Effect of viscosity stress on the low cycle fatigue of the cylinder head

Document Type : Research Article

Author

Department of Mechanical Engineering, Varamin-Pishva Branch, Islamic Azad University, Varamin, Iran

Abstract

Loading conditions and complex geometry have led the cylinder head to become the most challenging component in the engine. The cracks in valves in bridge areas are one of the vital durability problems in engines, showing the necessity of the simulation and analysis of fatigue cracks. The present study used the finite element method to analyze the low cycle fatigue (LCF) life. The ANSYS software was also used to predict the temperature, stresses, and LCF life through Morrow theory and nCode Design Life software. The LCF tests were conducted at different temperatures to obtain the mechanical properties of aluminum-silicon-magnesium alloy. The combination of the Chaboche nonlinear isotropic-kinematic hardening model with viscous stress law was used to consider the effect of stress viscosity. LCF tests were simulated by ANSYS software, showing a very good fit between the experimental and simulation results of LCF tests. The results of finite element analysis suggested that the maximum temperature and stress values in the cylinder head were 205.67°C and 83.958MPa. According to the fatigue life analysis results, neglecting the stress viscosity effect led to estimating 105 cycles, or about 5.9% higher than the limit. Therefore, it is necessary to consider the stress viscosity effect in the analysis of the low cycle fatigue life of the cylinder head.

Keywords

Main Subjects

References

[1] G.X. Jing, M.X. Zhang, S. Qub, J.C. Pang, C.M. Fu, C. Dong, S.X. Li, C.G. Xu,  Z.F. Zhang, Investigation into diesel engine cylinder head failure, Engineering Failure Analysis, 90 (2018) 36–46.
[2] W-J Lai, C. Engler-Pinto, Development of a Thermal Fatigue Test Bench for Cylinder Head Materials. SAE Technical Paper No.2018-01-1410, (2018).
[3] H. Zhang, Y. Cui, G. Liang,  L. Li, G. Zhang, X. Qiao, Fatigue life prediction analysis of high‑intensity marine diesel engine cylinder head based on fast thermal fluid solid coupling method,  Journal of the Brazilian Society of Mechanical Sciences and Engineering, 43 (2021) 1-15.
 [4] P-R. Ren, W. Song, G. Zhong, W.Q. Huang, Z.X. Zuo, C.Z. Zhao, K.J. Yan, High-cycle fatigue failure analysis of cast Al-Si alloy engine cylinder head, Engineering Failure Analysis, 127 (2021) 1-15.
[5] H. Ashouri, B. Beheshti, M.R. Ebrahimzadeh, Analysis of fatigue cracks of diesel engines cylinder heads, Journal of Theoretical and Applied Mechanics, 54(1) (2015) 369-383.
[6] H. Ashouri, Thermo-mechanical analysis of magnesium alloy diesel engines cylinder heads using a two-layer viscoplasticity model, Automotive Science Engineering, 12(3) (2022) 3892-3904.
[7] X. Zeng, X. Luo, G. Jing, P. Zou, Y. Lin, T. Wei, X. Yuan, H. Ge, Engine Cylinder Head Thermal-Mechanical Fatigue Evaluation Technology and Platform Application. SAE International Journal of Engines, 13(1) (2020) 101-120.
[8] T. Seifert, R. Hazime, C-C. Chang, C. Hu, Constitutive Modeling and Thermo-mechanical Fatigue Life Predictions of A356-T6 Aluminum Cylinder Heads Considering Ageing Effects, SAE Technical Paper No.2019-01-0534, (2019).
[9] Y. Liu, P. Annabattula, S. Mirmiran, L. Zhang, J. Chen, S. Gaikwad, K. Singh, Assessing Thermo-mechanical Fatigue of a Cast Aluminum Alloy Cylinder Head of an Internal Combustion Engine, SAE Technical Paper No.2020-01-1077, (2020).
[10] H. Ashouri, Thermal barrier coating effect on stress and temperature distribution of diesel engines cylinder heads using a two layer viscoelasticity model with considering viscosity, International Journal of Automotive Engineering, 7(2) (2017) 2380-2392.
[11] M. Beranger, J-M. Fiark, K. Ammar, G. Calletaud, A new fatigue model including thermal ageing for low copper aluminum-silicon alloys, Procedia Engineering, 213 (2018) 720-729.
[12] K. Satyanarayana, T.V. Hanumantha Rao, Response optimization of four stroke variable compression ratio diesel engine cylinder head with stress analysis, Material Today: Proceeding, 5 (2018) 19497-19506.
[13] M.  Fontea, L. Reis, V. Infanteb, M. Freitas,  Failure analysis of cylinder head studs of a four stroke marine diesel engine, Engineering Failure Analysis, 101 (2019) 101:298–308.
[14] Y. Wang, Z. Xu, M. Chen, Thermo-Mechanical Fatigue and Life Prediction of Turbocharged Engine Cylinder Head, SAE Technical Paper No.2020-01-1163, (2020).
[15] A. Pingale, C-C. Chang, J. Perander, Data Driven Model to Predict Cylinder Head Fatigue Failure, SAE Technical Paper No. 2021-01-0801, (2021).
[16] H. Ashouri, Evaluation of quenching process on low cycle fatigue life for cylinder head, Automotive Science Engineering, 12(4) (2022) 3971-3979.
[17] H. Blondet, K. Barthoux, Fatigue software improvement for calculating by FEA a complete map of the damage due to a duty cycle, regarding thermo-mechanical failure mode, Procedia Structural Integrity, 38 (2022) 526–537.
[18] W. Yang, J. Pang, L. Wang, X. Kang, S. Zhou, C. Zou, S. Li, Z. Zhang, Thermo-mechanical fatigue life prediction based on the simulated component of cylinder head, Engineering Failure Analysis, 135 (2022) 1-13.
[19] H. Ashouri, Low cycle fatigue prediction for cylinder heads considering stress gradient and local yielding. Proceedings of the Institution of Mechanical Engineers, Part D: Journal of Automobile Engineering, (2024). Accepted paper.
[20] H. Ashouri, Low cycle fatigue prediction for cylinder head considering notch stress-strain correction proposed by Neuber, Journal of Simulation and Analysis of Novel Technologies in Mechanical Engineering, 14(3) 2022 5-15.
[21] H. Ashouri, Finite element analysis of thermo-mechanical stresses in diesel engines cylinder heads using a two-layer viscoelasticity, International Journal of Automotive Engineering, 5(4) (2015) 2054-2064.
[22] J.L. Chaboche, A review of some plasticity and viscoplasticity constitutive theories, InternationalJournal of Plasticity, 24 (2008) 1642–1693.
[23] M. Bartošák, M. Španiel, K. Doubrava, Unified viscoplasticity modelling for a SiMo 4.06 cast iron under isothermal low-cycle fatigue-creep and thermo[1]mechanical fatigue loading conditions, International Journal of Fatigue, 136 (2020).
[24] M. Angeloni, Fatigue life evaluation of A356 aluminium alloy used for engine cylinder head, Ph.D Thesis, University of Sau Palu, Brazil, 2011.
[25] W. Yang, J. Pang, L. Wang, X. Kang, S. Zhou, C. Zou, S. Li, Z. Zhang, Thermo-mechanical fatigue life prediction based on the simulated component of cylinder head, Engineering Failure Analysis, 135, 1-13 (2022) 1-13.
[26] R. Stephens, A. Fatemi, H. Fuchs H, Metal fatigue in engineering. John Wiley, 2001.
[27] Q. Zhang, Z. Zuo, J. Liu, Failure analysis of a diesel engine cylinder head based on finite element method, Engineering Failure Analysis, 34 (2013) 51–58.
Amirkabir Journal of Mechanical Engineering
Volume 56, Issue 8
2024
Pages 1053-1074

Files

Share

How to cite

Statistics