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Stress and fatigue analysis of engine pistons using thermo-mechanical model

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Abstract

This paper presents a thermo-mechanical finite element analysis model for the stress and fatigue analyses of engine pistons. The model consists of the piston, piston pin, piston ring, bushing, cylinder liner and connecting rod. The oil film and contact pressure are considered in the contact surfaces between the piston and piston pin, the piston pin and bush, and the piston skirt and cylinder liner. A self-compiled code, which considers the factors of the piston skirt profile and ellipticity, is applied to calculate the initial clearance at the oil film surfaces between the piston and piston pin, the piston pin and bush, and the piston skirt and cylinder liner. The dynamic loads of the piston and connecting rod under the peak torque and peak power cases are calculated using powertrain commercial software, which are then used to carry out the stress and fatigue analyses. Compared with those published in literature, the present model is able to simulate the actual working conditions of the piston more accurately. The model can be used to evaluate and assess the piston skirt pressure, the stress and fatigue life of the concerned areas of the piston.

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Abbreviations

F N :

Normal force between the two contact surfaces

F τi :

Tangential force between the two contact surfaces

ΔN :

Relative normal displacement

Δτi :

Relative tangential displacement

δ0 :

Critical clearance at which the contact pressure of the oil film is zero

Δ:

Radius contraction

G :

Ellipticity

α :

Angle between the line from the point on the ellipse to the origin and the long axis of the ellipse

β :

Fullness factor of the ellipse

δ :

Clearance between the two contact surfaces

λ :

Empirical constant determined by experimental data

μ:

Friction coefficient

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Acknowledgments

The work presented in the paper was supported by Ningbo University via the Project (012-811701490) and sponsored by K. C. Wong Magna Fund in Ningbo University.

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Authors and Affiliations

  1. Faculty of Maritime and Transportation, Ningbo University, Feng Hua Road 818, Ningbo, China

    Zhenlei Chen, Jiancheng Li, Junxiong Liao & Fan Shi

Authors
  1. Zhenlei Chen
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  2. Jiancheng Li
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  3. Junxiong Liao
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  4. Fan Shi
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Corresponding author

Correspondence to Zhenlei Chen.

Additional information

Recommended by Associate Editor Seok Pil Jang

Zhenlei Chen earned his doctoral degree at the University of Illinois at Chicago in May 2000. Thereafter he became a Senior Engineer at Powertrain Engine Engineering of Ford Motor Company, USA. In May 2012 he was employed by Sany Heavy Machinery Co. Ltd. China, acting as a Technical Director and Vice President of the research institute. In May 2016 he was appointed as a Professor of Ningbo University in China.

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Chen, Z., Li, J., Liao, J. et al. Stress and fatigue analysis of engine pistons using thermo-mechanical model. J Mech Sci Technol 33, 4199–4207 (2019). https://doi.org/10.1007/s12206-019-0815-y

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  • DOI: https://doi.org/10.1007/s12206-019-0815-y

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