NUMERICAL MODELLING AND SIMULATION

LABORATORY REPORT

NAME: ZEYD OKUTAN MATRICOLA: 172754 EXERCISE 4: ROD ENGINE

1. Abstract The practice task is the strength verification of a rod subjected to the maximum loads during the operation cycle of an internal combustion engine. 2. Discrete Model Set-Up in Hypermesh Starting from the supplied geometrical model, the discrete model has to be obtained by using tetrahedral elements. In order to obtain the solid mesh of the rod, the external surface of the volume has to be meshed first by using shell elements. There are two critical conditions to be analyzed in the rod engine. - We make only static linear analysis and check the results. - When the rod will work in dynamic condition, we have to consider the gas pressure in maximum value, as a moment of most critical condition. When we setup our model, we should use tetrahedral mesh elements to define more complicated models than bulk materials as brick elements.

Figure 1 Engine Rod Model Material properties = 7.2E-6 kg/mm3 = 0.28 E = 165000 MPa Table 1: Material Properties 3. Loading Conditions & Theoretical Calculations Given the geometry and known the engine working conditions, it is possible to hypothesize and to analyze one or more critical conditions: Stroke: 90.4 mm Bore: 82 mm P max: 140 bar@1900 rpm Maximum number of revolutions: 5000 rpm Piston, ring and pin cumulative mass: 0.81 kg Bolts: M8x1.25 tightened at 32000 N 2

 (Gas)

(Inertia)

( ) (Inertia)

Figure 2 Forces Applied to the Engine Rod There will be two cases to be examined in this model: - First, the maximum gas force to be applied on the rod which is represented by . - Second case will be the maximum inertia force to be applied which is represented by So if we calculate the forces with the formulas given by: Fpmax = Pmax Finertiamax 2 82103 = 140105 4 4
2

m x (1+) x R x W2 = (0,81)x(1+0,9)x(45,2/1000)x(523)2 =18790N

For different cases, different load conditions will be used; as the spider models will be applied the opposite sides of the applied forces. 4. Modeling & Simulation Results In the beginning we need to import the document which is given as drawn. Then we can create the mesh model with R-trias type and 4 element size. After this, we will use the Edges command to refine the edges, under the Tool menu. Next, we can create the component with the material properties given by. For this model we have to use PSOLID property in order to get results for 3D element. Under the 3D/tetramesh menu we can fix the model in the middle of rod to create same mesh elements. After that, we use mask command to use the real model we created lately. Then, we can input the boundary conditions and also create the spider elements in order to apply the loads and constraints. We can also delete the unused nodes with Temp Nodes command under Geo. Then we can create spider element under 1D menu with Rigids command but we will only apply central node for the half part of the circle because the gas force will be effective only for lower part of the rod. After that we can apply the forces, create the Loadsteps and solve the model for the critical position.

Figure 3 Meshed Model of Engine Rod

Figure 4 Spider Node Applied

Figure 5 Forces & Constraints Applied Model

5. Results and Comparison

Figure 6 1st Case Solved Model Shows the Normal Stress Distribution

Figure 7 Solved Model of 2nd Case (Inertia Force) Stress Distribution

Figure 8 Solved Model of 2nd Case (Inertia Force) Critical Areas 5

Figure 9 1st Case Solved Model Shows the Maximum Stress Distribution

Figure 10 - 2nd Case Solved Model Shows the Maximum Stress Distribution For the first case we can see the maximum stress is around the 609MPa and it is around the pins; indeed, for the second case the maximum stress seems to be around the bolts connecting with the main body and it is around 599MPa.

Figure 11 1st Case Solved Model Shows Displacements

Figure 12 2nd Case Solved Model Shows Displacements