By PRADEEP PAWAR. Guide Prof. N. S.

Hanamapure

INTRODUCTION
What is Durability? Simply it describes overall life requirement Experimental Durability Tests and their limitations
Development of CAE tools Ever increasing power density requires highly optimized coolant flow (minimized volume) detail knowledge about material behavior and modeling understanding failure mechanism advanced and robust simulation processes

Durability analysis of Engine Head block

CAE Models (FE-Model, complete engine), (CFD models coolant jacket, combustion chamber & ports) Simulation variant no CFD simulation Inner cylinder flow, coolant flow Flow field (HTC, combustion)

Flow BCs

OK?

yes

Simulation variant

no

Heat transfer BCs

Heat transfer analysis (nucleate boiling)

Temperature field Heat flux

OK?

yes

Stresses / Strains Mechanical BCs Stress / strain analysis (durability testing, duty cycle) Durability (HCF, LCF, TMF) Gasket pressure Deformations (liner, ) Simulation variant no OK? yes Design Release (Durability)

Material - filling & solidification - behavior, modeling - testing - process

Multidisciplinary Simulation Approach

Thermodynamic Analysis Thermodynamic 1D calculations CFD simulation In-cylinder combustion simulation Coolant flow simulation Thermal or Heat Transfer Analysis Conjugate heat transfer analysis

Inputs Surface heat flux, under-hood HTC and T Outputs Solid temperatures

Thermo-structural Analysis
carried out to account for the different operating conditions of

the engine as per the real world usage pattern. This includes the
following,
Cold assembly Cold firing Warm-up Warm-up with peak firing load

FE Model - first activity Material Data - elasto-plastic curves

Fatigue Analysis
Fatigue analysis always begin at a crack

Stages of Fatigue Failure Crack initiation(life till crack of 2mm is detected) Crack propagation Sudden fracture due to unstable crack growth S-N or -N curves are base Alternating High Cycle Fatigue stress
Modes of failure HCF Endurance factor of safety LCF Damage
Endurance strength Low Cycle Fatigue

105

2*105

No. of cycles

Various Approaches for Fatigue Analysis

Stress Life approach Old Method Stress or S-N diagram is base Used for HCF applications (i.e. assembly expected to last for
100000 cycles)

Strain Life approach Strain or -N diagram is base Used for LCF applications Fracture Mechanics approach Used for calculation of remaining life i.e. crack propagation life

Case Study
Evaluation of strength of engine cylinder head and

crankcase assembly two cylinder four stroke engine Them0-dynamic Analysis CFD simulations
Coolant flow simulation In-cylinder HTC & Fluid temperature Under-hoodHTC & Air temperature

Conjugate Heat transfer

approach is used

 Thermo-structural Analysis Load cases

Assembly Load case Cold Firing Load case Engine Warm-up Hot firing load case

FE Model Consist two cylinders

Fatigue Analysis
HCF analysis is carried out to calculate fatigue safety

factor Stress life approach is used

Design Modification
Low safety factors were observed in some of the

regions. Modifications were suggested to improve the safety factors in those regions.

Case Study
Engine discussed hear is a diesel engine

due to increased power output, cylinder head is

susceptible to High cycle Fatigue (HCF) cracks as well as Low Cycle Fatigue (LCF) cracks at weaker areas like water bracket area, valve bridge on fire deck, fuel line boss, intake port bridge, etc.

 FE Model
Two complete cylinders (#5 and #6)

Boundary Conditions
Symmetric BC are applied at cutting

planes AA and BB.

 The full speed full load durability test on diesel engine

developed showed that cylinder head shows more cracks in head bolt boss area and intake port bridge due to HCF.

 The stress analysis under assembly loads, thermal

loads and high cycle firing loads is carried out in ABAQUS.

 FEMFAT Version 4.6b is used for calculations of fatigue

factor of safety. Safety Factor is less than 1 in some areas is observed therefore some design modifications are required.

 The supplementary rib is provided at intake port

bridge and augmented thickness is added at head bolt boss area

 This design modification increases bending stiffness at

crack location. The modified design at intake port bridge and head bolt boss is effective to improve the durability (increase of about 13% in safety factor).

Conclusion
Successful mechanical development of today's

increasingly high loaded engine designs demands new sophisticated simulation techniques. Cracks can be investigated by FE analysis and optimization design can be obtained. It is possibly increasing to replace the classic durability test in engine development . CAE is essential method in rapid development process.