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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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The Application of Virtual Engine in a PSA 1.41 SI Engine

MAHLE Metal Leve S.A.-Walter Zottin, Wagner Trindade, Marcos Clemente
PSA Peugeot Citroen-Rafael Bruno Bertoncini, Germano Moreira de Almeida
Published 2010-10-06 by SAE International in United States
Nowadays, due to the high competitiveness in the automotive market, the car manufacturers and the engine developers are concentrating as many efforts as possible in order to diminish the lead-time to production and to promote cost reductions of their engine developments.As a consequence, many systems and component tests are being substituted by numerical simulations, allowing a significant reduction in the amount of engine and bench tests. The integration of individual numerical simulation tools generates the philosophy of Virtual Engine Development, which is based on the concept of simulating as much as possible the entire engine as well as its components behaviors.This paper presents the application of Virtual Engine Development (VED) in a PSA 1.4l SI engine development. Theoretical results of engine performance as well as powercell components behavior such as piston, rings, conrod, bearings, liner, engine block and cylinder head, among others, are presented and discussed. Those simulations allowed a better knowledge of the entire engine system as well as the anticipation and solution of potential problems.To sum up, some numerical and experimental results comparisons…
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