ML18100A892: Difference between revisions

From kanterella
Jump to navigation Jump to search
(StriderTol Bot change)
(StriderTol Bot change)
 
Line 2: Line 2:
| number = ML18100A892
| number = ML18100A892
| issue date = 12/28/1993
| issue date = 12/28/1993
| title = Rev 1 of Finite Element Stress Analysis.
| title = Rev 1 of Finite Element Stress Analysis
| author name =  
| author name =  
| author affiliation = MPR ASSOCIATES, INC.
| author affiliation = MPR ASSOCIATES, INC.
Line 19: Line 19:
{{#Wiki_filter:*.
{{#Wiki_filter:*.
MPR ASSOCIATES, INC.
MPR ASSOCIATES, INC.
320 King Street, Alexandria, VA 22314
320 King Street, Alexandria, VA 22314  
~1--~~~~~~~~~~CA_L_c_u_L_A_T_I_O_N_T_IT_L_E_P_A_G_E~~~r--~~~~~~~
~1--~~~~~~~~~~CA_L_c_u_L_A_T_I_O_N_T_IT_L_E_P_A_G_E~~~r--~~~~~~~
Client \'\.,I                                     ' L. &o U-".)                      PAGE 1 OF  35
Client \\'\\.,I \\1,..
                .y'-'61\ 1......
S='"\\C."'
                          ,.. S='"\C."'
o 1
                                  ""--'.. .._ f kc,tr1             1 Project                                                                              TASK NO.
.y'-'61......
SQ.le.M EDCr Lv1~ Cr~c.k.1115                                                     l0'8. ~2 Calculation Title                                                                     CALCULATION NO.
.._ f kc,tr1 L. & U-".)
REVISION                       PAGE NO.                 PREPARER(S)/    CHECKER(S)/    REVIEWER(S)/
Project SQ.le.M EDCr Lv1~ Cr~c.k.1115 Calculation Title REVISION PAGE NO.
NO.                       AFFECTED                     DATE            DA'fij,      _ DATE cp                             -                    ;g!!
PREP ARER(S)/
11/t?/13 5 I 10 I II I \?.-I \')-2.~
NO.
j_                                                  j{fi) 7./21/13 1
AFFECTED DATE cp  
*~======+/-=============~*===============~
;g!!
                                                      ,'. .'l "
11/t?/13 j_
i *1*
5 10 I II \\?.- \\')-2.~
I.*
I I
I l__ L
I j{fi) 17./21/13 PAGE 1 OF 35 TASK NO.
l0'8. ~2 CALCULATION NO.
CHECKER(S)/
DA'fij, REVIEWER(S)/
DATE
*~======+/-=============~*===============~  
,'..'l ii *1*
I I.*
l __ L  


MPR Associates, Inc.
mMPR MPR Associates, Inc.
  '  . mMPR                                                                        320 King Street Alexandria, VA 22314 RECORD OF REVISIONS ahe~
320 King Street Alexandria, VA 22314 RECORD OF REVISIONS Calculation No.
Calculation No.               Prepared By Page 2-JD<6'*32'0/               I--                                       ~r:
Prepared By ahe~
Revision                                                 Description cb         :rf) 1~0,.\ 1..ss'-'C..
JD<6'*32'0/
                ~(grF~~l         'Z.-J lfo, ,. 1 (o""'""f..-,.~ f;.c-. ~Sl i.-<r-1-
I--
~r:
Page 2-Revision Description cb
:rf) 1~0,.\\ 1..ss'-'C..
1-
~(grF~~l 'Z.-J lfo,,.. 1 (o""'""f..-,.~ f;.c-. ~Sl i.-<r-


MPR Associates, Inc .
. mMPR MPR Associates, Inc.
  '    . mMPR                                                        320 King Street Alexandria, VA 22314 Calculation No.             Prepared By 108'51..-0'                   /-<-                     g~~                        Page 3
320 King Street Alexandria, VA 22314 Calculation No.
1.0       PURPOSE The purpose of this calculation is to estimate the stresses in an ALCO 251 diesel engine cylinder liner. The stresses are calculated for the nominal liner configuration and several other configurations to evaluate the effect of variations in design parameters.
Prepared By g~~
2.0       RESULTS For each case evaluated the maximum stress occurs at the relief groove, at a location about 45&deg; from the groove/flange intersection. The principal stresses at this. location are oriented at an angle of about 45&deg;. The maximum calculated stresses are summarized below in the "principal stress" coordinate system (rotated 45&deg;).
108'51..-0' Page 3
Stress Case               ax             O'             az           Intensity (psi)           (pli)         (psi)             (psi)
/-<-
Nominal           43420           9036           18770           34566 Block Gap           43449           9045           18785             34586 Relief           46239           6292           18779             40117 Groove Depth         43329           9010           18712             34498 2 Mil Offset         46516           9908           20232             36870 8 Mil Offset         55425           12413         24223             43550 Nominal Firing         24424           5049         11148             19461 2 Mil Offset Firing     27452           5902         12573             21713 8 Mil Offset Firing     32677           7335           14937           25659 Worst Case           59628           13533         25983             46158 Worst Case Firing       35258           8016           15947           27279 The cases evaluated are described in detail in section 3.3 .
1.0 PURPOSE The purpose of this calculation is to estimate the stresses in an ALCO 251 diesel engine cylinder liner. The stresses are calculated for the nominal liner configuration and several other configurations to evaluate the effect of variations in design parameters.
2.0 RESULTS For each case evaluated the maximum stress occurs at the relief groove, at a location about 45&deg; from the groove/flange intersection. The principal stresses at this. location are oriented at an angle of about 45&deg;. The maximum calculated stresses are summarized below in the "principal stress" coordinate system (rotated 45&deg;).
Stress Case ax O'
az Intensity (psi)
(pli)
(psi)
(psi)
Nominal 43420 9036 18770 34566 Block Gap 43449 9045 18785 34586 Relief 46239 6292 18779 40117 Groove Depth 43329 9010 18712 34498 2 Mil Offset 46516 9908 20232 36870 8 Mil Offset 55425 12413 24223 43550 Nominal Firing 24424 5049 11148 19461 2 Mil Offset Firing 27452 5902 12573 21713 8 Mil Offset Firing 32677 7335 14937 25659 Worst Case 59628 13533 25983 46158 Worst Case Firing 35258 8016 15947 27279 The cases evaluated are described in detail in section 3.3.  


                                                                  -: MPR' Associates, Inc .
.. mMPR"-
    . mMPR"-                                                        320 King Street Alexandria, VA 22314 Calculation No.
-: MPR' Associates, Inc.
106*32'0/
320 King Street Alexandria, VA 22314 Calculation No.
Prepared By
Prepared By  
                                    ~
~
Page   q-
Page q-106*32'0/
* i-----------"--------1-----L--
i-----------"--------1-----L--
3.0       CALCULATION 3.1       Model The stresses in the liner are calculated using an axisymmetric finite element model of the liner as shown in Figures 1 and 2. Contact (gap) elements are included between the liner and block to simulate the contact force. The finite element model of the cylinder liner was developed using nominal dimensions for the liner and engine block. As described below, other cases were also evaluated to determine the effect of changes in some of the.liner dimensions.
3.0 CALCULATION 3.1 Model The stresses in the liner are calculated using an axisymmetric finite element model of the liner as shown in Figures 1 and 2. Contact (gap) elements are included between the liner and block to simulate the contact force. The finite element model of the cylinder liner was developed using nominal dimensions for the liner and engine block. As described below, other cases were also evaluated to determine the effect of changes in some of the.liner dimensions.
The key dimensions used in developing the model are shown in Figure 3. The primary references for the dimensions are References 1 and 2, the Bombardier Design Print for the liner and the ALCO 251 Technical Manual. These dimensions are summarized below:
The key dimensions used in developing the model are shown in Figure 3. The primary references for the dimensions are References 1 and 2, the Bombardier Design Print for the liner and the ALCO 251 Technical Manual. These dimensions are summarized below:
RR4=1/2 BLKIR=l0.752/2                                   RR5=5/8 RELIEF=0.133 DEPTH=0.05                                       Cl=R3-9.8/2 FLOFF=0.0001 (the flange offset)
BLKIR=l0.752/2 RELIEF=0.133 DEPTH=0.05 FLOFF=0.0001 (the flange offset)
LTOT=21+15/16 IR=9/2                                           Ll = 1.732*(R2-Rl)
IR=9/2 R1=(9+9/16)/2 R2=10/2 R3=10.254/2 R4=10/2 R5=10.2/2 R6=10.71/2 R7=10/2 R8=10.75/2 R9=11.865/2 R10=R9-l/4 Rll=l0.660/2 R12=10/2 R13=(9+ 19/32)/2 R14=R9-1/8 BLKOR=R9+0.25 BLKHT=0.75 RTAN =RS-DEEP+ RELIEF RRl=l/2 RR2=5/8 RR3=5/8 RR4=1/2 RR5=5/8 Cl=R3-9.8/2 LTOT=21+15/16 Ll = 1.732*(R2-Rl)
R1=(9+9/16)/2                                     L3=0.333 R2=10/2                                           L5=5/16 R3=10.254/2                                       L7=5/16 R4=10/2                                          L6=(14+ 7/16)-(13+5/8)-L7 R5=10.2/2                                        L4=(2-L5-L7-L6)/2 R6=10.71/2                                        L2=LTOT-1.455-(14+ 7/16)-L1-L3-L4-L5 R7=10/2                                          L8=L4 R8=10.75/2                                        L9=0.333 R9=11.865/2                                      Lll=0.339 R10=R9-l/4                                        L10=(13+5/8)-L8-L9-(2+ 1/16)-3/8-1.5-Lll Rll=l0.660/2                                      L13=0.571 R12=10/2                                          L12= 1.5-L13 R13=(9+ 19/32)/2                                  L14=3/8 R14=R9-1/8                                        L15=0.478 BLKOR=R9+0.25                                    L17=0.573 BLKHT=0.75                                        L16=(2+ 1/16)-9/16-Ll7-LlS RTAN =RS-DEEP+ RELIEF                            L18=9/16 L20=7/16 RRl=l/2                                          L21=1/8
L3=0.333 L5=5/16 L7=5/16 L6=(14+ 7/16)-(13+5/8)-L7 L4=(2-L5-L7-L6)/2 L2=LTOT-1.455-(14+ 7/16)-L1-L3-L4-L5 L8=L4 L9=0.333 Lll=0.339 L10=(13+5/8)-L8-L9-(2+ 1/16)-3/8-1.5-Lll L13=0.571 L12= 1.5-L13 L14=3/8 L15=0.478 L17=0.573 L16=(2+ 1/16)-9/16-Ll 7-LlS L18=9/16 L20=7/16 L21=1/8 L22= 1.455-L20-L21  
* RR2=5/8 RR3=5/8 L22= 1.455-L20-L21


MPR Associates, Inc .
. mMPR Hl = 1.455-1.266 H2=0.01 H3=1/32 MPR Associates, Inc.
      . mMPR                                                         320 King Street Alexandria, VA 22314 Page  c; Hl = 1.455-1.266 H2=0.01 H3=1/32 The liner material is cast iron, so the following material properties were used:
320 King Street Alexandria, VA 22314 Page c; The liner material is cast iron, so the following material properties were used:
E = 16,000,000 psi (Reference 3 states modulus of elasticity is 14-17 ksi) v = 0.3 (assumed)
E = 16,000,000 psi (Reference 3 states modulus of elasticity is 14-17 ksi) v = 0.3 (assumed)
The ANSYS general purpose finite element program is used to calculate stresses. Attachment 1 is a listing of the ANSYS input for the nominal case. The inputs for the other cases a~e similar.
The ANSYS general purpose finite element program is used to calculate stresses. Attachment 1 is a listing of the ANSYS input for the nominal case. The inputs for the other cases a~e similar.
Line 70: Line 89:
* The analyses neglected friction effects at the lower seal (at the 0-rings). This friction force could reduce the calculated stresses if the rotation of the liner flange was restrained.
* The analyses neglected friction effects at the lower seal (at the 0-rings). This friction force could reduce the calculated stresses if the rotation of the liner flange was restrained.
* The potential for contact between the lower, upper guide is neglected. Although this contact is not expected, it could lower the calculated stresses.
* The potential for contact between the lower, upper guide is neglected. Although this contact is not expected, it could lower the calculated stresses.
3.2         Applied Loads/Boundary Conditions The liner is subject to the following loads and boundary conditions (as shown on Figure 4):
3.2 Applied Loads/Boundary Conditions The liner is subject to the following loads and boundary conditions (as shown on Figure 4):
* Bolt Preload - The cylinder liner is held in place by the head. The preload in the head bolts is applied as a pressure to the head/liner contact surface. This load is ultimately reacted by contact with the engine block mating surface under the liner flange. This force is applied as a pressure load as shown in Figure 4.
* Bolt Preload - The cylinder liner is held in place by the head. The preload in the head bolts is applied as a pressure to the head/liner contact surface. This load is ultimately reacted by contact with the engine block mating surface under the liner flange. This force is applied as a pressure load as shown in Figure 4.  
 
**MPR Calculation No.
;Dt*37.--0J Prepared By
* MPR Associates, Inc.
* MPR Associates, Inc.
  **MPR                              320 King Street Alexandria, VA 22314 Calculation No . Prepared By ('phecke.d By
320 King Street Alexandria, VA 22314
                              //:~~
('phecke.d By  
Page ~
//:~~
  ;Dt*37.--0J      ;"-"'-
Page  
~
 
mMPR Calculation No.
/08 ~ 32 '0)
Prepared By
/
_y**
.*.* (I (
-- MPR Associates, Inc.
320 King Street Alexandria, VA 22314 Page 7


                                -- MPR Associates, Inc.
. mMPR
mMPR                           320 King Street Alexandria, VA 22314 Calculation No. Prepared By Page
* MPR Associates, Inc.
  /08 ~ 32 '0)                                          7
320 King Street Alexandria, VA 22314 Calculation No.
_y**
Prepared By
                              /
(."?he<;-k~ By r--~/i-~8~-3_Z_'_O_l~--l~~~~~*--~~~L-~~~  
                    .*.* (I (
.~_:_~~~-=--~~...L.-Pa_g_e_f~--l R'i R.5 RS" R4-
* MPR Associates, Inc .
'R.~
      . mMPR                                                320 King Street Alexandria, VA 22314 Calculation No.         Prepared By       (."?he<;-k~             By
:t.IL --
* r--~/i-~8~-3_Z_'_O_l~--l~~~~~*--~~~L-~~~.~_:_~~~-=--~~...L.-Pa_g_e_f~--l R'i R.5
I l
                                                      "'--'R-1:L..11:-r--
~
RS"                RM
f l
"'--'R- -r-1:L..11: -
RM
(
(
Il                Dt:PTt+
D t:PTt+
                                ~
f l
U1>
U1>
* R4-R!\.\
R!\\.\\
                      'R.~
1..I
:t.IL --
 
1..I
* - MPR Associates, Inc.
320 King Street
- -Alexandria, VA 22314 Page 1  


  * - MPR Associates, Inc.
. mMPR Calculation No.
320 King Street
I f.)( -3 2.. -0 I Prepared By
  - -Alexandria, VA 22314 Page 1
~
* MPR Associates, Inc .
* MPR Associates, Inc.
      .mMPR                                                                320 King Street Alexandria, VA 22314 Calculation No.                        Prepared By Page / 0 I f.)( -3 2.. -0 I                      ~
320 King Street Alexandria, VA 22314 Page / 0 The head bolts are 1-1/4" diameter, installed with a 550 ft-lb torque. Assuming that typical lubricants are used, 550 ft-lb torque corresponds to a preload of about 35,000 lb per bolt (from Reference 15):  
The head bolts are 1-1/4" diameter, installed with a 550 ft-lb torque. Assuming that typical lubricants are used, 550 ft-lb torque corresponds to a preload of about 35,000 lb per bolt (from Reference 15):                                                                             \ I KTP(l.25) 550ft-lb       =- - -
\\ I KTP(l.25) 550ft-lb = ---
12 Em(tan(>.)+&#xb5;sec(a))         Dcml-'c KT = 20(1-&#xb5;tan(>.)sec(a) + 2Dsin(cp)
12 Em(tan(>.)+&#xb5;sec(a))
* where:
Dcml-'c KT = 20(1-&#xb5;tan(>.)sec(a) + 2Dsin(cp) where:
Em is the mean thread pitch diameter = 1.1572"
Em is the mean thread pitch diameter = 1.1572"  
                ). is the lead angle of thread = 2.25&deg; a is one-half the angle of thread = 30&deg;
). is the lead angle of thread = 2.25&deg; a is one-half the angle of thread = 30&deg;  
                &#xb5;is the thread friction coefficient = 0.11 (for lubricated threads) 1-'c is the collar friction coefficient = 0.11 Dem = (Sm +dh)/2 = (1.875+(1.25+0.0625))/2 = 1.5938" db= 1.25+0.0625 = 1.3125"
&#xb5;is the thread friction coefficient = 0.11 (for lubricated threads) 1-'c is the collar friction coefficient = 0.11 Dem = (Sm +dh)/2 = (1.875+(1.25+0.0625))/2 = 1.5938" db= 1.25+0.0625 = 1.3125"  
                  <P = 900
<P = 900  
        ~       =     (1.1572)(tan(2.25)+0.llsec(30)) + (1.5938)(0.11)
~ = (1.1572)(tan(2.25)+0.llsec(30)) + (1.5938)(0.11)
T       2(1.3125)(1-0.11tan(2.25)sec(30))       2(1.3125)sin(90)
T 2( 1.3125)( 1-0.11 tan(2.25)sec(30))
KT= 0.1405 p = 37580 lb
2( 1.3125)sin(90)
**    Assuming collar friction (against the head) is slightly higher than the value used in the above \
KT= 0.1405 p = 37580 lb Assuming collar friction (against the head) is slightly higher than the value used in the above \\ 1 calculation, P is about 35,000 lb per bolt.  
calculation, P is about 35,000 lb per bolt.
1


mMPR Calculation No.
f o~ -32.--o/
Prepared By
~
MPR Associates, Inc.
MPR Associates, Inc.
mMPR                                                          320 King Street Alexandria, VA 22314 Calculation No.                  Prepared By f o~ -32.--o/
320 King Street Alexandria, VA 22314 Page I (
Page   I(
                                      ~
There are seven bolts connecting the head to the block, for a total preload of 245,000 lb.
There are seven bolts connecting the head to the block, for a total preload of 245,000 lb.
The liner sealing surface has dimensions of 5.011 inside radius and 5.33" outside radius.
The liner sealing surface has dimensions of 5.0 11 inside radius and 5.33" outside radius.
Assuming the block contacts over this entire area, the contact pressure is p       -      (7)(35000)(2)         22877 .
Assuming the block contacts over this entire area, the contact pressure is p
seal - 27r(5.0+5.33)(5.33-5.0)   =       psi This force is applied for all cases when firing pressure is not considered.
(7)(35000)(2) 22877.
* Lower Seal Interference - The liner lower sealing surface (at the 0-rings) is an interference fit between the liner and the block insert. This interference fit is modeled as a zero displacement boundary condition (radially) at the edges of each 0-ring groove. The effect of the possible several mil interference fit on the stresses in the flange liner is considered small and neglected. This boundary condition is applied for all cases .
seal - 27r(5.0+5.33)(5.33-5.0) =
*
psi This force is applied for all cases when firing pressure is not considered.
* Firing Pressure - When the engine is firing, the combustion process produces an internal pressure inside the liner above the piston. This pressure occurs essentially only when the piston is at its top position. In an engine of this type, the firing pressure is typically about 1800 psi. This pressure is applied to the liner surfaces internal of the head sealing surface and approximately the top 1/411 of the liner inside diameter (the piston is about 1/4" from the top of liner at firing).
* Lower Seal Interference - The liner lower sealing surface (at the 0-rings) is an interference fit between the liner and the block insert. This interference fit is modeled as a zero displacement boundary condition (radially) at the edges of each 0-ring groove. The effect of the possible several mil interference fit on the stresses in the flange liner is considered small and neglected. This boundary condition is applied for all cases.
* Firing Pressure - When the engine is firing, the combustion process produces an internal pressure inside the liner above the piston. This pressure occurs essentially only when the piston is at its top position. In an engine of this type, the firing pressure is typically about 1800 psi. This pressure is applied to the liner surfaces internal of the head sealing surface and approximately the top 1/4 11 of the liner inside diameter (the piston is about 1/4" from the top of liner at firing).
The firing pressure also tends to reduce the bolt preload contact force on the liner. The area on the head which is inside the head/liner seal will experience this pressure, "pushing up" on the head. This effectively reduces the contact force. For firing cases, the effective sealing load is:
The firing pressure also tends to reduce the bolt preload contact force on the liner. The area on the head which is inside the head/liner seal will experience this pressure, "pushing up" on the head. This effectively reduces the contact force. For firing cases, the effective sealing load is:
2 Fseal = 245000-(1800}7r(5.0)     = 103,6001b for an approximate effective contact pressure of (the actual value is a function of the joint   \l stiffness):
Fseal = 245000-(1800}7r(5.0)2 = 103,6001b for an approximate effective contact pressure of (the actual value is a function of the joint  
P seal = 22877 103600 = 9674ps1.
\\ l stiffness):
245000
103600 P seal = 22877  
= 9674ps1 245000  


MPR Associates, Inc.
Calculation No.
320 King Street
Prepared By I ot, 3 2.--0 l r-MPR Associates, Inc.
                                                                    *Alexandria, VA 22314
320 King Street  
* 9.. ~(
*Alexandria, VA 22314 9.
Calculation No.                Prepared By                Che~k,d     By Page / 2-I ot , 3 2.--0 l                r-This sealing pressure applied only for the "firing" cases (described below).
Che~k,d By  
~(
Page / 2-This sealing pressure applied only for the "firing" cases (described below).
* Piston Transverse Loads - During piston motion, the cylinder liner reacts the piston transverse load. This load is minimal at the piston high point (firing). It is significant only when the piston is at lower positions. Since the transverse load is not significant when the piston is at the high point, transverse loads do not significantly affect the stresses near the flange. Therefore, this load is neglected in this analysis.
* Piston Transverse Loads - During piston motion, the cylinder liner reacts the piston transverse load. This load is minimal at the piston high point (firing). It is significant only when the piston is at lower positions. Since the transverse load is not significant when the piston is at the high point, transverse loads do not significantly affect the stresses near the flange. Therefore, this load is neglected in this analysis.
* Thermal Effects - The cylinder liner experiences two major thermal cycles: regular start-up/shutdown and engine firing. The thermal effects of firing are not considered to affect the stresses in the relief groove area (the location of maximum stress). The firing occurs at 450 cycles per second. The only material which will cycle thermally due to firing is the liner surface, so this effect is neglected.
* Thermal Effects - The cylinder liner experiences two major thermal cycles: regular start-up/shutdown and engine firing. The thermal effects of firing are not considered to affect the stresses in the relief groove area (the location of maximum stress). The firing occurs at 450 cycles per second. The only material which will cycle thermally due to firing is the liner surface, so this effect is neglected.
While the engine is running, the outside of the liner is in contact with jacket cooling water and is relatively cool, about 140&deg;F. The lower end of the liner is in contact with lube oil, which is also about 140&deg;F. The top of the liner inside diameter will likely be about 400-5000F during firing. Given this configuration, the major stress due to start-up is considered to be a hoop stress. Further, it is not expected that this stress would be significant enough to significantly change the results of calculated stress intensity.
While the engine is running, the outside of the liner is in contact with jacket cooling water and is relatively cool, about 140&deg;F. The lower end of the liner is in contact with lube oil, which is also about 140&deg;F. The top of the liner inside diameter will likely be about 400-5000F during firing. Given this configuration, the major stress due to start-up is considered to be a hoop stress. Further, it is not expected that this stress would be significant enough to significantly change the results of calculated stress intensity.  


MPR Associates, Inc.
mMPR MPR Associates, Inc.
mMPR                                                        320 King Street Alexandria, VA 22314 Calculation No.                 Prepared By 9chec~
320 King Street Alexandria, VA 22314 Calculation No.
* 3.3 1ot*;2-01 Cases
Prepared By 9chec~
                                        ~                       ~(                       Page IJ A total of eleven cases were evaluated. These cases include the nominal configuration and several parametric cases to evaluate the effect of variation in key dimensions. A summary of the cases is provided below.
1ot*;2-01  
Case         Relief     Firing     Block       Offset     Groove Radius     Pressure   Radius       (mils)     Depth (in)       (psi)     (in)                     (in)
~  
Nominal         0.133         0       5.376         0.1       0.050 Block Gap       0.133         0       5.377         0.1       0.050 Relief         0.125         0       5.376         0.1       0.050 Groove         0.133         0       5.376         0.1       0.045 Depth
~(
* 2 Mil Offset 8 Mil Offset Nominal Firing 0.133 0.133 0.133 0
Page IJ 3.3 Cases A total of eleven cases were evaluated. These cases include the nominal configuration and several parametric cases to evaluate the effect of variation in key dimensions. A summary of the cases is provided below.
0 1800 5.376 5.376 5.376 2
Case Relief Firing Block Offset Groove Radius Pressure Radius (mils)
8 0.1 0.050 0.050 0.050 2 Mil Offset     0.133       1800     5.376         2         0.050 Firing 8 Mil Offset     0.133       1800     5.376         8         0.050 Firing Worst Case       0.110
Depth (in)
* 0      5.377         8         0.045 Worst Case       0.110
(psi)
* 1800     5.377         8         0.045 Firing
(in)
* 11 Inspections of a liner showed that the groove radius could be as low as 0.110 so this value was used for the worst case configurations .
(in)
Nominal 0.133 0
5.376 0.1 0.050 Block Gap 0.133 0
5.377 0.1 0.050 Relief 0.125 0
5.376 0.1 0.050 Groove 0.133 0
5.376 0.1 0.045 Depth 2 Mil Offset 0.133 0
5.376 2
0.050 8 Mil Offset 0.133 0
5.376 8
0.050 Nominal 0.133 1800 5.376 0.1 0.050 Firing 2 Mil Offset 0.133 1800 5.376 2
0.050 Firing 8 Mil Offset 0.133 1800 5.376 8
0.050 Firing Worst Case 0.110 0
5.377 8
0.045 Worst Case 0.110
* 1800 5.377 8
0.045 Firing
* Inspections of a liner showed that the groove radius could be as low as 0.110 11
, so this value was used for the worst case configurations.  


                                                                      - -MPR Associates, Inc .
. mMPR Calculation No.
        .mMPR                                                      *-* 320
ID~.. 5z... o I 3.4 Results Prepared By P - -MPR Associates, Inc.
* King Street Alexandria, VA 22314 Calculation No.                Prepared By ID~ .. 5z. .. oI                  P                                                                                          Page   ff-3.4          Results
320
  . The results of the finite element analyses are contained in References 4 through 14. A summary of the key results is included in Section 2. Figures 8 through 18 show the calculated stresses along a path into the liner at an angle of 45&deg; from the relief groove. These stresses are in a coordinate system rotated 45&deg; from the vertical, as shown in Figures 5 to 7.
* King Street Alexandria, VA 22314 Page ff-
3.5         Conclusions Based on the stress analysis results, the following conclusions can ..be made:
. The results of the finite element analyses are contained in References 4 through 14. A summary of the key results is included in Section 2. Figures 8 through 18 show the calculated stresses along a path into the liner at an angle of 45&deg; from the relief groove. These stresses are in a coordinate system rotated 45&deg; from the vertical, as shown in Figures 5 to 7.
3.5 Conclusions Based on the stress analysis results, the following conclusions can.. be made:
* The size of the radial gap between the liner and engine block has very little effect on the calculated stresses.
* The size of the radial gap between the liner and engine block has very little effect on the calculated stresses.
* The radius of the relief groove is important. As the groove radius decreases, the stresses increase.
* The radius of the relief groove is important. As the groove radius decreases, the stresses increase.
Line 166: Line 222:
* Misalignment between the liner flange and block mating surface affects the stresses in the groove area. Although the stresses only increase a small amount for a 2 mil offset, the increase for an 8 mil offset is significant (about 25 to 30% ).
* Misalignment between the liner flange and block mating surface affects the stresses in the groove area. Although the stresses only increase a small amount for a 2 mil offset, the increase for an 8 mil offset is significant (about 25 to 30% ).
* The engine firing pressure reduces the stresses in the groove. However, the stresses remain tensile over the full load cycle.
* The engine firing pressure reduces the stresses in the groove. However, the stresses remain tensile over the full load cycle.
* The nominal strength of the liner material is about 36 ksi. The maximum stresses in the liner reported in Section 2 are local stresses concentrated at the inside surface of the relief groove. The liner likely can withstand maximum calculated elastic stresses slightly greater than 36 ksi. Based on the calculated stresses (and neglecting thermal stresses), the liner likely would not fail for the nominal case. However, the worst case stresses are significantly greater than the nominal stresses and local failure or damage could occur.
* The nominal strength of the liner material is about 36 ksi. The maximum stresses in the liner reported in Section 2 are local stresses concentrated at the inside surface of the relief groove. The liner likely can withstand maximum calculated elastic stresses slightly greater than 36 ksi. Based on the calculated stresses (and neglecting thermal stresses), the liner likely would not fail for the nominal case. However, the worst case stresses are significantly greater than the nominal stresses and local failure or damage could occur.  


MPR Associates, Inc.
**MPR Calculation No.
  **MPR                                                           320 King Street Alexandria, VA 22314 Calculation No.               Prepared By Page        /j IDB *3;. ~01                   r---
IDB *3;. ~01 Prepared By r---
ANSYS 5. 0 A DEC 17 1993 11:30:57 PLOT NO-       1 NODAL SOLUTION STEP=l SUB =1 TIME=l SY           (AVG)
ALCO 251 CYLINDER LINER -
RSYS=O DMX =0.006872 SMN =-25159 SMNB= - 34 79 8 SMX =37628 SMXB=41295
NO A~, c...\\
                                                                                -    -25159
s-tre!.~
                                                                                -    -18182
~-k-f" (lr\\e>lx.\\ (_o1lrJwJ ~~~~"')
                                                                                ~     -11206
E~0rc 5 MPR Associates, Inc.
                                                                                -    -4230
320 King Street Alexandria, VA 22314 Page /j ANSYS 5. 0 A DEC 17 1993 11:30:57 PLOT NO-1 NODAL SOLUTION STEP=l SUB =1 TIME=l SY (AVG)
                                                                                -    2747 9723
RSYS=O DMX =0.006872 SMN =-25159 SMNB= - 34 79 8 SMX =37628 SMXB=41295  
                                                                                ~ 16699
-25159  
                                                                                -    23675
-18182  
                                                                                -    30652 37628 ALCO 251 CYLINDER LINER - NO A~, c...\ s-tre!.~ ~-k-f" (lr\e>lx.\ (_o1lrJwJ ~~~~"')
~ -11206  
E~0rc 5
-4230 2747 9723  
~ 16699 23675 30652 37628  


MPR Associates, Inc .
. mMPR ALCO 251 CYLINDER LINER *
  . mMPR                                                            320 King Street Alexandria, VA 22314 Page   Uo ANSYS 5. 0 A DEC 17 1993 11:31:58 PLOT NO.     3 NODAL SOLUTION STEP=l SUB =l TIME=l SZ         (AVG)
\\-\\-oof s ~~) ~~)
RSYS=O DMX =0.006872 SMN =*25139 SMNB=-34917 SMX =18770 SMXB=24790
( G-~t>\\_\\
                                                                                  -      *25139
CoorJv-c.~ S.'1~\\... )
                                                                                  -      *20260
F&#xa5;Jvrt b MPR Associates, Inc.
                                                                                  ~     -15381
320 King Street Alexandria, VA 22314 Page Uo ANSYS 5. 0 A DEC 17 1993 11:31:58 PLOT NO.
                                                                                  -      -10502
3 NODAL SOLUTION STEP=l SUB =l TIME=l SZ (AVG)
                                                                                  -    -5624
RSYS=O DMX =0.006872 SMN =*25139 SMNB=-34917 SMX =18770 SMXB=24790  
                                                                                  =
*25139  
                                                                                  -    -744.912 c:::J 4134 9013 13891 18770 ALCO 251 CYLINDER LINER *
*20260  
                              \-\-oof  s~~)    ~~)
~ -15381  
( G-~t>\_\ CoorJv-c.~ S.'1~\ ...)
-10502  
F&#xa5;Jvrt b
-5624  
-744.912 c:::J 4134 9013  
=
13891 18770  
* mMPR Calculation No.
108~32 ""()/
Prepared By
~
ALCO 251 CYLINDER LINER -
NO
~l\\.._\\ S-ks\\ (P,.. tal./"3
( G-\\ol-\\ (ov )l""".h ~ls~-)
f \\  
~)'.>"- 7
* **MPR Associates, Inc.
320 King Street Alexandria, VA 22314 Page I?
ANSYS 5.0 A DEC 17 1993 11:31:17 PLOT NO.
2 NODAL SOLUTION STEP=l SUB =l TIME=l SX (AVG)
RSYS=O DMX =O. 006872 SMN =-24322 SMNB=-34100 SMX =31246 SMXB=35611
-24322
-18148
~ -11973
-5799 374.948 6549
~ 12723 18898 25072 31246


                                                                * **MPR Associates, Inc.
. mMPR Calculation No.
  *mMPR                                                            320 King Street Alexandria, VA 22314 Calculation No .            Prepared By Page     I?
108 <sz-01 (a IOU I) 434 3817.
108~32 ""()/                 ~
3293 171 119 144.847
ANSYS 5.0 A DEC 17 1993 11:31:17 PLOT NO. 2 NODAL SOLUTION STEP=l SUB =l TIME=l SX        (AVG)
-37'1.
RSYS=O DMX =O. 006872 SMN =-24322 SMNB=-34100 SMX =31246 SMXB=35611
Prepared By
                                                                                -     -24322
~
                                                                                -     -18148
MPR Associates, Inc.
                                                                                ~     -11973
* 320 King Street Alexandria, VA 22314 RSICJ Page / y ANSYS 5.0 A DEC 12 1993 01:53:27 PLOT NO.
                                                                                -     -5799
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv
                                                                                -     374.948 6549
=1 DIST=0.75 XF
                                                                                ~ 12723
=0.5 YF
                                                                                -      18898
=0.5 ZF
                                                                                -      25072 31246 ALCO 251 CYLINDER LINER - NO
=0.5 CENTROID HIDDEN
                                  ~l\.._\ S-ks\ (P,.. tal./"3
-~
( G-\ol-\ (ov )l""".h ~ls~-)
,A5I'71' Jl!U:C%
f \~)'.>"- 7
-'104. 446'---~--.---r---,..--~--..,.1----.---=:;:==--
b.545 I o.s17
*1.363 0
0.272 0.136 0.408 0.681 0.954 1.227 DIST ALCO 251 CYLINDER LINER - NOMINAL sinss.Ji. b '-l' ~
(\\<o+.-~J t\\~ *)  


MPR Associates, Inc .
**MPR l
    .mMPR
c.1000 434 Ja20*.
* 320 King Street Alexandria, VA 22314 Calculation No.                   Prepared By Page / y 108 <sz-01                            ~
3295 119 144.30
ANSYS 5.0 A DEC 12 1993 01:53:27 PLOT NO. 1 POSTl STEP=l (a IOU I)
-380.76
SUB =1 434                                                                              TIME=l PATH PLOT NOD1=339 3817.                                                                            NOD2=356 zv =1 3293                                                                              DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN 171 119 RSICJ 144.847
                                          ------------_--:::-_            -~
                                                                                ,A5I'71'
            -37'1.                                              .------        Jl!U:C%
          -'104. 446'---~--.---r---,..--~--..,.1----.---=:;:==--
0        0.272        b.545 I      o.s17                  *1.363 0.136      0.408        0.681        0.954      1.227 DIST ALCO 251 CYLINDER LINER - NOMINAL sinss            b '-l' ~
                                                  .Ji .
(\<o+.-~J t\~ *)
* MPR Associates, Inc.
* MPR Associates, Inc.
  **MPR                                                                      320 King Street Alexandria, VA 22314 Page   If l                                                                                    ANSYS 5.0 A DEC 12 1993 02:11:24 PLOT NO. 1 POST!
320 King Street Alexandria, VA 22314 lSlCZ Page If ANSYS 5.0 A DEC 12 1993 02:11:24 PLOT NO.
c.1000                                                                          STEP=l SUB =l 434 TIME=l PATH PLOT Ja20*.
1 POST!
NOD1=339 NOD2=356 3295 zv =1 DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN
STEP=l SUB =l TIME=l PATH PLOT NOD1=339 NOD2=356 zv  
* 119 144.30
=1 DIST=0.75 XF  
    -380.76 lSlCZ
=0.5 YF  
    -905 .837 ' - - - - - , ,----,----,--,.----r----~==:::;::=--
=0.5 ZF  
0             ci.212       0.545                       '1.J6J 0.136         0.408       0.681   0.954   1.227 DIST CYLINDER LINER - BLOCK GAP s+ro.s v~ DC(>~
=0.5 CENTROID HIDDEN  
11 c~~~J 4~ )
-905.837 '-----,,  
----,----,--,.----r----~==:::;::=--
0 ci.212 0.545 0.136 0.408 0.681 0.954 DIST CYLINDER LINER - BLOCK GAP s+ro.s v~ DC(>~
c~~~J 4~
11
)  
'1.J6J 1.227


MPR Associates, Inc .
. mMPR
  . mMPR                                                                       320 King Street-Alexandria, VA 22314 Page V>
(*IOUI) 462 407f' 351'1 29 241.(
ANSYS 5. 0 A DEC 12 1993 02:34:01 PLOT NO. 1 POST!
1861 755.71 203.11  
(*IOUI)                                                                         STEP=l 462                                                                           SUB =l TIME=l PATH PLOT 407f'                                                                         NOD1=335 NOD2=352 351'1                                                                         zv =l DIST=0.75 XF =0.5 29                                                                           YF =0.5
-:349.47 0.135 0.407  
_ZF =O. 5 CENTROID HIDDEN 241.(
. 0.679 0.951 I
1861
DIST ALCO 251 CYLINDER LINER - RELIEF  
* 755.71 203.11 RS'Jc;I
~). ~, \\Jto11...
__,/".-
        -:349.47 asrcz 1.088          1.36_
0.135   0.407     . 0.679     0.951       1.224 DIST IALCO 251 CYLINDER LINER - RELIEF
                                  ~). ~ , \Jto11...
(. (Lo 1z..;._J ~ o)
(. (Lo 1z..;._J ~ o)
_ _,/".-----**
1.088 1.224 MPR Associates, Inc.
320 King Street-Alexandria, VA 22314 RS'Jc;I asrcz 1.36_
Page V>
ANSYS 5. 0 A DEC 12 1993 02:34:01 PLOT NO.
1 POST!
STEP=l SUB =l TIME=l PATH PLOT NOD1=335 NOD2=352 zv
=l DIST=0.75 XF
=0.5 YF
=0.5
_ZF
=O. 5 CENTROID HIDDEN
* mMPR.
Calculation No.
!/}f']Z-t)/
c.1001>
43J3i 3285' 1~3.071
-380.65 Prepared By A.
-<104. 376 '-------,-,---r----*.-1 ---,-I -----,1----'==--,
0 0.273 b.546 O.BIQ 1.0'13
: 0. !36 0.683 0.'156 1.23 DIST ALCO 251 CYLINDER LINER - CUT DEPTH MPR Associates, Inc.
320 King Street Alexandria, VA 22314 RSI CI 11.SI-:f l\\SIC%.
1.366 Page '2(
ANSYS 5.0 A DEC 12 1993 02:57:44 PLOT NO.
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=345 NOD2=362 zv
=1 DIST=0.75 XF
=0.5 YF
=0.5 ZF
=0.5 CENTROID HIDDEN
* mMPR Calculation No.
!D8 -3z-01 c.1000 4651 40861:
3521
~' \\
\\\\
\\\\
\\ "
\\ *..
127.7.(
-437.741
-1003 0
0.136 0.272 Prepared By P--
0.40S
~.545 I 0.6Sl I 0.817 DIST
\\ALCO 251 CYLINDER LINER -
2 MIL OFFSET 5-\\n 'i.)e}
-.1, 1)' pfh (Q.. ~t-i 45')
l.0'1 l.227 MPR Associates, Inc.
320 King Street Alexandria, VA 22314 P.:Jl<.!l
'(. 363 Page 2z__
ANSYS 5. 0 A DEC 12 1993 15:47:26 PLOT NO.
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv
=l DIST=O. 75 XF
=0.5 YF
=0.5 ZF
=0.5 CENTROID HIDDEN


MPR Associates, Inc.
. mMPR Calculation No.  
  *mMPR.                                                                            320 King Street Alexandria, VA 22314 Calculation No.                       Prepared By Page '2(
/OB-:sz.-() I
  !/}f']Z-t)/                            A.
(.1001)
ANSYS 5.0 A DEC 12 1993 02:57:44 PLOT NO. 1 POSTl STEP=l c.1001>
'5543'.
SUB =1 43J3i                                                                            TIME=l PATH PLOT NOD1=345 NOD2=362 zv =1 3285'                                                                            DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN
4176 760.467 Prepared By  
* RSI CI 1~3 .071 11.SI-:f
""'L.  
          -380.65                                                                    l\SIC%.
* - MPR *Associates, Inc.
          -<104. 376  '-------,-,---r----*.-1---,-I- - - - - , 1 - - - - ' = = - - ,
* 320 King Street Alexandria, VA 22314 Page 2 ?
0          0.273    b.546      O.BIQ        1.0'13          1.366
ANSYS 5. 0 A DEC 12 1993 16:10:05 PLOT NO.
: 0. !36                0.683      0.'156        1.23 DIST ALCO 251 CYLINDER LINER - CUT DEPTH
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv  
 
=1 DIST=0.75 XF  
MPR Associates, Inc.
=0.5 YF  
  *mMPR                                                                                  320 King Street Alexandria, VA 22314
=0.5 ZF  
* Calculation No .
=0.5 CENTROID HIDDEN 77.316  
  !D8 -3z-01 Prepared By P--
-605.83 J.SlC%.  
Page    2z__
-128q 0
ANSYS 5. 0 A DEC 12 1993 15:47:26 PLOT NO. 1 POSTl STEP=l c.1000 SUB =1 4651                                                                                    TIME=l PATH PLOT NOD1=339 40861:                                                                                  NOD2=356 zv =l 3521                                                                                    DIST=O. 75
0.272 0.545 0.817 O.JJ6 0.4011 0.681 o.q54 J.227 DIST ALCO 251 CYLINDER LINER - 8 MIL OFFSET f\\j\\)~ \\ 3 s+rtw1 IJ<.  
              ~' \
~ ~-K
XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN
( (l.<>~.).tJ 45")  
                      \\
                      \\"
                      \
                        \ *..
P.:Jl<.!l 127.7.(
          -437.741
            -1003                                            I 0            0.272      ~.545 I          0.817    l .0'1        '(. 363 0.136      0.40S          0.6Sl                  l .227 DIST
    \ALCO 251 CYLINDER LINER - 2 MIL OFFSET 5-\n  'i.)e}  -.1, 1)' pfh
*                                              (Q .. ~t-i        45')
 
                                                                                * - MPR *Associates, Inc .
    .mMPR
* 320 King Street Alexandria, VA 22314 Calculation No.                    Prepared By Page 2 ?
  /OB-:sz.-() I                              ""'L.
ANSYS 5. 0 A DEC 12 1993 16:10:05 PLOT NO. 1 POSTl STEP=l
( .1001)                                                                            SUB =1
                '5543'.                                                                          TIME=l PATH PLOT NOD1=339 NOD2=356 zv =1 4176                                                                            DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN
* 760.467 77.316
          -605.83                                                                   J.SlC%.
                -128q         '                              ;
0      0.272         0.545           0.817 O.JJ6       0.4011         0.681         o.q54 J .227 DIST ALCO 251 CYLINDER LINER - 8 MIL OFFSET f\j\)~ \       3 s+rtw1       IJ<.   ~ ~-K
( (l.<>~.).tJ     45")
 
MPR Associates, Inc.
320 King Street Alexandria, VA 22314 Calculation No.                    Prepared By                        (,)Cheer~ By Page 7  10~-32.*0/                                                          /7~~
ANSYS 5. 0 A DEC 12 1993 03:59:50 PLOT NO. 1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv =1 222r                                                                              DIST=O. 75 XF =0.5 YF =0.5 187 ZF =0.5 CENTROID HIDDEN
                                                        ---~-----                il:3IC1 ASIC%
          !37.604
        -209.696                                                                RSI CY
        -556.997 '-------:-----,..-----;-----...,.----,----...,.i-----=:::::,..
o          0.272        o.545        o.8t7      t .09      1.363 .
0.136        0.4011        0.681      0.954      1.227 DIST ALCO 251 CYLINDER LINER - NOMINAL -- FIRING
* 5~,~t'.s vs. Dfe~
c  ~.~.~- i lt5;J)                                              I'


MPR Associates, Inc .
Calculation No.
    . mMPR-                                                                              320 King Street Alexandria, VA 22314
10~-32.*0/
                                                                            ~,Chee~~ By Calculation No.                        Prepared By Page    2.1
222r 187 Prepared By MPR Associates, Inc.
  !D~"3Z.-O/                                                               1:1. ~~
320 King Street Alexandria, VA 22314
ANSYS 5. 0 A l                                                                                              DEC 12 1993 08:37:55 PLOT NO. 1 POSTl STEP=l c.1oul)                                                                              SUB =1 3221-                                                                              TIME=l PATH PLOT NOD1=339 2833 :                                                                            NOD2=356 zv =1 2445*                                                                              DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 205  \\*                                                                          CENTROID HIDDEN 1670    *
(,)Cheer~ By  
* 8'14 .22 118.726.
/7~~
                                                                              ----       k!:J-::1 J\SIC%
Page 7 ANSYS 5. 0 A DEC 12 1993 03:59:50 PLOT NO.
            -269.02                                                                    J\3lcY'
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv  
            -656.776L-----,----------------==:::,.,..
=1 DIST=O. 75 XF  
0          0.272       0.545       ~.817        &deg;1.0'1 I      1.363 0.136       0.408      0.68i        C.95~          1.227 DIST ALCO 251 CYLINDER LINER - 2 MIL OFFSET -- FIRING Sro~,       V!.. 'Dtp-11,
=0.5 YF  
[(lp~t-L qs~)
=0.5 ZF  
=0.5 CENTROID HIDDEN  
---~-----
il:3IC1 ASIC%  
!37.604
-209.696 RSI CY
-556.997 '-------:-----,..-----;-----...,.----,----...,.i-----=:::::,..
o 0.272 o.545 o.8t7 t.09 1.363.
0.136 0.4011 0.681 0.954 1.227 DIST ALCO 251 CYLINDER LINER - NOMINAL --
FIRING 5~,~t'.s vs. Dfe~
c
~.~.~- i lt5;J)
I'


MPR Associates, Inc.
. mMPR-Calculation No.
  **MPR                                                                              320 King Street Alexandria, VA 22314 Calculation No.                      Prepared By Page    /<.,_
!D~"3Z.-O/
1ott *3z -o I                          r-ANSYS 5.0 A DEC 12 1993 09:01:55 PLOT NO. 1 POSTl c.1001>                                                                                STEP=l SUB =1 3853" TIME=l PATH PLOT NOD1=339 3383' NOD2=356 zv =1 DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN
l c.1oul) 3221-2833 :
*                                                                          ----    ~Sl<::t RSVi\"
2445*
Jl:;IC7.
205 \\\\*
        -85! .21@'----:------,--;-----;---,.---~--------====--
1670 8'14.22 118.726.
0             0.272       0.545         0.817       '1.0<1 0.136         0.408       0.681        0.954        1.227 DIST ALCO 251 CYLINDER LINER - 8 MIL OFFSET -- FIRING
-269.02 Prepared By MPR Associates, Inc.
* stn. . v.s    "". lJ<!~t-L
320 King Street Alexandria, VA 22314  
('R-o-l~i ~ ")
~,Chee~~ By 1:1. ~~
k!:J-::1 J\\SIC%
J\\3lcY' Page 2.1 ANSYS 5. 0 A DEC 12 1993 08:37:55 PLOT NO.
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv  
=1 DIST=0.75 XF  
=0.5 YF  
=0.5 ZF  
=0.5 CENTROID HIDDEN  
-656.776L-----,----------------==:::,.,..
0 0.272 0.545  
~.817  
&deg;1.0'1 I
1.363 0.136 0.408 0.68i C.95~
1.227 DIST ALCO 251 CYLINDER LINER -
2 MIL OFFSET --
FIRING Sro~,
V!.. 'Dtp-11,
[(lp~t-L qs~)  


MPR Associates, Inc.
**MPR Calculation No.
mMPR                                                              320 King Street Alexandria, VA 22314 Calculation No.                 Prepared By Page
1ott *3z -o I c.1001>
  !D8'32-0I                                                                                      77 ANSYS 5. 0 A DEC 12 1993 05:02:53 PLOT NO. 1 POSTl STEP=l (w lou1r SUB =1 5881-                                                                TIME=l PATH PLOT NOD1=343 5165                                                                  NOD2=360 zv =1 444q \*                                                              DIST=0.75 XF =0.5 YF =0.5 J7J                                                                  ZF =0.5 CENTROID HIDDEN 3017 158 r.:a.:;1 RSI'n" RStC'%.
3853" 3383' Prepared By r-MPR Associates, Inc.
              -1250'------,   ----------------==-
320 King Street Alexandria, VA 22314 Page /<.,_
o      0.272       0.545 '    0.817             1.363 0.136       0.408       0.681       0.'154 1.227 DIST ALCO 251 CYLINDER LINER - ALL EFFECTS
ANSYS 5.0 A DEC 12 1993 09:01:55 PLOT NO.
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv  
=1 DIST=0.75 XF  
=0.5 YF  
=0.5 ZF  
=0.5 CENTROID HIDDEN  
~Sl<::t RSVi\\"
Jl:;IC7.  
-85!.21@'----:------,--; -----;---,.---~--------====--
0.272 0.545 0.817  
'1.0<1 0
0.136 0.408 0.681 0.954 1.227 DIST ALCO 251 CYLINDER LINER -
8 MIL OFFSET --
FIRING stn.... v.s "". lJ<!~t-L
('R-o-l~i ~ ")


MPR Associates, Inc.
mMPR Calculation No.
    *mMPR                                                                        320 King Street Alexandria, VA 22314 n
!D8'32-0I (w lou1r 5881-5165 444q \\*
Calculation No.                   Prepared By                          Che~kr2 By t7. ~~-wt:-                  Page 2.P l                                                                                      ANSYS 5. 0 A DEC 12 1993 16:30:31 PLOT NO. 1 POSTl STEP=l (a IOU!)
J7J 3017 158 Prepared By MPR Associates, Inc.
SUB =1 409                                                                            TIME=l PATH PLOT NOD1=343 NOD2=360 zv =1 3103"                                                                          DIST=0.75 XF =0.5 YF =0.5 260                                                                            ZF =0.5 CENTROID HIDDEN 2l!S
320 King Street Alexandria, VA 22314 r.:a.:;1 RSI'n" RStC'%.
                      \
Page 77 ANSYS 5. 0 A DEC 12 1993 05:02:53 PLOT NO.
112
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=343 NOD2=360 zv  
_ _ _ ks-rc.t RSlCZ.
=1 DIST=0.75 XF  
140.406
=0.5 YF  
          -353.Jl                                                               ttzrcv
=0.5 ZF  
          -847.031                                                 i o         0.272       0.545       0.817       l.09        1.363 0.136        0.408       0.681       0.954       1.227 DIST ALCO 251 CYLINDER LINER - ALL EFFECTS -- FIRING s~~'C..I vc.. * 'D epti,
=0.5 CENTROID HIDDEN  
*                                              (flo~~[ ~")
-1250'------, ----------------==-
o 0.272 0.545 '
0.817 1.363 0.136 0.408 0.681 0.'154 1.227 DIST ALCO 251 CYLINDER LINER -
ALL EFFECTS
* mMPR Calculation No.
l (a IOU!)
409 3103" 260 2l!S 112 140.406  
-353.Jl  
-847.031 o  
\\
0.136 Prepared By 0.272 0.545 0.817 0.408 0.681 0.954 DIST ALCO 251 CYLINDER LINER - ALL EFFECTS --
FIRING MPR Associates, Inc.
320 King Street Alexandria, VA 22314 n Che~kr2 By t7. ~~-wt:-
Page 2.P i l.09
___ ks-rc.t RSlCZ.
ttzrcv 1.363 1.227 ANSYS 5. 0 A DEC 12 1993 16:30:31 PLOT NO.
1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=343 NOD2=360 zv
=1 DIST=0.75 XF
=0.5 YF
=0.5 ZF
=0.5 CENTROID HIDDEN s~~'C..I vc.. * 'D ep ti, (flo~~[ ~")  
* mMPR Calculation No.
,og.12-0 1


MPR Associates, Inc.
==4.0 REFERENCES==
      *mMPR                                                  320 King Street Alexandria, VA 22314 Calculation No.
Prepared By Ft-MPR Associates, Inc.
    ,og.12- 0 1 Prepared By Ft-Page    z1
320 King Street Alexandria, VA 22314 Page z 1
 
==4.0      REFERENCES==
: 1. Bombardier Inc. Drawing C21 1036124 1000 "Cylinder Liner Machining Drg.", Rev. 0.
: 1. Bombardier Inc. Drawing C21 1036124 1000 "Cylinder Liner Machining Drg.", Rev. 0.
2 ALCO 251 Diesel Engine Technical Manual
2 ALCO 251 Diesel Engine Technical Manual
Line 355: Line 517:
: 7. ANSYS Output, DEPTH.OUT, 12/12/93, 2:57a.
: 7. ANSYS Output, DEPTH.OUT, 12/12/93, 2:57a.
: 8. ANSYS Output, ML2.0UT, 12/12/93, 3:47p.
: 8. ANSYS Output, ML2.0UT, 12/12/93, 3:47p.
* 9. ANSYS Output, ML8.0UT, 12/12/93, 4:10p.
: 9. ANSYS Output, ML8.0UT, 12/12/93, 4:10p.
: 10. ANSYS Output, NOMFIRE.OUT, 12/14/93, 4:13p.
: 10. ANSYS Output, NOMFIRE.OUT, 12/14/93, 4:13p.
: 11. ANSYS Output, ML2FIRE.OUT, 12/14/93, 4:33p.
: 11. ANSYS Output, ML2FIRE.OUT, 12/14/93, 4:33p.
Line 361: Line 523:
: 13. ANSYS Output, WORST.OUT, 12/14/93, 5:35p.
: 13. ANSYS Output, WORST.OUT, 12/14/93, 5:35p.
: 14. ANSYS Output, WORSTFR.OUT, 12/14/93, 5:14p.
: 14. ANSYS Output, WORSTFR.OUT, 12/14/93, 5:14p.
: 15. Mechanical Engineering Design, Joseph Shigley, 1963.
: 15. Mechanical Engineering Design, Joseph Shigley, 1963.  


MPR Associates, Inc .
. *MPR MPR Associates, Inc.
  '  .*MPR                                  320 King Street Alexandria, VA 22314
320 King Street Alexandria, VA 22314 Calculation No.
                                      ~c~~
Prepared By
Calculation No. Prepared By
~c~~  
*  /O~ ~gz -o J       ~
/O~ ~gz -o J  
Page 3o ATTACHMENT 1 TYPICAL ANSYS INPUT FILE
~
Page 3o ATTACHMENT 1 TYPICAL ANSYS INPUT FILE  


                                                                      ~
. mMPR
* MPR Associates. Inc .
~
          . mMPR                                                        320 King Street Alexandria, VA 22314 Calculation No.                 Prepared By           (). ~~~~ By
* MPR Associates. Inc.
*r-~1_DB~*3_2_-_0_1~~~"--~~-~~~~~~.1...-J::;l.~-~~'V-~....:.:....~~~......L..-P_a_g_e~1_r~~
320 King Street Alexandria, VA 22314 Calculation No.
                        /FILNAM,FL
Prepared By
                        /TITLE,ALCO 251 CYLINDER LINER
(). ~~~~ By  
* NOMINAL
*r-~1_DB~*3_2_-_0_1~~~"--~~-~~~~~~.1...-J::;l.~-~~'V-~....:.:....~~~......L..-P_a_g_e~1_r~~  
                        /SHOW, NOMINAL, RES
/FILNAM,FL  
                        /PREP7 BLKIR=10.752/2 RELIEF=0.133 DEEP=0.05 PFIRE=O FLOFF=0.0001 G=386.4 PLEN=0.25 GSTIF=30E6 FBOLT=35000 IR=9/2 R1=(9+9/16)/2 R2=10/2 R3=10.254/2 R4=10/2 R5=10.2/2 R6=10.71/2 R7=10/2 R8=10.75/2 R9=11.865/2 R10=R9-1/4 R11=10.660/2 R12=10/2 R13=(9+19/32)12 R14=R9-1/8 BLKOR=R9+0.25 BLKHT=0.75 RTAN=R8*DEEP+RELIEF RR1=1/2 RR2=5/8 RR3=5/8 RR4=1/2 RR5=5/8 C1=R3-9.8/2 LTOT=21+15/16 L1=1.732*CR2*R1)
/TITLE,ALCO 251 CYLINDER LINER
L3=0.333 L5=5/16 L7=5/16 L6=C14+7/16)*(13+5/8)*L7 L4=C2*LS*L7*L6)/2 L2=LTOT*1.455*(14+7/16)-L1*L3*L4*L5 L8=L4 17 L9=0.333 L11=0.339 L10=C13+5/8)-L8-L9*(2+1/16)~3/8*1.5*L11 L13=0.571 L12=1.5-L13 L14=3/8 L15=0.478 L17=0.573 L16=C2+1/16)-9/16-L17*L15 L18--9/16 L20=7/16 L21=1/8 L22=1.455-L20-L21
* NOMINAL  
/SHOW, NOMINAL, RES  
/PREP7 BLKIR=10.752/2 RELIEF=0.133 DEEP=0.05 PFIRE=O FLOFF=0.0001 G=386.4 PLEN=0.25 GSTIF=30E6 FBOLT=35000 IR=9/2 R1=(9+9/16)/2 R2=10/2 R3=10.254/2 R4=10/2 R5=10.2/2 R6=10.71/2 R7=10/2 R8=10.75/2 R9=11.865/2 R10=R9-1/4 R11=10.660/2 R12=10/2 R13=(9+19/32)12 R14=R9-1/8 BLKOR=R9+0.25 BLKHT=0.75 RTAN=R8*DEEP+RELIEF RR1=1/2 RR2=5/8 RR3=5/8 RR4=1/2 RR5=5/8 C1=R3-9.8/2 LTOT=21+15/16 L1=1.732*CR2*R1)
L3=0.333 L5=5/16 L7=5/16 L6=C14+7/16)*(13+5/8)*L7 L4=C2*LS*L7*L6)/2 L2=LTOT*1.455*(14+7/16)-L1*L3*L4*L5 L8=L4 17 L9=0.333 L11=0.339 L10=C13+5/8)-L8-L9*(2+1/16)~3/8*1.5*L11 L13=0.571 L12=1.5-L13 L14=3/8 L15=0.478 L17=0.573 L16=C2+1/16)-9/16-L17*L15 L 18--9/16 L20=7/16 L21=1/8 L22=1.455-L20-L21  


MPR Associates, Inc.
mMPR MPR Associates, Inc.
mMPR                                                                    320 King Street Alexandria, VA 22314
320 King Street Alexandria, VA 22314 Calculation No.
.t--__Calculation No.
Prepared By f) c,;~c(!~ By
1_o_s_-_1_2_-0 Prepared By 1 ____---'-------r-.._------------"-----7 f) c,;~c(!~ By
.t--__ 1_o_s_-_1_2_-0 __
                                                                            --'i_~
1 ____ ---'-------r-.._------------"-----7--'i_~
9 P_a_e__J_L
________ ---L. __
                                                                                              ---L._ _        __- i H1=1.455*1.266 H2=0.01 H3=1/32 LA=L4+LS+L6+L7+L8+L9 LB=L1+L2+L3+LA+L10+L11+L12+L13 LF=LB+L14+L15+L16+L17+L18 LP=LTOT*H1*PLEN ASEAL=2*3.14159*CR11+R12)/2*CR11*R12)
P_a 9
FUP=3.14159*1R*IR*PFIRE PBOLT=(7*FBOLT-FUP)/ASEAL IC,101,IR,0 IC,102,R1,0 IC,103,R2,L1 IC, 104, IR L1 A,101, 102,103, 104       ! AREA 1 IC, 105,R2,L 1+L2 IC,106,IR,L1+L2 A,103,104,106,105         I AREA 2 IC,107,R3,L1+L2+L3 IC, 108,IR L1+L2+L3 A,106,10~ 1 107,108       I AREA 3 RECTNG,IR,R3,L1+L2+L3,L1+L2+L3+LA       I AREA 4 RECTNG,R3-C1,R3,L1+L2+L3+L4,L1+L2+L3+L4+LS       I AREA 5 ASBA,4,5 I NUMCHP,AREA RECTNG,R3*C1,R3,L1+L2+L3+L4+L5+L6,L1+L2+L3+L4+L5+L6+L7     I AREA 5 ASBA,4,5 I NUMCMP,AREA
_e __ J_L __ -i H1=1.455*1.266 H2=0.01 H3=1/32 LA=L4+LS+L6+L7+L8+L9 LB=L1+L2+L3+LA+L10+L11+L12+L13 LF=LB+L14+L15+L16+L17+L18 LP=LTOT*H1*PLEN ASEAL=2*3.14159*CR11+R12)/2*CR11*R12)
                \IPOFFS R4+RR1,L1+L2+L3+LA PCIRC 16iRR1      I AREA 5 ASBA,<t,) I NUMCMP,AREA
FUP=3.14159*1R*IR*PFIRE PBOLT=(7*FBOLT-FUP)/ASEAL IC,101,IR,0 IC,102,R1,0 IC,103,R2,L1 IC, 104, IR L 1 A,101, 102,103, 104 IC, 105,R2,L 1+L2 IC,106,IR,L1+L2 A,103,104,106,105 IC,107,R3,L1+L2+L3 IC, 108,IR L1+L2+L3 A,106,10~ 1 107,108  
                \IPSTYL,DEFA RECTNG,IR,R4,L1+L2+L3+LA,L1+L2+L3+LA+L10 I AREA 5 RECTNG,IR,R5,L1+L2+L3+LA+L10,L1+L2+L3+LA+L10+L11+L12   I AREA 6
! AREA 1 I AREA 2 I AREA 3 RECTNG,IR,R3,L1+L2+L3,L1+L2+L3+LA I AREA 4 RECTNG,R3-C1,R3,L1+L2+L3+L4,L1+L2+L3+L4+LS ASBA,4,5 I
                ~Ffs R4+RR2,L1+L2+L3+LA+L10 PCIRC, 6 LRR2     I AREA 7 ASBA,6,t I NUMCMP,AREA WPSTYL,DEFA RECTNG,IR,R6,LB*L13,LB+L14+L15     I AREA 7 WPOFFS R5+RR3,LB*L13 PCIRCL6LRR3      I AREA 8 ASBA,t ,a I NUMCMP,AREA
NUMCHP,AREA I AREA 5 RECTNG,R3*C1,R3,L1+L2+L3+L4+L5+L6,L1+L2+L3+L4+L5+L6+L7 ASBA,4,5 I
                \IPSTYL,DEFA WPOFFS R7+RR4,LB+L14+L15 PCIRCL6LRR4      I AREA 8 ASBA,t,a I NUMCMP,AREA
NUMCMP,AREA  
 
\\IPOFFS6 R4+RR1,L1+L2+L3+LA PCIRC1 iRR1 I AREA 5 ASBA,<t,)
MPR Associates, Inc .
I NUMCMP,AREA  
      .mMPR                                                                  320 King Street Alexandria, VA 22314 Calculation No.                  Prepared By
\\IPSTYL,DEFA I
*    /08~-gz.-O/
AREA 5 RECTNG,IR,R4,L1+L2+L3+LA,L1+L2+L3+LA+L10 I AREA 5 RECTNG,IR,R5,L1+L2+L3+LA+L10,L1+L2+L3+LA+L10+L11+L12 I AREA 6  
t - - -_            _ . . _ _ __      l'L..      _ . _ i_                  _
~Ffs 6
Page  5)
R4+RR2,L1+L2+L3+LA+L10 PCIRC, LRR2 I AREA 7 ASBA,6,t I
                                                                                      ----..1------f WPSTYL,DEFA RECTNG,lR,R7,LB+L14+L15,LB+L14+L15+L16 I AREA 8 RECTNG,lR,RTAN,LB+L14+L15+L16,LF*RELlEF      I AREA 9 PClRCL6 ,RRS
NUMCMP,AREA WPSTYL,DEFA RECTNG,IR,R6,LB*L13,LB+L14+L15 I AREA 7 WPOFFS6 R5+RR3,LB*L13 PCIRCL LRR3 I AREA 8 ASBA,t,a I NUMCMP,AREA  
                  ~OFFs R7+RR5,LB+L14+L15+L16 I AREA 10 ASBA,Y,10 I NUMCMP,AREA WPSTYL,DEFA RECTNG,R8,RTAN,LB+L14+L15+L16,LF*RELlEF/2 I AREA 10 ASBA,9,10 NUMCMP,AREA WPOFFS RTAN,LF-RELlEF PClRCL6,RELlEF      I AREA 10 ASBA,Y, 10 I NUMCMP,AREA WPSTYL,DEFA RECTNG,lR,RTAN,LF*RELlEF,LP ! AREA 10 RECTNG R8,RTAN,LB+L14+L15+L16,LF-RELlEF/2      ! AREA 11 ASBA,1 6 , 11 NUMCMP,AREA
\\IPSTYL,DEFA WPOFFS6 R7+RR4,LB+L14+L15 PCIRCL LRR4 I AREA 8 ASBA,t,a I NUMCMP,AREA  
                  ~OFFS,RTAN,LF*RELlEF PClRC,0,RELlEF      I AREA 11                          I ASSA, 10, 11 I                                            I NUMCMP,AREA                                            I WPSTYL,DEFA                                            I RECTNG,lR,RTAN,LP,LTOT I AREA 11 RECTNG,lRLR13,LTOT*H1*H2-H3,LTOT    I AREA 12 ASBA,11, 1" NUMCMP,AREA RECTNG,R13,R12,LTOT*H1*H2,LTOT    I AREA 12 ASBA,11,12 NUMCMP,AREA RECTNG\R12,R11,LTOT*H1,LTOT    I AREA 12 ASBA,1 ,12 NUMCMP,AREA NUMCMP,ALL RECTNG,RTAN,R9,LF,LTOT    I AREA 12 IC,501,R9,LF+L20                                      I IC,502,R9 LTOT                                        I K,503,R16,uoT                                          I IC,504,R14,LTOT*L22                                    I A,501 1 502L503,504 I AREA 13                          I ASBA, 12, b                                            I NUMCMP,AREA                                            I NUMCMP,ALL                                              I NUMMRG,ALL                                              I NUMCMP,ALL                                              I KMCX>lF,46,R9,LF*FLOFF AGLUE,1,2
 
MPR Associates, Inc.
  *mMPR                                                                320 King Street Alexandria, VA 22314
*                                                              /,) Che9~d By Calculation No .                  Prepared By 1D~ .. 32,-01                          ,,,,..,,_            y((~                    Page 3q AGLUE,2,3 AGLUE,3,4 AGLUE,4,5 AGLUE,5,6 AGLUE,6,7 AGLUE,7,8 AGLUE,8,9 AGLUE,9 10 AGLUE, 10, 11 AGLUE, 10, 12 AGLUE,11,13 NUMCMP,AREA RECTNG,BLKIR,BLKOR,LF-BLKHT,LF-FLOFF      I AREA 13 1 K,601,BLKIR,LF-FLOFF K,602,BLKIR+0.125,LF-FLOFF K,603,BLKIR 1 LF-FLOFF-0.125 A,601,602,6u3    I AREA 14 ASBA, 13, 14 NUMCMP ,AREA                                        I ET,1,PLANE42 KEYOPT, 1,3, 1 DR=1/32 KSEL,S,KP,,27 KSEL,A,KP ,,31 LSLK
          !LSEL,S,LINE,,40,41 LESIZE,ALL,DR LSEL,All HP,EX, 1, 16E6 HP,NUXY, 1,0.3 HP,DENS, 1,0.284/G ALLSEL TYPEi1 HAT, ESIZ.E,1/8 AHESH,9 ESIZE,1/12 AHESH, 10 ESIZE, 1/8 AHESH, 11L12 ESIZE,1/o AHESH, 13 ESIZ.E,1/8 AMESH,1,8 ET ,Z,CONTAC48              I Contact Elements TYPE,2 R, 1,GSTIF REAL, 1 LSEL,S,LINE,,46 NSLL,S, 1 CM,CONTACT1,NOOE NSEL,All LSEL,All LSEL,S,LINE,,68 NSLL,S, 1 CM,TARGET1,NOOE NSEL,ALL LSEL,ALL GCGEN,CONTACT1,TARGET1,1 GCGEN,TARGET1,CONTACT1,1


. mMPR Calculation No.
Prepared By l'L..
MPR Associates, Inc.
MPR Associates, Inc.
  *mMPR                                                                320 King Street Alexandria, VA 22314 Calculation No.                   Prepared By 10~ ... 3z-01                      ,rr..._
320 King Street Alexandria, VA 22314 Page 5)
Page ii LSEL, S,LINE, ,56 NSLL,S, 1 CH,CONTACT2,NOOE NSEL,'ALL LSEL,ALL LSEL,S,LINE, ,69 NSLL,S,1 CM,TARGET2,NOOE NSEL,ALL LSEL,ALL GCGEN,CONTACT2,TARGET2,1 GCGEN,TARGET2,CONTACT2,1 KSEL,S,LOC,Y,lf*BLKHT KSEL,R,LOC X,BLKIR,BLKOR DK,ALL,UY, 0, , 1 KSEL,S,LOC,X,R3 KSEL,R,LOC Y,L1+L2+L3+L4,L1+L2+L3+L4+L5+L6+L7 DK,ALL,UX, 0,,
/08~-gz.-O/
LSEL,S,LOC,Y,LTOT*H1*.001,LTOT-H1+.001 SFL,ALL,PRES,PBOLT LSEL,ALL LSEL,S,LOC,Y,LTOT*H1*H2*H3*.001,LTOT-H1*H2+.001 LSEL,R,LOC,X,IR*0.001,R12*0.001 SFL,ALL,PRES,PFIRE LSEL,ALL LSEL,S,LOC,X,IR*.001,IR+.001 LSEL,R,LOC,Y,LP,LTOT*H1*H2-H3 SFL,ALL,PRES,PFIRE LSEL,ALL ALLSEL SBCTRAN ANTYPE,STATIC OUTPR,ALL,0 OUTRES,ALL,0 OUTRES,NSOL,1 OUTRES,RSOL,1 OUTRES,STRS,1 OUTRES,NLOAD,1 FINISH SAVE
t---_
              /SOLUTION SOLVE SAVE,NOMINAL,DB FINISH
_._i _ _
              /POST1 CSYS,O RSYS,O LPATH,NOOE(RTAN*RELIEF*0.7071,LF*RELIEF*(1*0.7071),0),NOOE(IR,LP,0)
----..1------f WPSTYL,DEFA RECTNG,lR,R7,LB+L14+L15,LB+L14+L15+L16 I AREA 8 RECTNG,lR,RTAN,LB+L14+L15+L16,LF*RELlEF I AREA 9
LOCAL 1 11,0,0,0,0,45 RSYS,11 PDEF,RSIGX,S,X PDEF,RSIGY,S,Y PDEF,RSIGZ,S,Z PDEF,RSIGI,S,INT PLPATH,RSIGX,RSIGY,RSIGZ,RSIGI PRPATH,RSIGX,RSIGY,RSIGZ,RSIGI
~OFFs 6
*}}
R7+RR5,LB+L14+L15+L16 PClRCL,RRS I AREA 10 ASBA,Y,10 I
NUMCMP,AREA WPSTYL,DEFA RECTNG,R8,RTAN,LB+L14+L15+L16,LF*RELlEF/2 I AREA 10 ASBA,9,10 NUMCMP,AREA WPOFFS RTAN,LF-RELlEF PClRCL6,RELlEF I AREA 10 ASBA,Y, 10 I
NUMCMP,AREA WPSTYL,DEFA RECTNG,lR,RTAN,LF*RELlEF,LP
! AREA 10 RECTNG 6
R8,RTAN,LB+L14+L15+L16,LF-RELlEF/2 ASBA,1, 11 NUMCMP,AREA
~OFFS,RTAN,LF*RELlEF PClRC,0,RELlEF I AREA 11 ASSA, 10, 11 I
NUMCMP,AREA WPSTYL,DEFA RECTNG,lR,RTAN,LP,LTOT I AREA 11 RECTNG,lRLR13,LTOT*H1*H2-H3,LTOT I AREA 12 ASBA,11, 1" NUMCMP,AREA RECTNG,R13,R12,LTOT*H1*H2,LTOT I AREA 12 ASBA,11,12 NUMCMP,AREA RECTNG\\R12,R11,LTOT*H1,LTOT I AREA 12 ASBA,1,12 NUMCMP,AREA NUMCMP,ALL RECTNG,RTAN,R9,LF,LTOT I AREA 12 IC,501,R9,LF+L20 IC,502,R9 LTOT K,503,R16,uoT IC,504,R14,LTOT*L22 A,501 1502L503,504 ASBA, 12, b NUMCMP,AREA NUMCMP,ALL NUMMRG,ALL NUMCMP,ALL I AREA 13 KMCX>lF,46,R9,LF*FLOFF AGLUE,1,2 AREA 11 I
I I
I I
I I
I I
I I
I I
I
* mMPR Calculation No.
1D~.. 32,-01 AGLUE,2,3 AGLUE,3,4 AGLUE,4,5 AGLUE,5,6 AGLUE,6,7 AGLUE,7,8 AGLUE,8,9 AGLUE,9 10 AGLUE, 10, 11 AGLUE, 10, 12 AGLUE,11,13 NUMCMP,AREA Prepared By 1
RECTNG,BLKIR,BLKOR,LF-BLKHT,LF-FLOFF I AREA 13 K,601,BLKIR,LF-FLOFF K,602,BLKIR+0.125,LF-FLOFF K,603,BLKIR1LF-FLOFF-0.125 A,601,602,6u3 I AREA 14 ASBA, 13, 14 NUMCMP,AREA I
ET,1,PLANE42 KEYOPT, 1,3, 1 DR=1/32 KSEL,S,KP,,27 KSEL,A,KP,,31 LSLK
!LSEL,S,LINE,,40,41 LESIZE,ALL,DR LSEL,All HP,EX, 1, 16E6 HP,NUXY, 1,0.3 HP,DENS, 1,0.284/G ALLSEL TYPEi1
: HAT, ESIZ.E,1/8 AHESH,9 ESIZE,1/12 AHESH, 10 ESIZE, 1/8 AHESH, 11L12 ESIZE,1/o AHESH, 13 ESIZ.E,1/8 AMESH,1,8 ET,Z,CONTAC48 I Contact Elements TYPE,2 R, 1,GSTIF REAL, 1 LSEL,S,LINE,,46 NSLL,S, 1 CM,CONTACT1,NOOE NSEL,All LSEL,All LSEL,S,LINE,,68 NSLL,S, 1 CM,TARGET1,NOOE NSEL,ALL LSEL,ALL GCGEN,CONTACT1,TARGET1,1 GCGEN,TARGET1,CONTACT1,1 MPR Associates, Inc.
320 King Street Alexandria, VA 22314
/,) Che9~d By y((~
Page 3q
* mMPR Calculation No.
10~... 3z-01 LSEL, S,LINE,,56 NSLL,S, 1 CH,CONTACT2,NOOE NSEL,'ALL LSEL,ALL LSEL,S,LINE,,69 NSLL,S,1 CM,TARGET2,NOOE NSEL,ALL LSEL,ALL Prepared By
,rr..._
GCGEN,CONTACT2,TARGET2,1 GCGEN,TARGET2,CONTACT2,1 KSEL,S,LOC,Y,lf*BLKHT KSEL,R,LOC0 X,BLKIR,BLKOR DK,ALL,UY,,, 1 KSEL,S,LOC,X,R3 KSEL,R,LOC0 Y,L1+L2+L3+L4,L1+L2+L3+L4+L5+L6+L7 DK,ALL,UX,,,
LSEL,S,LOC,Y,LTOT*H1*.001,LTOT-H1+.001 SFL,ALL,PRES,PBOLT LSEL,ALL LSEL,S,LOC,Y,LTOT*H1*H2*H3*.001,LTOT-H1*H2+.001 LSEL,R,LOC,X,IR*0.001,R12*0.001 SFL,ALL,PRES,PFIRE LSEL,ALL LSEL,S,LOC,X,IR*.001,IR+.001 LSEL,R,LOC,Y,LP,LTOT*H1*H2-H3 SFL,ALL,PRES,PFIRE LSEL,ALL ALLSEL SBCTRAN ANTYPE,STATIC OUTPR,ALL,0 OUTRES,ALL,0 OUTRES,NSOL,1 OUTRES,RSOL,1 OUTRES,STRS,1 OUTRES,NLOAD,1 FINISH SAVE  
/SOLUTION SOLVE SAVE,NOMINAL,DB FINISH  
/POST1 CSYS,O MPR Associates, Inc.
320 King Street Alexandria, VA 22314 Page ii RSYS,O LPATH,NOOE(RTAN*RELIEF*0.7071,LF*RELIEF*(1*0.7071),0),NOOE(IR,LP,0)
LOCAL111,0,0,0,0,45 RSYS,11 PDEF,RSIGX,S,X PDEF,RSIGY,S,Y PDEF,RSIGZ,S,Z PDEF,RSIGI,S,INT PLPATH,RSIGX,RSIGY,RSIGZ,RSIGI PRPATH,RSIGX,RSIGY,RSIGZ,RSIGI}}

Latest revision as of 01:42, 6 January 2025

Rev 1 of Finite Element Stress Analysis
ML18100A892
Person / Time
Site: Salem  PSEG icon.png
Issue date: 12/28/1993
From:
MPR ASSOCIATES, INC.
To:
Shared Package
ML18100A891 List:
References
108-32-01, 108-32-01-R01, 108-32-1, 108-32-1-R1, NUDOCS 9402280229
Download: ML18100A892 (35)
v • d • e


Text

  • .

MPR ASSOCIATES, INC.

320 King Street, Alexandria, VA 22314

~1--~~~~~~~~~~CA_L_c_u_L_A_T_I_O_N_T_IT_L_E_P_A_G_E~~~r--~~~~~~~

Client \\'\\.,I \\1,..

S='"\\C."'

o 1

.y'-'61......

.._ f kc,tr1 L. & U-".)

Project SQ.le.M EDCr Lv1~ Cr~c.k.1115 Calculation Title REVISION PAGE NO.

PREP ARER(S)/

NO.

AFFECTED DATE cp

g!!

11/t?/13 j_

5 10 I II \\?.- \\')-2.~

I I

I j{fi) 17./21/13 PAGE 1 OF 35 TASK NO.

l0'8. ~2 CALCULATION NO.

CHECKER(S)/

DA'fij, REVIEWER(S)/

DATE

  • ~======+/-=============~*===============~

,'..'l ii *1*

I I.*

l __ L

mMPR MPR Associates, Inc.

320 King Street Alexandria, VA 22314 RECORD OF REVISIONS Calculation No.

Prepared By ahe~

JD<6'*32'0/

I--

~r:

Page 2-Revision Description cb

rf) 1~0,.\\ 1..ss'-'C..

1-

~(grF~~l 'Z.-J lfo,,.. 1 (o""'""f..-,.~ f;.c-. ~Sl i.-<r-

. mMPR MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Calculation No.

Prepared By g~~

108'51..-0' Page 3

/-<-

1.0 PURPOSE The purpose of this calculation is to estimate the stresses in an ALCO 251 diesel engine cylinder liner. The stresses are calculated for the nominal liner configuration and several other configurations to evaluate the effect of variations in design parameters.

2.0 RESULTS For each case evaluated the maximum stress occurs at the relief groove, at a location about 45° from the groove/flange intersection. The principal stresses at this. location are oriented at an angle of about 45°. The maximum calculated stresses are summarized below in the "principal stress" coordinate system (rotated 45°).

Stress Case ax O'

az Intensity (psi)

(pli)

(psi)

(psi)

Nominal 43420 9036 18770 34566 Block Gap 43449 9045 18785 34586 Relief 46239 6292 18779 40117 Groove Depth 43329 9010 18712 34498 2 Mil Offset 46516 9908 20232 36870 8 Mil Offset 55425 12413 24223 43550 Nominal Firing 24424 5049 11148 19461 2 Mil Offset Firing 27452 5902 12573 21713 8 Mil Offset Firing 32677 7335 14937 25659 Worst Case 59628 13533 25983 46158 Worst Case Firing 35258 8016 15947 27279 The cases evaluated are described in detail in section 3.3.

.. mMPR"-

-: MPR' Associates, Inc.

320 King Street Alexandria, VA 22314 Calculation No.

Prepared By

~

Page q-106*32'0/

i-----------"--------1-----L--

3.0 CALCULATION 3.1 Model The stresses in the liner are calculated using an axisymmetric finite element model of the liner as shown in Figures 1 and 2. Contact (gap) elements are included between the liner and block to simulate the contact force. The finite element model of the cylinder liner was developed using nominal dimensions for the liner and engine block. As described below, other cases were also evaluated to determine the effect of changes in some of the.liner dimensions.

The key dimensions used in developing the model are shown in Figure 3. The primary references for the dimensions are References 1 and 2, the Bombardier Design Print for the liner and the ALCO 251 Technical Manual. These dimensions are summarized below:

BLKIR=l0.752/2 RELIEF=0.133 DEPTH=0.05 FLOFF=0.0001 (the flange offset)

IR=9/2 R1=(9+9/16)/2 R2=10/2 R3=10.254/2 R4=10/2 R5=10.2/2 R6=10.71/2 R7=10/2 R8=10.75/2 R9=11.865/2 R10=R9-l/4 Rll=l0.660/2 R12=10/2 R13=(9+ 19/32)/2 R14=R9-1/8 BLKOR=R9+0.25 BLKHT=0.75 RTAN =RS-DEEP+ RELIEF RRl=l/2 RR2=5/8 RR3=5/8 RR4=1/2 RR5=5/8 Cl=R3-9.8/2 LTOT=21+15/16 Ll = 1.732*(R2-Rl)

L3=0.333 L5=5/16 L7=5/16 L6=(14+ 7/16)-(13+5/8)-L7 L4=(2-L5-L7-L6)/2 L2=LTOT-1.455-(14+ 7/16)-L1-L3-L4-L5 L8=L4 L9=0.333 Lll=0.339 L10=(13+5/8)-L8-L9-(2+ 1/16)-3/8-1.5-Lll L13=0.571 L12= 1.5-L13 L14=3/8 L15=0.478 L17=0.573 L16=(2+ 1/16)-9/16-Ll 7-LlS L18=9/16 L20=7/16 L21=1/8 L22= 1.455-L20-L21

. mMPR Hl = 1.455-1.266 H2=0.01 H3=1/32 MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Page c; The liner material is cast iron, so the following material properties were used:

E = 16,000,000 psi (Reference 3 states modulus of elasticity is 14-17 ksi) v = 0.3 (assumed)

The ANSYS general purpose finite element program is used to calculate stresses. Attachment 1 is a listing of the ANSYS input for the nominal case. The inputs for the other cases a~e similar.

Two key assumptions were made developing the model. These are summarized below.

  • The analyses neglected friction effects at the lower seal (at the 0-rings). This friction force could reduce the calculated stresses if the rotation of the liner flange was restrained.
  • The potential for contact between the lower, upper guide is neglected. Although this contact is not expected, it could lower the calculated stresses.

3.2 Applied Loads/Boundary Conditions The liner is subject to the following loads and boundary conditions (as shown on Figure 4):

  • Bolt Preload - The cylinder liner is held in place by the head. The preload in the head bolts is applied as a pressure to the head/liner contact surface. This load is ultimately reacted by contact with the engine block mating surface under the liner flange. This force is applied as a pressure load as shown in Figure 4.
    • MPR Calculation No.
Dt*37.--0J Prepared By

320 King Street Alexandria, VA 22314

('phecke.d By

//:~~

Page

~

mMPR Calculation No.

/08 ~ 32 '0)

Prepared By

/

_y**

.*.* (I (

-- MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Page 7

. mMPR

320 King Street Alexandria, VA 22314 Calculation No.

Prepared By

(."?he<;-k~ By r--~/i-~8~-3_Z_'_O_l~--l~~~~~*--~~~L-~~~

.~_:_~~~-=--~~...L.-Pa_g_e_f~--l R'i R.5 RS" R4-

'R.~

t.IL --

I l

~

f l

"'--'R- -r-1:L..11: -

RM

(

D t:PTt+

U1>

R!\\.\\

1..I

320 King Street

- -Alexandria, VA 22314 Page 1

. mMPR Calculation No.

I f.)( -3 2.. -0 I Prepared By

~

320 King Street Alexandria, VA 22314 Page / 0 The head bolts are 1-1/4" diameter, installed with a 550 ft-lb torque. Assuming that typical lubricants are used, 550 ft-lb torque corresponds to a preload of about 35,000 lb per bolt (from Reference 15):

\\ I KTP(l.25) 550ft-lb = ---

12 Em(tan(>.)+µsec(a))

Dcml-'c KT = 20(1-µtan(>.)sec(a) + 2Dsin(cp) where:

Em is the mean thread pitch diameter = 1.1572"

). is the lead angle of thread = 2.25° a is one-half the angle of thread = 30°

µis the thread friction coefficient = 0.11 (for lubricated threads) 1-'c is the collar friction coefficient = 0.11 Dem = (Sm +dh)/2 = (1.875+(1.25+0.0625))/2 = 1.5938" db= 1.25+0.0625 = 1.3125"

lx.\\ (_o1lrJwJ ~~~~"') E~0rc 5 MPR Associates, Inc. 320 King Street Alexandria, VA 22314 Page /j ANSYS 5. 0 A DEC 17 1993 11:30:57 PLOT NO-1 NODAL SOLUTION STEP=l SUB =1 TIME=l SY (AVG) RSYS=O DMX =0.006872 SMN =-25159 SMNB= - 34 79 8 SMX =37628 SMXB=41295 -25159 -18182 ~ -11206 -4230 2747 9723 ~ 16699 23675 30652 37628 . mMPR ALCO 251 CYLINDER LINER * \\-\\-oof s ~~) ~~) ( G-~t>\\_\\ CoorJv-c.~ S.'1~\\... ) F¥Jvrt b MPR Associates, Inc. 320 King Street Alexandria, VA 22314 Page Uo ANSYS 5. 0 A DEC 17 1993 11:31:58 PLOT NO. 3 NODAL SOLUTION STEP=l SUB =l TIME=l SZ (AVG) RSYS=O DMX =0.006872 SMN =*25139 SMNB=-34917 SMX =18770 SMXB=24790

  • 25139
  • 20260

~ -15381 -10502 -5624 -744.912 c:::J 4134 9013 = 13891 18770

  • mMPR Calculation No.

108~32 ""()/ Prepared By ~ ALCO 251 CYLINDER LINER - NO ~l\\.._\\ S-ks\\ (P,.. tal./"3 ( G-\\ol-\\ (ov )l""".h ~ls~-) f \\ ~)'.>"- 7

  • **MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Page I? ANSYS 5.0 A DEC 17 1993 11:31:17 PLOT NO. 2 NODAL SOLUTION STEP=l SUB =l TIME=l SX (AVG) RSYS=O DMX =O. 006872 SMN =-24322 SMNB=-34100 SMX =31246 SMXB=35611 -24322 -18148 ~ -11973 -5799 374.948 6549 ~ 12723 18898 25072 31246 . mMPR Calculation No. 108 <sz-01 (a IOU I) 434 3817. 3293 171 119 144.847 -37'1. Prepared By ~ MPR Associates, Inc.

  • 320 King Street Alexandria, VA 22314 RSICJ Page / y ANSYS 5.0 A DEC 12 1993 01:53:27 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv =1 DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN -~ ,A5I'71' Jl!U:C% -'104. 446'---~--.---r---,..--~--..,.1----.---=:;:==-- b.545 I o.s17

  • 1.363 0

0.272 0.136 0.408 0.681 0.954 1.227 DIST ALCO 251 CYLINDER LINER - NOMINAL sinss.Ji. b '-l' ~ (\\<o+.-~J t\\~ *)

    • MPR l

c.1000 434 Ja20*. 3295 119 144.30 -380.76

320 King Street Alexandria, VA 22314 lSlCZ Page If ANSYS 5.0 A DEC 12 1993 02:11:24 PLOT NO. 1 POST! STEP=l SUB =l TIME=l PATH PLOT NOD1=339 NOD2=356 zv =1 DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN -905.837 '-----,,

,----,--,.----r----~==:::;::=--

0 ci.212 0.545 0.136 0.408 0.681 0.954 DIST CYLINDER LINER - BLOCK GAP s+ro.s v~ DC(>~

c~~~J 4~

11

)

'1.J6J 1.227

. mMPR

(*IOUI) 462 407f' 351'1 29 241.(

1861 755.71 203.11

-:349.47 0.135 0.407

. 0.679 0.951 I

DIST ALCO 251 CYLINDER LINER - RELIEF

~). ~, \\Jto11...

(. (Lo 1z..;._J ~ o)

_ _,/".-----**

1.088 1.224 MPR Associates, Inc.

320 King Street-Alexandria, VA 22314 RS'Jc;I asrcz 1.36_

Page V>

ANSYS 5. 0 A DEC 12 1993 02:34:01 PLOT NO.

1 POST!

STEP=l SUB =l TIME=l PATH PLOT NOD1=335 NOD2=352 zv

=l DIST=0.75 XF

=0.5 YF

=0.5

_ZF

=O. 5 CENTROID HIDDEN

  • mMPR.

Calculation No.

!/}f']Z-t)/

c.1001>

43J3i 3285' 1~3.071

-380.65 Prepared By A.

-<104. 376 '-------,-,---r----*.-1 ---,-I -----,1----'==--,

0 0.273 b.546 O.BIQ 1.0'13

0. !36 0.683 0.'156 1.23 DIST ALCO 251 CYLINDER LINER - CUT DEPTH MPR Associates, Inc.

320 King Street Alexandria, VA 22314 RSI CI 11.SI-:f l\\SIC%.

1.366 Page '2(

ANSYS 5.0 A DEC 12 1993 02:57:44 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=345 NOD2=362 zv

=1 DIST=0.75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN

  • mMPR Calculation No.

!D8 -3z-01 c.1000 4651 40861:

3521

~' \\

\\\\

\\\\

\\ "

\\ *..

127.7.(

-437.741

-1003 0

0.136 0.272 Prepared By P--

0.40S

~.545 I 0.6Sl I 0.817 DIST

\\ALCO 251 CYLINDER LINER -

2 MIL OFFSET 5-\\n 'i.)e}

-.1, 1)' pfh (Q.. ~t-i 45')

l.0'1 l.227 MPR Associates, Inc.

320 King Street Alexandria, VA 22314 P.:Jl<.!l

'(. 363 Page 2z__

ANSYS 5. 0 A DEC 12 1993 15:47:26 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv

=l DIST=O. 75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN

. mMPR Calculation No.

/OB-:sz.-() I

(.1001)

'5543'.

4176 760.467 Prepared By

""'L.

  • - MPR *Associates, Inc.
  • 320 King Street Alexandria, VA 22314 Page 2 ?

ANSYS 5. 0 A DEC 12 1993 16:10:05 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv

=1 DIST=0.75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN 77.316

-605.83 J.SlC%.

-128q 0

0.272 0.545 0.817 O.JJ6 0.4011 0.681 o.q54 J.227 DIST ALCO 251 CYLINDER LINER - 8 MIL OFFSET f\\j\\)~ \\ 3 s+rtw1 IJ<.

~ ~-K

( (l.<>~.).tJ 45")

Calculation No.

10~-32.*0/

222r 187 Prepared By MPR Associates, Inc.

320 King Street Alexandria, VA 22314

(,)Cheer~ By

/7~~

Page 7 ANSYS 5. 0 A DEC 12 1993 03:59:50 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv

=1 DIST=O. 75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN

---~-----

il:3IC1 ASIC%

!37.604

-209.696 RSI CY

-556.997 '-------:-----,..-----;-----...,.----,----...,.i-----=:::::,..

o 0.272 o.545 o.8t7 t.09 1.363.

0.136 0.4011 0.681 0.954 1.227 DIST ALCO 251 CYLINDER LINER - NOMINAL --

FIRING 5~,~t'.s vs. Dfe~

c

~.~.~- i lt5;J)

I'

. mMPR-Calculation No.

!D~"3Z.-O/

l c.1oul) 3221-2833 :

2445*

205 \\\\*

1670 8'14.22 118.726.

-269.02 Prepared By MPR Associates, Inc.

320 King Street Alexandria, VA 22314

~,Chee~~ By 1:1. ~~

k!:J-::1 J\\SIC%

J\\3lcY' Page 2.1 ANSYS 5. 0 A DEC 12 1993 08:37:55 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv

=1 DIST=0.75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN

-656.776L-----,----------------==:::,.,..

0 0.272 0.545

~.817

°1.0'1 I

1.363 0.136 0.408 0.68i C.95~

1.227 DIST ALCO 251 CYLINDER LINER -

2 MIL OFFSET --

FIRING Sro~,

V!.. 'Dtp-11,

[(lp~t-L qs~)

    • MPR Calculation No.

1ott *3z -o I c.1001>

3853" 3383' Prepared By r-MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Page /<.,_

ANSYS 5.0 A DEC 12 1993 09:01:55 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=339 NOD2=356 zv

=1 DIST=0.75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN

~Sl<::t RSVi\\"

Jl:;IC7.

-85!.21@'----:------,--; -----;---,.---~--------====--

0.272 0.545 0.817

'1.0<1 0

0.136 0.408 0.681 0.954 1.227 DIST ALCO 251 CYLINDER LINER -

8 MIL OFFSET --

FIRING stn.... v.s "". lJ<!~t-L

('R-o-l~i ~ ")

mMPR Calculation No.

!D8'32-0I (w lou1r 5881-5165 444q \\*

J7J 3017 158 Prepared By MPR Associates, Inc.

320 King Street Alexandria, VA 22314 r.:a.:;1 RSI'n" RStC'%.

Page 77 ANSYS 5. 0 A DEC 12 1993 05:02:53 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=343 NOD2=360 zv

=1 DIST=0.75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN

-1250'------, ----------------==-

o 0.272 0.545 '

0.817 1.363 0.136 0.408 0.681 0.'154 1.227 DIST ALCO 251 CYLINDER LINER -

ALL EFFECTS

  • mMPR Calculation No.

l (a IOU!)

409 3103" 260 2l!S 112 140.406

-353.Jl

-847.031 o

\\

0.136 Prepared By 0.272 0.545 0.817 0.408 0.681 0.954 DIST ALCO 251 CYLINDER LINER - ALL EFFECTS --

FIRING MPR Associates, Inc.

320 King Street Alexandria, VA 22314 n Che~kr2 By t7. ~~-wt:-

Page 2.P i l.09

___ ks-rc.t RSlCZ.

ttzrcv 1.363 1.227 ANSYS 5. 0 A DEC 12 1993 16:30:31 PLOT NO.

1 POSTl STEP=l SUB =1 TIME=l PATH PLOT NOD1=343 NOD2=360 zv

=1 DIST=0.75 XF

=0.5 YF

=0.5 ZF

=0.5 CENTROID HIDDEN s~~'C..I vc.. * 'D ep ti, (flo~~[ ~")

  • mMPR Calculation No.

,og.12-0 1

4.0 REFERENCES

Prepared By Ft-MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Page z 1

1. Bombardier Inc. Drawing C21 1036124 1000 "Cylinder Liner Machining Drg.", Rev. 0.

2 ALCO 251 Diesel Engine Technical Manual

3. Metals Handbook, 9th Edition, Volume 1.
4. ANSYS Output, NOMINAL.OUT, 12/12/93, 1:53a.
5. ANSYS Output, BLOKGAP.OUT, 12/12/93, 2:11a.
6. ANSYS Output, RELIEF.OUT, 12/12/93, 2:34a.
7. ANSYS Output, DEPTH.OUT, 12/12/93, 2:57a.
8. ANSYS Output, ML2.0UT, 12/12/93, 3:47p.
9. ANSYS Output, ML8.0UT, 12/12/93, 4:10p.
10. ANSYS Output, NOMFIRE.OUT, 12/14/93, 4:13p.
11. ANSYS Output, ML2FIRE.OUT, 12/14/93, 4:33p.
12. ANSYS Output, ML8FIRE.OUT, 12/14/93, 4:54p.
13. ANSYS Output, WORST.OUT, 12/14/93, 5:35p.
14. ANSYS Output, WORSTFR.OUT, 12/14/93, 5:14p.
15. Mechanical Engineering Design, Joseph Shigley, 1963.

. *MPR MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Calculation No.

Prepared By

~c~~

/O~ ~gz -o J

~

Page 3o ATTACHMENT 1 TYPICAL ANSYS INPUT FILE

. mMPR

~

320 King Street Alexandria, VA 22314 Calculation No.

Prepared By

(). ~~~~ By

  • r-~1_DB~*3_2_-_0_1~~~"--~~-~~~~~~.1...-J::;l.~-~~'V-~....:.:....~~~......L..-P_a_g_e~1_r~~

/FILNAM,FL

/TITLE,ALCO 251 CYLINDER LINER

  • NOMINAL

/SHOW, NOMINAL, RES

/PREP7 BLKIR=10.752/2 RELIEF=0.133 DEEP=0.05 PFIRE=O FLOFF=0.0001 G=386.4 PLEN=0.25 GSTIF=30E6 FBOLT=35000 IR=9/2 R1=(9+9/16)/2 R2=10/2 R3=10.254/2 R4=10/2 R5=10.2/2 R6=10.71/2 R7=10/2 R8=10.75/2 R9=11.865/2 R10=R9-1/4 R11=10.660/2 R12=10/2 R13=(9+19/32)12 R14=R9-1/8 BLKOR=R9+0.25 BLKHT=0.75 RTAN=R8*DEEP+RELIEF RR1=1/2 RR2=5/8 RR3=5/8 RR4=1/2 RR5=5/8 C1=R3-9.8/2 LTOT=21+15/16 L1=1.732*CR2*R1)

L3=0.333 L5=5/16 L7=5/16 L6=C14+7/16)*(13+5/8)*L7 L4=C2*LS*L7*L6)/2 L2=LTOT*1.455*(14+7/16)-L1*L3*L4*L5 L8=L4 17 L9=0.333 L11=0.339 L10=C13+5/8)-L8-L9*(2+1/16)~3/8*1.5*L11 L13=0.571 L12=1.5-L13 L14=3/8 L15=0.478 L17=0.573 L16=C2+1/16)-9/16-L17*L15 L 18--9/16 L20=7/16 L21=1/8 L22=1.455-L20-L21

mMPR MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Calculation No.

Prepared By f) c,;~c(!~ By

.t--__ 1_o_s_-_1_2_-0 __

1 ____ ---'-------r-.._------------"-----7--'i_~

________ ---L. __

P_a 9

_e __ J_L __ -i H1=1.455*1.266 H2=0.01 H3=1/32 LA=L4+LS+L6+L7+L8+L9 LB=L1+L2+L3+LA+L10+L11+L12+L13 LF=LB+L14+L15+L16+L17+L18 LP=LTOT*H1*PLEN ASEAL=2*3.14159*CR11+R12)/2*CR11*R12)

FUP=3.14159*1R*IR*PFIRE PBOLT=(7*FBOLT-FUP)/ASEAL IC,101,IR,0 IC,102,R1,0 IC,103,R2,L1 IC, 104, IR L 1 A,101, 102,103, 104 IC, 105,R2,L 1+L2 IC,106,IR,L1+L2 A,103,104,106,105 IC,107,R3,L1+L2+L3 IC, 108,IR L1+L2+L3 A,106,10~ 1 107,108

! AREA 1 I AREA 2 I AREA 3 RECTNG,IR,R3,L1+L2+L3,L1+L2+L3+LA I AREA 4 RECTNG,R3-C1,R3,L1+L2+L3+L4,L1+L2+L3+L4+LS ASBA,4,5 I

NUMCHP,AREA I AREA 5 RECTNG,R3*C1,R3,L1+L2+L3+L4+L5+L6,L1+L2+L3+L4+L5+L6+L7 ASBA,4,5 I

NUMCMP,AREA

\\IPOFFS6 R4+RR1,L1+L2+L3+LA PCIRC1 iRR1 I AREA 5 ASBA,<t,)

I NUMCMP,AREA

\\IPSTYL,DEFA I

AREA 5 RECTNG,IR,R4,L1+L2+L3+LA,L1+L2+L3+LA+L10 I AREA 5 RECTNG,IR,R5,L1+L2+L3+LA+L10,L1+L2+L3+LA+L10+L11+L12 I AREA 6

~Ffs 6

R4+RR2,L1+L2+L3+LA+L10 PCIRC, LRR2 I AREA 7 ASBA,6,t I

NUMCMP,AREA WPSTYL,DEFA RECTNG,IR,R6,LB*L13,LB+L14+L15 I AREA 7 WPOFFS6 R5+RR3,LB*L13 PCIRCL LRR3 I AREA 8 ASBA,t,a I NUMCMP,AREA

\\IPSTYL,DEFA WPOFFS6 R7+RR4,LB+L14+L15 PCIRCL LRR4 I AREA 8 ASBA,t,a I NUMCMP,AREA

. mMPR Calculation No.

Prepared By l'L..

MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Page 5)

/08~-gz.-O/

t---_

_._i _ _

..1------f WPSTYL,DEFA RECTNG,lR,R7,LB+L14+L15,LB+L14+L15+L16 I AREA 8 RECTNG,lR,RTAN,LB+L14+L15+L16,LF*RELlEF I AREA 9

~OFFs 6

R7+RR5,LB+L14+L15+L16 PClRCL,RRS I AREA 10 ASBA,Y,10 I

NUMCMP,AREA WPSTYL,DEFA RECTNG,R8,RTAN,LB+L14+L15+L16,LF*RELlEF/2 I AREA 10 ASBA,9,10 NUMCMP,AREA WPOFFS RTAN,LF-RELlEF PClRCL6,RELlEF I AREA 10 ASBA,Y, 10 I

NUMCMP,AREA WPSTYL,DEFA RECTNG,lR,RTAN,LF*RELlEF,LP

! AREA 10 RECTNG 6

R8,RTAN,LB+L14+L15+L16,LF-RELlEF/2 ASBA,1, 11 NUMCMP,AREA

~OFFS,RTAN,LF*RELlEF PClRC,0,RELlEF I AREA 11 ASSA, 10, 11 I

NUMCMP,AREA WPSTYL,DEFA RECTNG,lR,RTAN,LP,LTOT I AREA 11 RECTNG,lRLR13,LTOT*H1*H2-H3,LTOT I AREA 12 ASBA,11, 1" NUMCMP,AREA RECTNG,R13,R12,LTOT*H1*H2,LTOT I AREA 12 ASBA,11,12 NUMCMP,AREA RECTNG\\R12,R11,LTOT*H1,LTOT I AREA 12 ASBA,1,12 NUMCMP,AREA NUMCMP,ALL RECTNG,RTAN,R9,LF,LTOT I AREA 12 IC,501,R9,LF+L20 IC,502,R9 LTOT K,503,R16,uoT IC,504,R14,LTOT*L22 A,501 1502L503,504 ASBA, 12, b NUMCMP,AREA NUMCMP,ALL NUMMRG,ALL NUMCMP,ALL I AREA 13 KMCX>lF,46,R9,LF*FLOFF AGLUE,1,2 AREA 11 I

I I

I I

I I

I I

I I

I I

I

  • mMPR Calculation No.

1D~.. 32,-01 AGLUE,2,3 AGLUE,3,4 AGLUE,4,5 AGLUE,5,6 AGLUE,6,7 AGLUE,7,8 AGLUE,8,9 AGLUE,9 10 AGLUE, 10, 11 AGLUE, 10, 12 AGLUE,11,13 NUMCMP,AREA Prepared By 1

RECTNG,BLKIR,BLKOR,LF-BLKHT,LF-FLOFF I AREA 13 K,601,BLKIR,LF-FLOFF K,602,BLKIR+0.125,LF-FLOFF K,603,BLKIR1LF-FLOFF-0.125 A,601,602,6u3 I AREA 14 ASBA, 13, 14 NUMCMP,AREA I

ET,1,PLANE42 KEYOPT, 1,3, 1 DR=1/32 KSEL,S,KP,,27 KSEL,A,KP,,31 LSLK

!LSEL,S,LINE,,40,41 LESIZE,ALL,DR LSEL,All HP,EX, 1, 16E6 HP,NUXY, 1,0.3 HP,DENS, 1,0.284/G ALLSEL TYPEi1

HAT, ESIZ.E,1/8 AHESH,9 ESIZE,1/12 AHESH, 10 ESIZE, 1/8 AHESH, 11L12 ESIZE,1/o AHESH, 13 ESIZ.E,1/8 AMESH,1,8 ET,Z,CONTAC48 I Contact Elements TYPE,2 R, 1,GSTIF REAL, 1 LSEL,S,LINE,,46 NSLL,S, 1 CM,CONTACT1,NOOE NSEL,All LSEL,All LSEL,S,LINE,,68 NSLL,S, 1 CM,TARGET1,NOOE NSEL,ALL LSEL,ALL GCGEN,CONTACT1,TARGET1,1 GCGEN,TARGET1,CONTACT1,1 MPR Associates, Inc.

320 King Street Alexandria, VA 22314

/,) Che9~d By y((~

Page 3q

  • mMPR Calculation No.

10~... 3z-01 LSEL, S,LINE,,56 NSLL,S, 1 CH,CONTACT2,NOOE NSEL,'ALL LSEL,ALL LSEL,S,LINE,,69 NSLL,S,1 CM,TARGET2,NOOE NSEL,ALL LSEL,ALL Prepared By

,rr..._

GCGEN,CONTACT2,TARGET2,1 GCGEN,TARGET2,CONTACT2,1 KSEL,S,LOC,Y,lf*BLKHT KSEL,R,LOC0 X,BLKIR,BLKOR DK,ALL,UY,,, 1 KSEL,S,LOC,X,R3 KSEL,R,LOC0 Y,L1+L2+L3+L4,L1+L2+L3+L4+L5+L6+L7 DK,ALL,UX,,,

LSEL,S,LOC,Y,LTOT*H1*.001,LTOT-H1+.001 SFL,ALL,PRES,PBOLT LSEL,ALL LSEL,S,LOC,Y,LTOT*H1*H2*H3*.001,LTOT-H1*H2+.001 LSEL,R,LOC,X,IR*0.001,R12*0.001 SFL,ALL,PRES,PFIRE LSEL,ALL LSEL,S,LOC,X,IR*.001,IR+.001 LSEL,R,LOC,Y,LP,LTOT*H1*H2-H3 SFL,ALL,PRES,PFIRE LSEL,ALL ALLSEL SBCTRAN ANTYPE,STATIC OUTPR,ALL,0 OUTRES,ALL,0 OUTRES,NSOL,1 OUTRES,RSOL,1 OUTRES,STRS,1 OUTRES,NLOAD,1 FINISH SAVE

/SOLUTION SOLVE SAVE,NOMINAL,DB FINISH

/POST1 CSYS,O MPR Associates, Inc.

320 King Street Alexandria, VA 22314 Page ii RSYS,O LPATH,NOOE(RTAN*RELIEF*0.7071,LF*RELIEF*(1*0.7071),0),NOOE(IR,LP,0)

LOCAL111,0,0,0,0,45 RSYS,11 PDEF,RSIGX,S,X PDEF,RSIGY,S,Y PDEF,RSIGZ,S,Z PDEF,RSIGI,S,INT PLPATH,RSIGX,RSIGY,RSIGZ,RSIGI PRPATH,RSIGX,RSIGY,RSIGZ,RSIGI

Retrieved from "https://kanterella.com/w/index.php?title=ML18100A892&oldid=5003337"