ML18100A892

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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)
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Text

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MPR ASSOCIATES, INC.

320 King Street, Alexandria, VA 22314

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' . mMPR 320 King Street Alexandria, VA 22314 Calculation No. Prepared By 108'51..-0' /-<- g~~ 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 .

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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:

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)

LTOT=21+15/16 IR=9/2 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

  • RR2=5/8 RR3=5/8 L22= 1.455-L20-L21

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:

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.
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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 . . 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) 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 ALCO 251 CYLINDER LINER * \-\-oof s~~) ~~) ( G-~t>\_\ CoorJv-c.~ S.'1~\ ...) F¥Jvrt b

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

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ANSYS 5.0 A DEC 12 1993 01:53:27 PLOT NO. 1 POSTl STEP=l (a IOU I) 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

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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' ~

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c.1000 STEP=l SUB =l 434 TIME=l PATH PLOT Ja20*.

NOD1=339 NOD2=356 3295 zv =1 DIST=0.75 XF =0.5 YF =0.5 ZF =0.5 CENTROID HIDDEN

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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(>~

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ANSYS 5. 0 A DEC 12 1993 02:34:01 PLOT NO. 1 POST!

(*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

_ZF =O. 5 CENTROID HIDDEN 241.(

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ANSYS 5.0 A DEC 12 1993 02:57:44 PLOT NO. 1 POSTl STEP=l c.1001>

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

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

0 0.273 b.546 O.BIQ 1.0'13 1.366

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

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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

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-1003 I 0 0.272 ~.545 I 0.817 l .0'1 '(. 363 0.136 0.40S 0.6Sl l .227 DIST

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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

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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

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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

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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 *

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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,

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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

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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

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!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'%.

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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

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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!)

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

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140.406

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  • mMPR 320 King Street Alexandria, VA 22314 Calculation No.

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4.0 REFERENCES

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 Associates, Inc .

' .*MPR 320 King Street Alexandria, VA 22314

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  • NOMINAL

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/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 L18--9/16 L20=7/16 L21=1/8 L22=1.455-L20-L21

MPR Associates, Inc.

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---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 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

\IPOFFS R4+RR1,L1+L2+L3+LA PCIRC 16iRR1 I AREA 5 ASBA,<t,) I NUMCMP,AREA

\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

~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

\IPSTYL,DEFA WPOFFS R7+RR4,LB+L14+L15 PCIRCL6LRR4 I AREA 8 ASBA,t,a I NUMCMP,AREA

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..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

~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

~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

MPR Associates, Inc.

  • mMPR 320 King Street Alexandria, VA 22314 Calculation No. Prepared By 10~ ... 3z-01 ,rr..._

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,,

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 RSYS,O LPATH,NOOE(RTAN*RELIEF*0.7071,LF*RELIEF*(1*0.7071),0),NOOE(IR,LP,0)

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

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