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Use of staircase method to validate a new design of engine pulley

Cummins Brasil LTDA-Tadeus Marchesi, Wagner Trindade
  • Technical Paper
  • 2019-36-0255
Published 2020-01-13 by SAE International in United States
A Cummins internal project demanded the development of a new crankshaft pulley. This new pulley will be mounted in the engine, but before this mounting process, a validation phase must be accomplished with the primary goal of avoiding failures during engine tests and, most of all, during vehicle operation. This article documents part of the work done to validate the new pulley, aiming to deliver a component that meets the specification demanded by the application to be released in the market. It is presented how acceptable unreliability of the pulley was assessed by means of fatigue testing. Several approaches could be used, but following internal standards for this kind of component, the procedure chosen was the staircase fatigue method. After finishing the testing phase and data treatment, the findings indicated that the new crankshaft pulley presented infinite life when subjected to the hub load found in the application with a design margin of 82%. Another validation that was carried out is related to the bolts used in the mounting. The bolted joint measurement and its…
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