Synergic computational and experimental development of a cast iron crankshaft for high performance automotive diesel engine

• Autorzy: Peirano R. , Barbato S. , Ceronetti G. , Di Franco A. , Golisano R. , Vassallo A.
• Konferencja: Kongres Silników Spalinowych (20-23.05.2007; Kraków, Poland)
• Języki publikacji: EN

Abstrakty

EN

In order to achieve consistent cost reduction, an extensive and simultaneous experimental and computational activity has been performed within GM Powertrain Europe (GMPT-E) with the aim of substituting a steel crankshaft with a cast iron one in a high performance automotive diesel engine, as described in this paper. By means of a preliminary simulation analysis the most critical sections of the crankshaft have been identified andsubsequently strain-gauges have been installed in such locations on a prototype crankshaft. This latter has been then installed on a firing engine in order to provide bending and torsion stresses on the selected points, so to correlate the crankshaft mathematical model outputs with actual results. The following step has been to run a more detailed simulation, by using the calibrated finite element model of the crankshaft, in the framework of a multi-body analysis, with the aim of assessing the crankshaft fatigue behaviour. A key feature of the above described approach is the ability to set-up a reliable mathematical model to be extensively applied for Virtual Validation, by means of DOE (Design Of Experiment), FLP (Fatigue Life Prediction) and DFSS (Design For Six Sigma) approaches, aimed at assuring a final robust design of the crankshaft. The activities described above, together with GM standard components reliability verification, demonstrated the feasibility of this cost reduction initiative and provided a powerful design and validation technique in the framework of the ongoing migration from "road to rig to math".

Słowa kluczowe

EN

crankshaft; cast iron; diesel engine; virtual validation

PL

wał korbowy; żeliwo; silnik Diesla

• Wydawca: Polskie Towarzystwo Naukowe Silników Spalinowych
• Czasopismo: Silniki Spalinowe
• Rocznik: 2007
• Tom: R. 46, nr SC1
• Strony: 98--110
• Opis fizyczny: Bibliogr. 10 poz.

Twórcy

autor

Peirano R.

autor

Barbato S.

autor

Ceronetti G.

autor

Di Franco A.

autor

Golisano R.

autor

Vassallo A.

• General Motors Powertrain Europe, Torino, Italy

Bibliografia

• [1] J. Raub, J. D. Jones, P. Kley and M. Rebbert, "Analytical Investigation of Crankshaft Dynamics as a Virtual Engine Module", SAE Paper 1999-01-1750, 1999
• [2] T. Ortjohann, M. Rebbert, F. Maassen and M. Robers, "3D-Durability Analysis of Crankshafts via Coupled Dynamic Simulation including Modal Reduction", SAE Paper 2006-01-0823, 2006
• [2] A. Di Franco and R. Golisano, "Z19DT/H cast iron crankshaft - simulation activity", GMPT-E internal report, 2005
• [3] J. Raub, J. Jeff Jones and B. Tickel, "Engine Structural Vibrations", ADAMS International Users' Conference, 1998.
• [4] R.R. Craig and M.C.C. Bampton, "Coupling of Substructures for Dynamic Analysis", AIAA Journal, Vol. 6, No. 7, 1968
• [5] S. Barbato, G. Ceronetti and A. Vassallo, "Z19DT/H cast iron crankshaft - testing activity", GMPT-E internal report, 2006
• [6] AAVV, "Crankshaft testing for design verification", GMPT-E internal test procedure, 2000
• [7] G. Genta, "Principles and methodologies of mechanical designing", Levrotto&Bella Torino, 1999 (in Italian)
• [8] D.C. Montgomery, "Design and analysis of experiments", Wiley, 2005
• [9] A.C. Pickard, "The application of 3-D finite element methods to fracture mechanics and fatigue life prediction", Warley, 1986
• [10] K. Yang and B. El-Haik, "Design for Six Sigma: a roadmap for product development", McGraw-Hill, 2003 Konstrukcja/Design Synergic computational and experimental development[...] 110