Effect of residual stress in low cycle fatigue for coated exhaust manifold
محورهای موضوعی :
فصلنامه شبیه سازی و تحلیل تکنولوژی های نوین در مهندسی مکانیک
Hojjat ashouri
1
1 - Department of Mechanical Engineering, Varamin-Pishva Branch, Islamic Azad University, Varamin, Iran
تاریخ دریافت : 1401/04/06
تاریخ پذیرش : 1401/05/30
تاریخ انتشار : 1401/03/11
کلید واژه:
Finite Element Analysis,
thermo-mechanical fatigue,
Exhaust manifolds and Residual stress,
چکیده مقاله :
The exhaust manifolds are subjected to higher loads than before, due to the increasing power output, fuel consumption and exhaust gas emission. Thus, simulation and analysis of fatigue cracks is essential. The effect of residual stress on the thermal stress and low cycle fatigue (LCF) life of exhaust manifolds using strain life methods was investigated. For this purpose, Solidworks software was used to model the exhaust manifolds. Then the thermo-mechanical analysis was carried out to determine the temperature and stress distribution in ANSYS software. Finally, the fatigue life prediction that considers residual stress effect was done. The simulated results proved that the thermal stresses and number of cycles to failure have the most critical values at the confluence region of the exhaust manifolds. The LCF results showed that the number of failure cycles for coated exhaust manifold is about 89% higher than the results obtained from the uncoated exhaust manifolds. Evaluating the residual stress, the TBC improves the number of failure cycles approximately 52% in comparison the uncoated exhaust manifold. The results of FEA proved a very good agreement between numerical simulation results and LCF analysis results, performed in references.
منابع و مأخذ:
Saravanan, T.N., Valarmathi, N., Rajdeep K. (2017). Prasanth, Experimental Analysis of Exhaust Manifold with Ceramic Coating for Reduction of Heat Dissipation. Journal of Materials Science and Engineering, 97, 1-6.
Padmanabha, A., Amith, R., S. Ishwara Prasanna, S. (2021). Computational Investigation of the Effect of Mullite Coating and Shape Variation on Inflow Characteristics and Thermal Stability on the Exhaust Manifold. SAE Technical Paper No.2021 01-5026.
Kuribara, H., Horikawa, H., Teraguchi, T., Nagata, T., D. Kitamura, D. (2015). Prediction of Fatigue Strength of Motorcycle Exhaust System Considering Vibrating and Thermal Stresses. SAE Technical Paper 2015-32-0739.
Castro Güiza, G.M., Hormaza, W., Andres, R., Galvis, E., Méndez Moreno L.M. (2017). Bending overload and thermal fatigue fractures in a cast exhaust Manifold. Journal of Engineering Failure Analysis, doi: 10.1016/j.engfailanal.2017.08.016.
Liu, Y., Hsin Chen, Y., Sawkar, N., Xu, N., Gaikwad S., Seaton P., Singh K. (2018). A Thermo-mechanical Fatigue Analysis on a Ductile Cast Iron Exhaust Manifold. SAE Technical Paper No.2018-01-1215.
Luo, X., Zou, P., Zeng, X., Yuan, X., Li, B. (2020). Failure Prediction and Design Optimization of Exhaust Manifold based on CFD and FEM Analysis. SAE Technical Paper No.2020-01-1166.
Ekström, M., Thibblin, A., Tjernberg, A., Blomqvist, C., Jonsson, S. (2015). Evaluation of internal thermal barrier coatings for exhaust manifolds. Journal of surface & coating technology, 272, 198-212.
Ashouri, H. (2019). Evalluation of thermal barrier coating in low cycle fatigue for exhaust manifold. Journal of Simulation & Analysis of Novel Technologies in Mechanical Engineering, 11( 2), 59-66
Caputo, S., Millo, F., Boccardo, G., Piano, A., Cifali, G., Concetto Pesce, F. (2019). Numerical and experimental investigation of a piston thermal barrier coating for an automotive diesel engine application. Journal of Applied Thermal Engineering,https://doi.org/10.1016/j.applthermaleng.2019.114233.
Godiganur, V.S., Nayaka, S., Kumar, G.N. (2020). Thermal barrier coating for diesel engine application–A review. Journal of Materials Today: Proceedings, https://doi.org/10.1016/j.matpr.2020.10.112.
Saravanan, S., Ramesh Kumar, C., Pugazhendhi, A., Brindhadevi, K. (2020). Role of thermal barrier coating and porous medium combustor for a diesel engine: An experimental study. Journal of Fuel. https://doi.org/10.1016/j.fuel.2020.118597.
Ranjbar-Far, M., Absi, J., Shahidi, S., Mariaux G. (2011). Impact of the non-homogenous temperature distribution and the coatings process modeling on the thermal barrier coatings system. Journal of Materials and Design, 32, 728–735.
Wang, L., Wang, Y., Sun X.G., J.Q. He, Pan Z.Y., Wang C.H. (2012). Finite element simulation of residual stress of double-ceramic-layer La2Zr2O7/8YSZ thermal barrier coatings using birth and death element technique. Journal of Computational Materials Science, 53, 117–127.
Pang, M., Zhang, X., Liu, Q., Fu, Y., Liu G., Tan, W. (2020). Effect of preheating temperature of the substrate on residual stress of Mo/8YSZ functionally gradient thermal barrier coatings prepared by plasma spraying, Journal of Surface &CoatingsTechnology.https://doi.org/10.1016/j.surfcoat.2020.125377.
Durga Prasad, K.V.V., Sanmala, R., Mohan Krishna, K., Hari Narayana Rao, J. (2015). Thermal Analysis of Exhaust Manifold Coating with High Temperature Resistant Materials, International. Journal of Science Engineering and Advance Technology, 3(12), 1207-1212.
Valarmathi T.N., Sekar, S., M. Purusothaman, M., Saravanan, ,K. Balan, N., Sekar, S.D., Mothilal, T. (2018). Design and thermal analysis of coated and uncoated exhaust manifold., International Journal of Ambient Energy. DOI: 10.1080/01430750.2018.1456969, (2018).
Ashouri, H. (2021). Low cycle fatigue life improvement for exhaust manifold using perimeter fins. Journal of Engine Research, 61, 23-34.
Ashouri, H. (2021). Evaluation of temperature effect on modal analysis for exhaust manifold. Journal of engine reserch, 61, 11-21.
Salehnejad, M.A., Mohammadi, A., Rezaei, M., Ahangari, (2019). Cracking failure analysis of an engine exhaust manifold at high temperatures based on critical fracture toughness and FE simulation approach. Journal of Engineering Fracture Mechanics.DOI.org/10.1016/j.engfracmech.2019.02.005, 1-54.
Ashouri, H. (2018). Thermo-mechanical fatigue simulation of exhaust manifolds, Journal of Simulation & Analysis of Novel Technologies in Mechanical Engineering, 11(2), 59-66.
Vyas, S., Patidar, A., Kandreegula, S., Gupta, U. (2015). Multi-Physics Simulation of 6-Cylinder Diesel Engine Exhaust Manifold for Investigation of Thermo-Mechanical Stresses. SAE Technical Paper 2015-26-0182.
Jianghui, M., Engler-Pinto, C., Xuming, S. (2015). Comparative Assessment of Elastio-Viscoplastic Models for Thermal Stress Analysis of Automotive Powertrain Component. SAE Technical Paper No. 2015-01-0533.
Pevev, M., Oder, G., Sraml, M. (2014). Elevated temperature low cycle fatigue of grat cast iron used for automotive brake disks. Journal of engineering failture analysis, 42, 221–230.
L. Chaboche, J.L. (2008). A review of some plasticity and viscoplasticity constitutive theories. International Journal of Plasticity, 24, 1642–1693.
Li, X., Wang, W., Zou, X., Zhang, Z., Zhang, W., Zhang, S., Chen, T., Cao, Y., Chen, Y. (2017). Simulation and Test Research for Integrated Exhaust Manifold and Hot End Durability. SAE Technical Paper No .2017-01-2432.
B. Heywood, J.B. (1998). Internal combustion engine fundamentals. McGraw-Hill press.
Chen, M., Wang, Y., Wu, W., Xin, J. (2014). Design of the Exhaust Manifold of a Turbo Charged Gasoline Engine Based on a Transient Thermal Mechanical Analysis Approach. SAE Technical Paper 2014-01-2882.
Mamiya, N., Masuda, T., Noda, Y. (2006). Thermal Fatigue Life of Exhaust Manifolds Predicted by Simulation. SAE Technical Paper 2002-01-0854.
Stephens, R., Fatemi, A., Fuchs, A. (2005). Metal fatigue in engineering, 2nd edition, John Wiley.
Lee, Y.L., Pan, J., Hathaway, R.B., Barkey, M.E. (2005). Fatigue Testing and Analysis: Theory and Practice, Elsevier Butterworth-Heinemann.
Tzimas, E., Muellejans, H., Peteves, S., Bressers, J., Stamm, W. (2000). Failure of Thermal Barrier Coating Systems under Cyclic Thermomechanical Loading. Journal of Acta Materialia, 48, 4699-4707.
Trampert, S., Göcmez, T., Quadflieg, F. (2006). Thermomechanical Fatigue Life Prediction of Cast Iron Cylinder Heads. ASME Internal Combustion Engine Division 2006 Spring Technical Conference, ICES2006-1420.
Londhe, A., and Yadav, (2007). Thermo-structural Strength Analysis for Failure Prediction and Concern Resolution of an Exhaust Manifold. CAE, R&D, Mahindra and Mahindra Ltd,Automotive Sector, Nasik, India.
