Advanced Modeling and Analysis of Diesel Engine Test Support Structure (ETSS) Using (FEM) and (XFEM): A Comprehensive Study on Fracture Mechanics, Fatigue Life, and Modal Analysis of Crack Growth

Subject Areas : Mechanical Engineering

Mohammad Mohammadi ¹ , Seyed Mohammad Reza Nazemosadat ^{2 *} , Ahmad Afsari ³

1 - Department of Mechanical Engineering, Faculty of Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran
2 - Department of Mechanical Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran.
3 - Department of Mechanical Engineering, College of Engineering, Shiraz Branch, Islamic Azad University, Shiraz, Iran

Received: 2025-02-08 Accepted : 2025-06-09 Published : 2025-11-23

Keywords: Extended Finite Element Method, Finite Element Method, Modal Analysis, Diesel Engine Test Support Structure, Fracture Mechanics, Fatigue Life Evaluation, Buckling.,

Abstract :

The Engine Test Support Structure is vital in testing engines and enhancing technician safety across various industries. This study proposed and modeled a steel structure using INVENTOR software.­ Subsequently, static analysis, modal vibration analysis, safety factor analysis, fracture mechanics, fatigue life analysis, and modal crack growth analysis were performed on this structure using ABAQUS software. The static analysis results showed that the maximum von Mises stress in the telescopic support of the engine handle and the longitudinal and transverse chassis ranged between 275 and 617 MPa. The modal vibration analysis indicated that the maximum displacement in the longitudinal and transverse chassis areas, engine block, and radiator holder was 0.08135 mm at 7.20 Hz. The fracture mechanics and XFEM analysis showed that areas with a value of 1.0 indicated fully developed cracks and the highest level of discontinuities, suggesting good resistance to fracture. Additionally, the modal crack growth analysis results showed that the maximum crack growth was 0.014 mm under a force of 12 KN. The fatigue life analysis indicated that under a force ranging from 0 to 10 KN over 15 cycles, the structure exhibited good toughness and strength against cyclic loading at critical points. The safety factor analysis revealed that the central longitudinal and transverse floor frames (Body 5) require reinforcement and optimization due to having a safety factor of less than 1.0. A safety factor range of 1.5 to 3 is recommended for these areas, while other components do not require reinforcement.

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