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Fatigue Analysis of HSDI Diesel Cylinder Heads (First Report)
Published May 23, 2007 by Society of Automotive Engineers of Japan in Japan
Event: JSAE Spring Conference
The time and cost pressures on today's product engineering and development market demand rapid analysis, advanced development capabilities and high levels of precision. Where mechanical items were traditionally developed through empirical testing, today analytical tools such as FEA, MBS, EHD or CFD are in common use. Modern mechanical development strategies are characterized by an intensive model-based optimization of a virtual prototype followed by validation testing on physical high-level prototypes. Only by using these advanced methodologies it becomes possible to design today's high-performance engines much closer to the mechanical limits. The present paper focuses on the virtual phase of the mechanical development process of modern HSDI diesel cylinder heads. Apart from classical fatigue mechanisms such as TMF (thermo-mechanical fatigue) and HCF (high-cycle fatigue), also transient fatigue problems will be discussed. Detailed nonlinear FEA of the structure's load history is the basis for a better understanding of complex load mechanisms. Gaining a deeper understanding of these mechanisms can be seen as a precondition for the provision of time and cost-effective solutions to structural failure problems.