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Research Papers: Internal Combustion Engines

Thermomechanical Fatigue Life Prediction of Cylinder Heads in Combustion Engines

[+] Author and Article Information
Stefan Trampert

 FEV Motorentechnik GmbH, Neuenhofstraße 181, 52078 Aachen, Germany

Taner Gocmez, Stefan Pischinger

RWTH Aachen, Institute for Internal Combustion Engines (VKA), Schinkelstraße 8, D-52062 Aachen, Germany

J. Eng. Gas Turbines Power 130(1), 012806 (Jan 11, 2008) (10 pages) doi:10.1115/1.2771251 History: Received July 19, 2006; Revised May 16, 2007; Published January 11, 2008

While the deformation and damage behavior of aluminum cylinder heads under complex thermal mechanical loading has been the subject of numerous studies in the past, cast iron cylinder heads have been in the focus of thermomechanical fatigue (TMF) only to a minor extent. In this paper, a feasible procedure is presented to set up material models and estimate service life of cast iron cylinder heads under variable thermomechanical loading conditions by the use of computer-aided engineering tools. In addition, the influence of thermal load and mechanical constraints on TMF life span is shown. A specimen model is used for parameter identification in material model setup and a cylinder head model is used for correlation with cracking phenomena. Investigation of different thermomechanical load influences is conducted on the cylinder head model. The principal strain and energy based fatigue criteria are used in assessment of TMF lifetime for the cast iron family and material specific evaluation procedures are pointed out. The results highlight the importance of exact definitions of the boundary conditions and underline the sensitivity of TMF lifespan of cast iron cylinder heads with respect to the defined boundary conditions. Considering this sensitivity, an approach conforming to the engine development requirements is proposed. It is shown that both the crack location and fatigue lifetime are predicted with high accuracy.

Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

Standpoint for material modeling in TMF analysis

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Figure 2

TMF analysis approach for specimen model

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Figure 3

The two most common matrix structures; ferrite and pearlite on the left (2) and graphite shapes on the right

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Figure 4

Thermal expansion coefficient as a function of temperature

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Figure 5

Thermal conductivity as a function of temperature

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Figure 6

Young’s modulus as a function of temperature

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Figure 7

Analysis history for parameter identification, temperatures, and stresses and strains over time

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Figure 8

Maximum and minimum stresses as a function of temperature amplitude: Tmin=150°C=const, εm,tGJS-600=4‰, εm,tGJL-300=−1‰

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Figure 9

Mean stress as a function of mean strain for GJL-300, GJV-300, GJS-400, and GJS-600. Tmin=150°C, Tamplitude=150°C.

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Figure 10

Number of cycles to failure as a function of mean total strain. Tmin=150°C, Tmax=450°C.

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Figure 11

Number of cycles to failure as a function of temperature amplitude. εm,tGJS-600=4‰, εm,tGJS-400=0‰, εm,tGJV-300=0‰, εm,tGJL-300=−1‰.

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Figure 12

Correlation of experimental and simulation results

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Figure 13

TMF cracks on a heavy duty diesel cast iron-GJV-450-CH

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Figure 14

TMF analysis approach for CH

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Figure 15

Temperature comparison (left) and life span comparison with respect to Modified Manson–Coffin (right) of nominal rated and increased power for GJL-300

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Figure 16

Influence of friction between CH and CHG on lifetime with respect to Modified Manson–Coffin and SWT parameter for GJL-300 and GJV-450, respectively, at increased power

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Figure 17

Temperature distribution at nominal rated power for different types of cast irons

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Figure 18

Lifetime distribution at increased power (+16%) for different types of cast irons, flame deck surface injector-valve bridge area

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