cid:5)Torsion(cid:5)Test based on experimental tests with
crankshafts under torsion load
•Stair Case Method is applied for
endurance limit evaluation
•10 million cycles
+
T •The stresses are measured in the
bearings center by torque strain
-T
gauges
•Endurance limits are calculated for
bearings fillets, webs and oil hole
regions based on measured data and
FEA results extrapolation
•The number of specimen tested in
torsional stair cases is not enough to
allow statistical treatment. Thus, the
endurance limit is obtained from
critical specimen result
Torsional(cid:8)Strain(cid:8)Gauge(cid:8)Position Material Properties
•SR: ultimate tensile strength
•SE: yield tensile strength
••EE:: YYoouunngg’’ss mmoodduulluuss
•Poisson
•NC and NL: number of load cycles
•SC and SL: endurance limits
Max(cid:8)Principal(cid:8)Stress(cid:8)have(cid:8)excellent(cid:8)correlation(cid:8)with(cid:8) SN Methodology
strain(cid:8)gauge(cid:8)measurement
•PUC Criteria
Page(cid:11)#8/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
5.(cid:5)Bench(cid:5)Test
Endurance(cid:8)Limit(cid:8)(SL)(cid:8)for(cid:8)10(cid:8)
Stair(cid:8)Case(cid:8)Method(cid:8)for(cid:8)Torsion million(cid:8)cycles(cid:8)(NL)(cid:8)@(cid:8)strain(cid:8)gage
16.3
Endurance(cid:8)Limit(cid:8)(SC)(cid:8)for(cid:8)1(cid:8)million(cid:8)cycles(cid:8)(NC)
112(cid:5)[MPa]
Page(cid:11)#9/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)
6.(cid:5)Dynamic(cid:5)Analysis

Piston1 Piston2 Piston3 Piston4 Piston5 Piston6
21 P istonPin21R1P istonPin21R2P istonPin21R3P istonPin21R4P istonPin21R5P istonPinR6

P-Pin1 P-Pin2 P-Pin3 P-Pin4 P-Pin5 P-Pin6
212 SSmmaallllEEnndd21211 SSmmaallllEEnndd21222 SSmmaallllEEnndd21233 SSmmaallllEEnndd21244 SSmmaallllEEnndd12155 SSmmaallllEEnndd66

Conrod1 Conrod2 Conrod3 Conrod4 Conrod5 Conrod6
21 BigEnd121 BigEnd221 BigEnd 321 BigEnd421 BigEnd521 BigEnd6
Crankshaft
12 12 1 1
MainBearing1 1 MainBearing3 1 MainB2earing5 1 MainB2earing7
2 2 22
MainBearing2 MainBearing4 MainBearing6
Engine

Page(cid:11)#10/22
CLEAR(cid:6)Crankshaft(cid:6)For(cid:6)Low(cid:6)Emission(cid:6)And(cid:6)Friction(cid:6)–TR01011_03#
ThyssenKrupp(cid:11)Forging(cid:11)Group
May,(cid:6)2011(cid:6)