Durability Improvement of Engine Bulkhead by Adjusting Design Parameters

설계인자변화에 따른 엔진 벌크헤드 내구성 향상

  • Yang, Chull-Ho (Department of Mechanical & Automotive Engineering, Andong National University) ;
  • Han, Moon-Sik (Department of Mechanical & Automotive Engineering, Keimyung University)
  • 양철호 (안동대학교 기계자동차공학과) ;
  • 한문식 (계명대학교 기계자동차공학과)
  • Received : 2010.06.03
  • Accepted : 2010.11.09
  • Published : 2011.03.01

Abstract

Three-dimensional finite element analyses have been performed to improve the durability of bulkhead. To keep pace with design changes and concentrate on regions of interest, SUBMODEL technique in ABAQUS was used for analysis. An analysis was conducted with following load cases: 1) Cap press-fit, 2) Bearing crush, 3) Bolt assembly, 4) Hot assembly, 5) Firing load, 6) Alternating firing load, 7) 2nd hot assembly. Fatigue analysis was done using commercial software FEMFAT and fatigue factors at the interested regions such as bolt tip area, counter bore, breathing hole, honing clearance were calculated and compared to aid design validation. Finite element modeling in the area of thread engagement used a simple constraint equations. Increasing bolt length, to a minimum of 39 mm above joint face gives a better fatigue resistance to the bulkhead. Breathing hole helps not only circulate the air in the crankcase but also fatigue resistance of bulkhead by relieving the stress at the critical locations.

Keywords

References

  1. SAE Fatigue Design Handbook 3rd Edn., SAE, 1997.
  2. N.-H. Cho, S.-U. Lee, S.-K. Lee and S.-H. Lee, "Finite Element Analysis of Thermal Fatigue Safety for a Heavy-Duty Diesel Engine," Transactions of KSAE, Vol.12, No.1, pp.122-129, 2004.
  3. T. Takahashi, T. Nagayoshi and M. Kumano, "Thermal Plastic-elastic Creep Analysis of Engine Cylinder Head," SAE 2002-01-0585, World Congress, Detroit, 2002.
  4. ABAQUS Users Manual, Ver 6.2, HKS, 2002.
  5. FEMFAT Users Manual, Magna-Steyr, Femfat, 2003.
  6. C. Yang and M. Han, "Finite Element Analysis of Engine Cylinder Block and Main Bore for Reliable Design," Transactions of KSAE, Vol.13, No.4, pp.39-48, 2005.
  7. C. Yang, New V6 3.5L Bulkhead Design Iteration, Ford Internal Report, 2000BEDD034, 2000.
  8. R. Juvinall and K. Marshek, Fundamentals of Machine Component Design 3rd Edn., John Wiely & Sons, Inc., New York, 1999.
  9. CRS, CRS Fatigue Laboratory Report of Testing of Specimens of HP Die Cast V6 Cylinder Block Castings, CRS Report S-8109, 1998.
  10. C. Yang, Cyclone V6 3.5L Cylinder Block Fatigue Assesment, Ford Internal Report, 2002BED-D001, 2002.