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Chapter 26: Interference Fit Contact

26 Interference Fit Contact


Summary 456

Introduction 457

Solution Requirements 457

Analytical Solution 457

FEM Solution 458

Modeling Tips 460

Input File(s) 460

Video 461
456 MD Demonstration Problems
CHAPTER 26

Summary
Title Chapter 26: Interference Fit Contact
Contact features Deformable-deformable contact
Contact interference
Geometry • Valve insert inside radius, a = 15.5 mm
• Valve insert outside radius, b + h = 20 + 0.05 mm
• Cylinder head valve insert opening radius, b = 20 mm

a
b+h

CL

Material properties E head = 224 kN/mm


2
E seat = 125 kN/mm
2

 hea d = 0.26  s eat = 0.25

Analysis type Quasi-static analysis


Boundary conditions • Some nodes on the periphery of the cylinder head are fixed
• Contact between cylinder head and valve insert includes an initial interference fit
Applied loads None
Element type 10-node tetrahedron elements
Contact properties Coefficient of friction  = 0.15 with an interference shrink of 0.050 mm.
FE results Plots of radial and hoop stresses versus radial distance from valve center
Radius (mm)
15 16 17 18 19 20 21 249166
0 246621 246815
A B 247999 B
246823 247587
-100 Radial Stress 248815

246622 A 246615
Radial Stress FEA
-200
248830 249221
Hoop Stress FEA
X Y, r
-300 Hoop Stress 246821 246816
Z

248019 248604
-400

246619 246617
-500 Stress (MPa) 248024 246820 248039
CHAPTER 26 457
Interference Fit Contact

Introduction
The interference fitting of a valve insert into a cylinder head recess is to be simulated. The general arrangement is
shown in Figure 26-1. The compressive interference between the valve insert external radius and the cylinder head
valve recess opening is 0.05 mm. Only a portion of the relatively stiff cylinder head is modeled. An approximate
analytical solution for the stress in the valve insert can be found from a deformation analysis of thick-walled cylinders
subject to symmetric external loading.

Figure 26-1 Valve Insert Fitted into Cylinder Head

Solution Requirements
A single solution is sought and the average hoop and radial stresses in the valve insert are compared to a thick cylinder
solution assuming the cylinder head is rigid. Comparison plots include average hoop and radial stresses plotted along
the radial distance from the value center for the predicted and analytic solutions.

Analytical Solution
An estimate for the hoop and radial stresses in the valve insert can be obtained from the analytical solution of a two-
dimensional plane stress (axial stress assumed to be zero) thick walled cylinder with prescribed displacement on its
external radius. The analytical solution assumes the cylinder head is rigid and the radial displacement of the insert at
its external radius is equal to the interference fit.
The thick walled cylinder solution only varies with radius, r , where the radial displacement, u , becomes the solution
C
of d  1--- d  ur  = 0 or u  r  = C 1 r + -----2- . The stresses are then determined from the radial displacement as,
dr r dr r

E C
-  1 +  C 1 –  1 –   -----2-
 rr = -------------------
2 r
1 –  
subjected to the boundary conditions, u  b  = h = – 0.05 mm and  rr  a  = 0 .
E C
-  1 +  C 1 +  1 –   -----2-
  = -------------------
2 r
1 –  
458 MD Demonstration Problems
CHAPTER 26

This yields the analytic solutions of

– bh  1 +  a 2 +  1 –  r 2-
u  r  = --------- ------------------------------------------------------
r  1 +  a 2 +  1 –  b 2

– Ebh a2
 rr = ----------------------------------------------------------
- 1 – ----
-
  1 + v a 2 +  1 –  b 2  r2

– Ebh a2
  = ----------------------------------------------------------
- 1 + ----
-
  1 + v a 2 +  1 –  b 2  r2

FEM Solution
A numerical solution has been obtained with MD Nastran's SOL 400 for the element mesh (shown in Figure 26-2)
using higher order tetrahedron elements. The contours show the two contact bodies defined in this analysis.

Figure 26-2 FEA Model for Interference Fit

Contact body id 1 is identified by the element property IDs 1 and 3 for the cylinder head while contact body ID 4 is
identified by the element property ID 2 for the valve insert as:
BCPROP 1 1 3
BCBODY 1 3D DEFORM 1 0
...

and
BCPROP 4 2
BCBODY 4 3D DEFORM 4 0
...

Furthermore, the BCTABLE entries shown below identify that these bodies can touch each other:
BBCTABLE 0 1
SLAVE 4 0.3 0. .0 0. 0 0.
1 1 0
MASTERS 1
CHAPTER 26 459
Interference Fit Contact

BCTABLE 1 1
SLAVE 4 0. 0. .15 0.050 0 0.
1 0 0
MASTERS 1

Additionally, BCTABLE ID 1 shows the coefficient of friction to be 0.15 and the interference closure to be 0.05 mm.
BCTABLE ID 1 is referenced in the BCONTACT entry of the STEP case control command:
STEP 1
BCONTACT=1
SUBTITLE=FRETTAGE
NLPARM = 1
SPC = 2
LOAD = 10

Although there are no forces applied in this problem, a dummy LOAD = n case control is required for SOL 400.
Figure 26-3 plots the FEA and analytical solutions for the hoop and radial stresses in the valve insert against the radius
from the valve center. An arbitrary cross-section (high noon position of Figure 26-1) of the valve insert along the free
surface was chosen to pick the FEA stresses. The results of the analytical and FEA solutions are in general agreement.

Radius (mm)
15 16 17 18 19 20 21 249166
0 246621 246815
A B 247999 B
246823 247587
-100 Radial Stress 248815

246622 A 246615
Radial Stress FEA
-200
248830 249221
Hoop Stress FEA
X Y, r
-300 Hoop Stress 246821 246816
Z

248019 248604
-400

246619 246617
-500 Stress (MPa) 248024 246820 248039

Figure 26-3 Hoop and Radius Stress versus Radius From Valve Center

Several factors may have contributed to the difference in results. The analytical solution assumes a perfectly shaped
insert with prescribed displacements on the outside radius. On the other hand, the portion of the cylinder head that is
modeled using FEA is a nonsymmetric deformable body, which makes the FEA results slightly nonuniform across the
circumference as shown in Figure 26-4. The valve insert is in contact with the cylinder head not only across the insert's
cylindrical surface but across its bottom surface as well. In addition, the shape of the cross-section of the valve seat
disc has a slant edge on its top free surface.
460 MD Demonstration Problems
CHAPTER 26

Figure 26-4 Slightly Nonuniform Hoop Stress in Valve Insert

Modeling Tips
This application example holds the insert in position by contact and friction. Take out friction, and the insert may (or
may not) pop out - in which case, the best thing is to add some soft springs, or a very small amount of friction to hold
it in place in the axial direction. Using the parabolic tetrahedral elements allows for good contact detection of the
cylindrical surface which yields a very smooth contact condition between the two bodies.
If the interference distance is small compared to the element size, the default contact tolerances will probably be ok;
however, it is possible that the interference fit will end up larger than the contact distance tolerance and contact will
be missed (one reason for a spotty stress plot). The remedy is to specify a distance tolerance equal to the interference
fit for the contact pair in the table, as well as a bias of 0.99 in general.

Input File(s)
File Description
nug_26s4.dat Parabolic Tetrahedral Elements With Friction
CHAPTER 26 461
Interference Fit Contact

Video
Click on the image or caption below to view a streaming video of this problem; it lasts approximately 30 minutes and
explains how the steps are performed.

a
b+h

CL

Figure 26-5 Video of the Above Steps

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