Improving High Cycle Fatigue Life in A Gasoline Engine Piston using Oil Gallery with Considering Stress Gradient
الموضوعات :
Hojjat Ashouri
1
(
Department of Mechanical Engineering, Varamin-Pishva Branch, Islamic Azad University, Varamin, Iran
)
تاريخ الإرسال : 18 الثلاثاء , رجب, 1442
تاريخ التأكيد : 07 الخميس , ذو القعدة, 1442
تاريخ الإصدار : 26 الأربعاء , ربيع الثاني, 1443
الکلمات المفتاحية:
stress gradient,
gasoline engine piston,
oil gallery,
high cycle fatigue life,
ملخص المقالة :
Fatigue due to thermo-mechanical stresses plays an effective role in causing damage and reducing piston fatigue life. The effect of oil gallery on the thermal stress and High Cycle Fatigue (HCF) life in a gasoline engine piston using oil gallery with considering stress gradient was investigated. For this purpose, coupled thermo-mechanical analysis of a gasoline engine piston was carried out. Then HCF life of the component was predicted using a standard stress-life analysis and results were compared to the original piston. The results of Finite Element Analysis (FEA) indicated that the stress and number of cycles to failure have the most critical values at the upper portion of piston pin. The obtained thermo-mechanical analysis results proved that the oil gallery reduces the stress distribution in the piston about 7MPa and 12MPa at engine speed 1000rpm and 5000rpm, respectively. The results of high cycle fatigue life showed that the number of cycles of failure for modified piston is approximately 33% and 37% higher than original piston at 1000rpm and 5000rpm, respectively. To evaluate properly of results, stress analysis and high cycle fatigue results is compared with real sample of damaged piston and it has been shown that critical identified areas, match well with areas of failure in the real sample.
المصادر:
He, T., Lu, X., Zou, D., Guo, Y., Li, W., and Huang, M., Thermo-Mechanical Fatigue Life Prediction for A Marine Diesel Engine Piston Considering Ring Dynamics, Journal of Advances in Mechanical Engineering, 2014, 2014, pp. 1-10.
Caldera, M., Massone, J. M., and Martı´nez, R. A., Failure Analysis of a Damaged Direct Injection Diesel Engine Piston, Journal of Failure Analysis and Prevention, 17, 2017, pp. 979-999.
Deng, X., Lei, J., Wen, J., Wen, Z., and Shen, L., Numerical Investigation On the Oscillating Flow and Uneven Heat Transfer Processes of the Cooling Oil Inside a Piston Gallery, Journal of Applied Thermal Engineering, 132, 2018, pp. 441-449.
Deng, L., Liu, Y., Wang, Z., Liu, S., and Zhang, J., Optimization of the Location of the Oil Cooling Gallery in the Diesel Engine Piston, The Open Mechanical Engineering Journal, 10, 2016, pp. 126-134.
Najafi, M., Dastani, H., Abedini, M., and Pirani, S., Stress Analysis and Fatigue Life Assessment of a Piston in an Upgraded Engine, Journal of Failure Analysis and Prevention, https://doi.org/10.1007/s11668-019-00583-4, 2019.
Zhu, N., Dong, F., Zong, M., and Ni, J., Simulation and Optimization on Oscillating Cooling Characteristics in High- Enhanced Piston Oil Cooling Gallery, SAE International Paper No.2017-01-1049, 2017.
Peng, W., Jizu, L., Minli, B. I., W. Yuyan, W., Chengzhi, H., and Liang, Z., Numerical Simulation on the Flow and Heat Transfer Process of Nanofluids Inside a Piston Cooling Gallery, Journal of Numerical Heat Transfer, Part A: Applications, Vol. 65, 2014, pp. 378-400.
Wang, P., Lv, J., Bai, M., Hu, C., Zhang, L., and Liu, H., Numerical Investigation into the Cooling Process of Conventional Engine Oil and Nano-Oil Inside the Piston Gallery, Proceedings of the FISITA 2012 World Automotive Congress, China, DOI: 10.1007/978-3-642-33750-5_26, 2012.
Luff, D. C., Law, T., and Shayler, P. J., The Effect of Piston Cooling Jets on Diesel Engine Piston Temperatures, Emissions and Fuel Consumption, SAE International Paper No. 2012-01-1212, 2012.
Binder, C., Vasanth, E., and Norling, D., Experimental Determination of the Heat Transfer Coefficient in Piston Cooling Galleries, SAE International Paper No. 2018-01-1776, 2018.
Han, S., Kim, H., Im, G., and Yoo, Y., Effect of Cooling Gallery On the Piston Temperature in a Gasoline Direction Injection Engine, Spain, http://dx.doi.org/10.4172/2167-7670.C1.005, 2016.
Wang, P., Liang, R., Yu, Y., Zhang, J., Lv, J., and Bai, M., The Flow and Heat Transfer Characteristics of Engine Oil inside the Piston Cooling Gallery, Journal of Applied Thermal Engineering, doi: http://dx.doi.org/10.1016/j.applthermaleng.2017.01.014, 2017.
Deng, X., Lei, J., Wen, J., Wen, Z., and Shen, L., Numerical Investigation On the Oscillating Flow and Uneven Heat Transfer Processes of the Cooling Oil Inside a Piston Gallery, Journal of Applied Thermal Engineering, 126, 2017, pp. 139-150.
Chen, Y., Moghe, S., Heavy Duty Engine Piston Cooling Gallery Oil Filling Ratio Measurement and Comparison of Results with Simulation, ASME Internal Combustion Engine Division Fall Technical Conference, USA, November 4-7, 2018.
Ayatollahi, M. R., Mohammadi, F., and Chamani, H., Notch Effects On High Cycle Fatigue Life of Engine Components, In: 7th International Conference on Internal Combustion Engines, Iran, 2013.
Carpenter, M., Jha, P., Ray, S., and Nienhuis, D., Fatigue Tests of Un-Notched and Notched Specimens and Life Prediction Using a Variable Critical Distance Method, SAE Technical Paper No. 2019-01-0801, 2019.
Golbakhshi, H., Namjoo, M., Dowlati, M., and Khoshnam, F., Evaluating the Coupled Thermo-Mechanical Stresses for an Aluminum Alloy Piston Used in A Gasoline Engine XU7, The Journal of Engine Research, 42, 2016, pp. 33-41.
Mirmohammadi, A., Kalhor, A., Studying Turbocharging Effects On Engine Performance and Emissions by Various Compression Ratios, American Journal of Energy Power Engineering, 4, No. 6, 2017, pp. 84-88.
Yao, Z., Qian, Z., Thermal Analysis of Nano Ceramic Coated Piston Used in Natural Gas Engine, Journal of Alloys and Compounds, doi: 10.1016/j.jallcom.2018.07.278, 2018.
Liu, X. F., Wanga, Y., and Liuc, W. H., Finite Element Analysis of Thermo-Mechanical Conditions Inside the Piston of a Diesel Engine, Journal of Applied Thermal Engineering, doi:http://dx.doi.org/10.1016/j.applthermaleng.2017.03.063, 2017.
Lee, Y. L., Pan, J., Hathaway, R. B., and Barkey, M. E., Fatigue Testing and Analysis: Theory and Practice: Elsevier Butterworth-Heinemann, 2005.
McKelvey, S. A., Lee, Y. L., and Barkey, M. E., Stress-Based Uniaxial Fatigue Analysis Using Methods Described in FKM-Guideline, Journal of Failure Analysis and Prevention, 12, 2012, pp. 445-484.
Lee, Y. L., Barkey, M., and Kang, H. T., Metal Fatigue Analysis Handbook: Practical Problem-Solving Techniques for Computer-Aided Engineering: Elsevier, 2012.
Ansys, Ver. 18.0, User’ s Manual, 2018.
Giacopini, M., Sissa, S., Rosi, R., and Fantoni, S., Influence of Different Temperature Distributions On the Fatigue Life of a Motorcycle Piston, Journal of Automotive Engineering, 229, No. 1, 2015, pp. 1276-1288.
Ayatollahi, M. R., Mohammadi, F., and Chamani, H. R., Thermo-Mechanical Fatigue Life Assessment of a Diesel Engine Piston, International Journal of Automotive Engineering, 1, No. 4, 2011, pp. 256-266.
Zhongjian, P., Qinghua, H., High Cycle Fatigue Analysis for Oil Pan of Piston Aviation Kerosene Engine, Journal of Engineering Failure Analysis, 49, 2015, pp. 104-112.
Durat, M., Kapsiz, M., Nart, E., Ficici, F., and Parlak, A., The Effects of Coating Materials in Spark Ignition Engine Design, Journal of Material and Design, 36, 2012, pp. 540-545.
Pandian, S. G., Rengarajan, S. P., Babu, T. P., Natarajan, V., Kanagasabesan, H., Thermal and Structural Analysis of Functionally Graded NiCrAlY/YSZ/Al2O3 Coated Piston, SAE International Paper No.2015-01-9081, 2015.
Dudarevaa, N. Y., Enikeeva, R. D., and Ivanov, V. Y., Thermal Protection of Internal Combustion Engines Pistons, Journal of Procedia Engineering, 206, 2017, pp. 1382-1387.
Giacopini, M., Sissa, S., Rosi, R., and Fantoni, S., Influence of Different Temperature Distributions On the Fatigue Life of a Motorcycle Piston, Journal of Automotive Engineering, 229, No. 9, 2015, pp. 1276–1288.
Ghouchani, N., Hamzei, M., Piston Stress Analysis of an Internal Combustion Engine and Provide Solutions for Piston Material, The First International Conference on New Approaches to Energy Mapping, Tehran, 2011.
Carpenter, M., Jha, P., Ray, S., and Nienhuis, D., Fatigue Tests of Un-Notched and Notched Specimens and Life Prediction Using a Variable Critical Distance Method, SAE Technical Paper: 2019-01-0801, 2019.
Silva, F. S., Fatigue on Engine Pistons – A Compendium of Case Studies, Journal of Engineering Failure and Analysis, 13, 2006, pp. 480-492.
