M. M. Rahman, A. K. Ariffin, N. Jamaludin, and C. H. C.

Haron

FINITE ELEMENT BASED VIBRATION FATIGUE ANALYSIS FOR A NEW FREE PISTON ENGINE COMPONENT
M. M. Rahman*
Faculty of Mechanical Engineering Universiti Malaysia Pahang, Malaysia

A. K. Ariffin, N. Jamaludin, and C. H. C. Haron

Department of Mechanical and Materials Engineering Faculty of Engineering Universiti Kebangsaan Malaysia 43600 UKM, Bangi, Selangor, Malaysia

1. INTRODUCTION Structures and mechanical components are frequently subjected to the oscillating loads which are random in nature. Random vibration theory has been introduced for more then three decades to deal with all kinds of random vibration behaviour. Since fatigue is one of the primary causes of component failure, fatigue life prediction has become a most important issue in almost any random vibration problem [14]. Nearly all structures or components have been designed using the time based structural and fatigue analysis methods. However, by developing a frequency based fatigue analysis approach, the accurate composition of the random stress or strain responses can be retained within a greatly optimized fatigue design process. Fatigue analysis is generally thought of as a time domain approach, that is, all of the operations are based on time descriptions of the load function. This paper demonstrates that an alternative frequency domain [4,8,9] fatigue approach can be more appropriate. A vibration analysis is generally carried out to ensure that structural natural frequencies or resonant modes are not excited by the frequencies present in the applied load. Sometimes this is not possible and designers then have to estimate the maximum response at the resonance caused by the loading. These are the best performed in the frequency domain using the power spectral density functions of input loading and stress response. It is often easier to obtain a PSD of stress rather than a time history [10, 11]. The dynamic analysis of complicated finite element models is considered in this study. It is valuable to carry out the frequency response analysis instead of a computationally intensive transient dynamic analysis in the time domain. A finite element analysis based on the frequency domain can simplify the problem. The designer can perform the frequency response analysis on the finite element model (FEM) to determine the transfer function between the load and stress in the structure. This approach requires that the PSD of load is multiplied by the transfer function to obtaining the PSD of stress. The main purpose of this paper is to predict fatigue life when the component is subjected to statistically-defined random stresses.

Key words: fatigue life, vibration fatigue, power spectral density functions, frequency response, cylinder block, free piston
____________________ * Corresponding Author Faculty of Mechanical Engineering Universiti Malaysia Pahang Locked Bag 12, 25000 Kuantan, Pahang, Malaysia Phone: +(6)09-5492239, Fax: +(6)09-5492244 E-mail: mustafizur@ump.edu.my
Paper Received: 23 April 2005; Revised 15 May 2007; Accepted 30 May 2007

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2. THEORETICAL BASIS The stress power spectra density [34, 912] represents the frequency domain approach input into the fatigue. This is a scalar function that describes how the power of the time signal is distributed among frequencies [13]. Mathematically, this function can be obtained by using a Fourier Transform of the stress time historys autocorrelation function, and its area represents the signals standard deviation. It is clear that the PSD is the most complete and concise representation of a random process. There are many important correlations between the time domain and frequency domain representations [14] of a random process. Bendat [13] showed that the probability density function (PDF) of peaks for the narrow band signal tended towards Rayleigh distributions as the bandwidth reduced. Furthermore, for the narrow banded time history Bendat assumed that all the positive peaks in the time history would be followed by corresponding troughs of similar magnitude regardless of whether they actually formed the stress cycles. Using this technique, the PDF of stress range would also tend to the Rayleigh distribution. Bendat used a series of equations derived by Rice [15] to estimate the expected number of peaks using the moments of area beneath the PSD. Bendats narrow band solution for the range mean histogram is therefore expressed in Equation (1). Assume p(S) is the Rayleigh distribution which is represented by a narrow band process and stress amplitude (S) can be treated as a continuous random variable:
E[ D] =
i

ni S = t S b p ( S ) dS N (Si ) k

S 2 E[ P] T b S 8 m0 e = S dS 4 m0 k

(1)

where N(Si) is the number of cycles of stress range (S) occurring in T seconds, ni is the actual counted number of cycle, St is the total number of cycles equals to {E[P]. T}, E[P] is the number of peak per seconds, and mo is the zero order moment of area of the PSD. Parameters k and b are the materials constants that would be defined in the SN curve. The Dirlik solution [16] is expressed by Equation (2) [1621].
N ( S ) = E[ P ] T p ( S )
2

(2)

where N(S) is the number of stress cycles of range (S) N/mm expected in T seconds. E[P] is the expected number of peaks and p(S) is the probability density function.
D1 e Q
Z Q

D2 Z

p( S ) =
2( x m 2 ) 1+
2

R2 2 m0

Z 2 2 e 2R

+ D3

Z 2 Ze 2

(3)

D1 =

D2 =

2 1 D1 + D1 , 1 R

D3 = 1 D1 D2 , = m1 m0

m2 m0 m 4

(4)

Q=

1.25( D3 D2 R ) , D1

R=

x m D12
1 D1 +
2 D1

xm =

m2 S , Z= m4 2 m0

(5)

where xm, D1, D2, D3, Q, and R depend on the m0, m1, m2, and m4; Z is a normalized variable. m0, m1, m2, and m4 are the zeroth, 1st, 2nd, and 4th order spectral moments area, respectively. 3. LOADING INFORMATION Several types of variable amplitude loading history were selected from the SAE and ASTM profiles for the FE based fatigue analysis. It is important to emphasize that these sequences are not intended to represent standard loading spectra in the same way as in Carlos or Falstaf [12]. However, they do contain many features which are typical of the automotive industries applications, and therefore, are useful in the evaluation of the life estimation methods. [22, 23]. The variable amplitude loadtime histories are shown in Figure 1 and the corresponding power spectral density response are shown in Figure 2. The terms of SAETRN, SAESUS, and SAEBRAKT represent the loadtime history for the transmission, suspension, and bracket respectively. The considered loadtime histories are based on the SAE profile. In addition, I-N, A-A, A-G, R-C, and TRANSP represent the ASTM instrumentation and navigation typical fighter, ASTM air to air typical fighter, ASTM air to ground typical fighter, ASTM composite mission typical fighter, and ASTM composite mission typical transport loading history, respectively [22]. The abscissa is the time in seconds.

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Figure 1. Different timeloading histories

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Probability Density 0 .575

2.10E-3 -2 Probability Density 1.014 0 2 4 6

MPa

SAE Standard Transmission (SAETRN) Loading

2.220E-5

-6 Probability Density

-4

-2

SAE Standard Suspension (SAESUS) Loading

MPa

0.2704

0.245E-4 -6 Probability Density 0.5440 -4 -2 0 2 4 MPa

SAE Standard Bracket (SAEBKT) Loading

5.475E-4

0 Probability Density

ASTM Instrumentation &Navigation (I-N) Loading

MPa

0.5005

0 Probability Density 0.4002

MPa 6

ASTM Air to Air (A-A) Typical Fighter Loading

-1 0.585

5 MPa

ASTM Air to Ground (A-G) Typical Fighter Loading

Probability Density

0 Probability Density 04.07

6 MPa

ASTM Composite Mission (R-C) Typical Fighter Loading

-4

-2

MPa

ASTM Composite Mission (TRANSP) typical Transport Loading

Figure 2. Power spectral densities (PSD) responses

4. NUMERICAL EXAMPLE 4.2. Finite Element Modeling (FEM) The cylinder block is the one of the important and safety-critical components of the free piston engine. A geometric model is considered as an example parts in this study. There are several contact areas including the cylinder head, gasket, and hole for bolt. Therefore, constraints are employed for the following purposes: (i) to specify the prescribed enforce displacements; (ii) to simulate the continuous behavior of displacement in the interface area; (iii) to enforce rest condition in the specified directions at grid points of reaction.

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A three-dimensional model of the free piston linear engine cylinder block was developed using CATIA software. A 10 nodes tetrahedral element was used for the solid mesh. Sensitivity analysis was performed to obtain the optimum element size. These analyses were performed iteratively at different element lengths until the solution obtained appropriate accuracy. Convergence of the stresses was observed, as the mesh size was successively refined. The element size of 0.20 mm was finally considered. A total of 35 415 elements and 66 209 nodes were generated with 0.20 mm element length. A pressure of 7.0 MPa was applied to the surface of the combustion chamber, generating a compressive load. A pressure of 0.3 MPa was applied to the bolt-hole surface, generating a preload. This preload is obtained according to the RB&W recommendations [24]. In addition, 0.3 MPa pressure was applied on the gasket surface. Multi-Point Constraints (MPCs) were applied on the bolt-hole surface for all six degree of freedom, and [25] were used to connect the parts thru the interface nodes. These MPCs acted as an artificial bolt and nut that connect each part of the structure. Each MPC will be connected using a Rigid Body Element (RBE) that indicates the independent and dependent nodes. The configuration of the engine is constrained by bolting between the cylinder head and cylinder block. In the condition with no loading configuration, RBE elements with six degrees of freedom were assigned to the bolts and the hole on the cylinder block. The independent node was created on the cylinder head hole. Due to the complexity of the geometry and loading on the cylinder block, a three-dimensional FEM was adopted as shown in Figure 3. The loading and constraints on the cylinder block are also shown in Figure 4.

Figure 3. Three dimensional finite element model

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Preload on bolt (0.3 MPa)

Pressure (7 MPa)

Constraints (Bolt)

Gasket pressure (0.3 MPa)

Constraints (Bolt)

Figure 4. Loading, constraints, and boundary conditions

5. RESULTS AND DISCUSSION 5.1. Modal Analysis Modal analysis is usually used to determine the natural frequencies and mode shapes of a component. It can also be used as the starting point for the frequency response analysis. The finite element analysis codes usually used several mode extraction methods. The Lanczos mode extraction method is used in this study Lanczos is the recommended method for the medium to large models. In addition to its reliability and efficiency, the Lanczos method supports sparse matrix methods that significantly increase computational speed and reduce the storage space. This method also computes precisely the eigenvalues and eigenvectors. The number of modes was extracted and used to obtain the cylinder block stress histories, which is the most important factor in this analysis. Using this method to obtain the first 10 modes of the cylinder block, which are presented in Table 1 and the shape of the mode are shown in Figure 5. It can be seen that the working frequency (50Hz) is far away from the natural frequency (186.32 Hz) of the first mode.

Table 1. The Results of the Modal Analysis Mode No. 1 2 3 4 5 6 7 8 9 10 Natural Frequency (Hz) 186.32 259.05 306.61 317.65 327.65 339.84 382.20 462.17 650.87 721.28

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186.32 Hz, Mode 1

259.05 Hz, Mode 2

306.61 Hz, Mode 3

317.65 Hz, Mode 4

327.65 Hz, Mode 5

339.84 Hz, Mode 6

383.20 Hz, Mode 7

462.17 Hz, Mode 8

65.87 Hz, Mode 9

721.28 Hz, Mode 10

Figure 5. The mode shapes of the cylinder block

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Frequency Response Stress Analysis The frequency response analyses were performed using the finite element analysis code. The frequency response analysis used the damping ratio of 5% of critical. The damping ratio is the ratio of the actual damping in the system to the critical damping. Most of the experimental modal reported that the modal damping in terms of nondimensional critical damping ratio expressed as a percentage [26, 27]. In fact, most structures have critical damping values in the range of 0 to 10%, with values of 1 to 5% as the typical range [28]. Zero damping ratio indicates that the mode is undamped. Damping ratio of one represents the critically damped mode. The results of the pseudo-static and the frequency response finite element analysis with zero Hz, i.e. the maximum principal stresses distribution of the cylinder block are presented in Figures 6 and 7 respectively. From the results, the maximum and minimum principal stresses of 380.0 MPa and 77.5 MPa for the pseudo-static analysis, and 380.0 MPa and 78.3 MPa for the frequency response analysis for zero Hz were obtained respectively. These two maximum principal stresses contour plots are almost identical.

Maximum principal stress 380 MPa at node 49360 Maximum principal stress (MPa)
3.80+02 3.50+02 3.19+02 2.89+02 2.58+02 2.28+02 1.97+02 1.67+02 1.36+02 1.06+02 7.50+01 4.45+01 1.40+01 -1.65+01

Default_Fringe Max 3.80+02@Nd49360 Min -7.75+01@Nd13559

-4.70+01 -7.75+01

Figure 6. Maximum principal stresses distribution for the pseudo-static linear analysis

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Maximum principal stress 380.0 MPa at node 49360 Maximum principal stress (MPa)
3.80+02 3.49+02 3.19+02 2.88+02 2.58+02 2.27+02 1.97+02 1.66+02 1.35+02 1.05+02 7.44+01 4.38+01 1.33+01 -1.73+01

Default_Fringe Max 3.80+02@Nd49360 Min -7.83+01@Nd13559

-4.78+01 -7.83+01

Figure 7. Maximum principal stresses distribution for the frequency response analysis at zero Hz

The variation of the maximum principal stresses with the frequency is shown in Figure 8. It can be seen that the maximum principal stress varies with higher frequencies. This variation is due to the dynamic influences of the first mode shape. It is also observed that the maximum principal stress occurs at a frequency of 32 Hz. The maximum principal stresses of the cylinder block for 32 Hz is presented in Figure 9. From the results, the maximum and minimum principal stresses of 561.0 MPa and 207.0 MPa were obtained at node 49 360 and 47 782, respectively.

625 Maximum Principal stress (MPa) 545 465 385 305 225 145 65 0

561 MPa

32 Hz

10

15

20

25

30

35

40

45

50

Frequency (Hz)
Figure 8. Maximum principal stresses plotted against frequency

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Maximum principal stress 561 MPa at node 49360 Maximum principal stress (MPa)
5.61+02 5.10+02 4.59+02 4.07+02 3.56+02 3.05+02 2.54+02 2.03+02 1.51+02 1.00+02 4.91+01 -2.07+01 -5.33+02 -1.04+02 -1.56+02

Default_Fringe Max 5.61+02@Nd49360 Min -2.07+02@Nd47782

-2.07+02

Figure 9. Maximum principal stresses contour for frequency response analysis at 32 Hz

Figures 1013 show the applied time histories, PSDs of narrow band signal (SAESUS), corresponding probability density function (PDF) and cycle histogram, respectively

2104

-2104 0

Force (Newton)

1000

2000 3000 Time (Seconds)

Figure 10. Timeload histories

4000

5000

1.4107 RMS Power (N . HZ) 0

10 15 Frequency (Hz)

20

25

Figure 11. Corresponding (Figure 10) power spectral density

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1.210-4 Probability density 0 -1.53104

Force (Newtons)
Figure 12. Corresponding (Figure 10) probability density function

1.53104

458 Cycles Z-Axis 0

0 Range Newtons X-Axis

4 3.1104 -1.5310

1.53104 Mean Newtons Y-Axis

Figure 13. Corresponding (Figure 10) cycle histogram

5.3. Vibration Fatigue Life Prediction Analysis The results of the fatigue life contour for the SAETRN loading histories at the most critical locations for the pseudo-static analysis and frequency response approach with 32 Hz are shown in Figures 14 and 15 respectively. The minimum life prediction for the pseudo-static analysis and frequency response approach with 32 Hz are obtained as 107.67 and 109.44 seconds respectively. It would be expected that the condition of lower stress would correspond to longer life and vice versa. However, the results indicates the opposite, because is the frequency resolution of the transfer function is selected for the low value then the results show the non-conservative prediction. From Figures 14 and 15, it can be seen that the fatigue life contours are different and most damage was found at a frequency of 32 Hz.

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Predicted minimum life is 107.67 seconds at node 49360

Log of Life (Seconds)

Figure 14. Predicted fatigue life contours plotted for pseudo-static linear analysis

Predicted minimum life is 109.44 seconds at node 49360

Log of Life (Seconds)

Figure 15. Predicted fatigue life contours plotted for frequency response analysis at 32 Hz

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The full set of the comparison results for the untreated polished cylinder block at critical location (node 49 360) is given in Table 2 with various loading conditions. The narrow band solution is considered in this study. It is observed that from Table 2, the SAESUS loading condition gives the longest life for all materials due to the load histories are predominantly compressive mean. The compressive mean loading beneficial for fatigue. In addition, the AG loading condition gives the lowest lives for all materials.

Table 2. Predicted Life in Seconds at Critical Location (Node 49 360) for Various Loading Conditions and Materials Loading conditions Predicted vibration fatigue life in seconds 2024-HV-T6 6061-T6-80-HF No (zero) Goodman Gerber Goodman mean 2.53109 2.74109 2.10107 2.02107 1.461012 1.521012 8.74109 7.97109 10 10 8 3.1510 3.3510 1.0610 8.86107 1.391010 1.461010 2.30108 2.21108 9 9 7 3.3710 3.5910 3.9310 3.79107 8.47108 9.13108 8.23106 8.17106 9 9 7 1.8210 1.9510 1.8310 1.75107 1.441011 1.501011 2.27109 2.12109

SAETRN SAESUS SAEBKT IN AA AG RC TRANSP

No (zero) mean 2.75109 1.531012 3.361010 1.471010 3.60109 9.14108 1.96109 1.511011

Gerber

2.09107 8.62109 1.03108 2.28108 3.89107 8.20106 1.81107 2.24109

5.4. Effect of the Frequency Resolution

Frequency resolution of the transfer function is significant to capture the input PSD. The significances of the frequency resolutions of SAETRN loading histories are also shown in Figures 16 and 17. Two types of Fast Fourier Transform (FFT) buffer size width namely 8192:0.06104 Hz and 16384:0.03052 Hz were used in these figures. The FFT buffer size defines the resolution of the power spectrum. The buffer must be a power of 2 and of course the longer the buffer, the higher the resolution of the spectral lines. To calculate the resolution divide the Nyquist frequency by half the FFT buffer size. If the Nyquist frequency is 250 Hz and the FFT buffer size selected is 8192, then the spectral lines are 250/(8192/2) = 0.06104 Hz apart. Another use of a smaller buffer size is for short data files as these cannot be adequately analyzed with a big buffer, since there may not be enough data to give a good spectral average. Using a smaller buffer size could give a better spectral average at the expense of spectral line width. The total area under each input PSD curve is determined to be identical. However, the 16384:0.03052 Hz width has twice as many points compares to the 8192:0.06104 Hz.

10 RMS Power (MPa2. Hz-1) 0 0

Frequency (Hz)

10

Figure 16. Power spectral density at FFT buffer size of 8192:0.06104 Hz width

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10 RMS Power (MPa2. Hz-1) 0 0

Frequency (Hz)

10

Figure 17. Power spectral density at FFT buffer size of 16384:0.03052 Hz width

The frequency resolution of the transfer function in the important areas of the input PSD is the dominant factor. This is shown in Figure 18 for two different cases. Figure 18 shows that utilizing many points in the input PSD can identify the damage more accurately. However, the approach is not suitable for accurately identifying damage with a large spike occurred between two frequencies in the transfer function. For the worst case scenario the technique can entirely miss the damage.

Input PSD

Transfer function

Response PSD Potentially less damaging More damaging

Figure 18. Effect of the frequency resolution

6. CONCLUSIONS

The concept of vibration fatigue analysis has been presented, where the random loading and response are categorized using PSD functions. A state of art of the vibration fatigue techniques has been presented. Frequency response fatigue analysis has been applied to a typical cylinder block for a free-piston engine. From the results, it can be concluded that the Goodman mean stress correction method gives the most conservative prediction for all loading conditions and materials. The results clearly indicate that AA2024-HV-T6 is a superior material for all the mean stress correction methods. The life predicted from the vibration fatigue analysis is consistently higher except for the bracket loading condition. In addition, vibration fatigue analysis can improve the understanding of system behaviors in terms of frequency characteristics of the structures, loads, and their couplings.
ACKNOWLEDGMENTS

The authors would like to thank the Department of Mechanical and Materials Engineering, Faculty of Engineering, Universiti Kebangsaan Malaysia. The authors are grateful to the Malaysian Government, especially the Ministry of Science, Technology and Environment under IRPA project (IRPA project no: 03-02-02-0056 PR0025/04-03) for providing financial support.

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