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GT-SUITE曲軸機(jī)構(gòu)分析李書澤所屬:CDAJ-China目錄曲軸系分析功能簡(jiǎn)介1.曲軸系剛體動(dòng)力學(xué)2.發(fā)動(dòng)機(jī)平衡不平衡力/力矩3.
機(jī)體振動(dòng)
–
懸置分析與設(shè)計(jì)4.曲軸扭振5.軸承油膜分析6.曲軸柔性(彎曲)模型7.曲軸應(yīng)力恢復(fù)與后處理選項(xiàng)8.校核Copyright
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Reserved.1曲軸系分析目的:多缸機(jī)中振動(dòng)、動(dòng)力學(xué)、摩擦學(xué)仿真缸內(nèi)壓力和往復(fù)慣性力對(duì)曲軸系部件結(jié)構(gòu)的影響。GT-SUITE工具:通用多體動(dòng)力學(xué)庫(kù)曲軸設(shè)計(jì)分析庫(kù)Copyright
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Reserved.2GT-SUITE的曲軸系設(shè)計(jì)分析功能Copyright
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Reserved.3曲軸動(dòng)力學(xué)分析曲軸系剛性Rigid運(yùn)動(dòng)學(xué)和動(dòng)力學(xué)曲軸扭振Torsional(時(shí)域+頻域)曲軸3D彈性elastic分析:扭轉(zhuǎn)+彎曲,與軸承油膜耦合(動(dòng)力學(xué)或準(zhǔn)靜力學(xué)),應(yīng)力恢復(fù)&疲勞后處理其他功能平衡–
不平衡力/力矩,平衡軸機(jī)體振動(dòng)
- 懸置分析設(shè)計(jì)曲軸連桿軸承油膜分析與GT-SUITE其他模塊的集成仿真曲軸動(dòng)力學(xué)分析剛性Rigid, 平衡扭振Torsional (頻域或時(shí)域)彎曲Bend(3D梁有限元)Copyright
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Reserved.5與發(fā)動(dòng)機(jī)、車輛、其余子系統(tǒng)集成發(fā)動(dòng)機(jī),燃燒模型
(GT-POWER)氣閥/凸輪軸車身與動(dòng)力總成Copyright
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Reserved.7四缸機(jī)曲軸系模型曲軸部件組成軸承油膜曲軸分析控制缸壓活塞連桿缸體懸置,底盤Copyright
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Reserved.8GT-SUITEmp曲軸分析應(yīng)用范圍Copyright
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Reserved.92-或4-沖程任意的氣缸布置型式(直列,V,W,Box等.)單,雙或者開口銷曲拐V型發(fā)動(dòng)機(jī)左或右手交替考慮活塞銷,曲柄和連桿軸向偏心每個(gè)氣缸可單獨(dú)設(shè)置屬性(缸壓曲線,活塞,連桿,曲軸等)靈活的氣缸編號(hào)規(guī)則缸壓曲線隨轉(zhuǎn)速而變,或者由IMEP產(chǎn)生穩(wěn)態(tài)或瞬態(tài)分析預(yù)定義的曲軸轉(zhuǎn)速,或者在預(yù)定義負(fù)荷下的自由加速GT-SUITE進(jìn)行曲軸系設(shè)計(jì)分析的優(yōu)勢(shì)Copyright
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Reserved.10所有的分析功能及模式在單一軟件內(nèi)完成廣泛的適應(yīng)性,完全的通用性快速,易用,優(yōu)化功能附帶GT-SUITE
通用工具DOE,
Optimizer,
Dist.
Run,
NN,
Controls等與其他GT-SUITE模塊易于集成GT-POWER:燃燒計(jì)算配氣機(jī)構(gòu),凸輪軸齒輪、鏈和帶傳動(dòng)液壓、潤(rùn)滑和軸承(曲軸系分析功能簡(jiǎn)介-結(jié)束)Copyright
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Reserved.111.曲軸系剛體動(dòng)力學(xué)活塞,曲柄銷及軸承受力曲軸內(nèi)應(yīng)力及發(fā)動(dòng)機(jī)扭矩軸承油膜及質(zhì)心軌跡計(jì)算Copyright
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Reserved.12“合成”的缸壓曲線Copyright
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Reserved.13可以根據(jù)用戶的輸入合成隨曲軸轉(zhuǎn)角變化的缸壓曲線:IMEP進(jìn)排氣壓力燃燒燃燒始點(diǎn),持續(xù)期對(duì)于概念研究,還沒(méi)有缸壓曲線時(shí)特別有用,也適用于瞬態(tài)模擬。2.發(fā)動(dòng)機(jī)平衡不平衡力/力矩Copyright
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Reserved.14不平衡力矩(發(fā)動(dòng)機(jī)反作用扭矩,Mz)不平衡(搖晃)力和力矩-Fx,
Fy,
Mx,
My活塞、連桿往復(fù)慣性力及力矩帶一或多平衡重的平衡軸不平衡力、力矩、扭矩階次分析精確求解(包含高階諧次,無(wú)近似)自動(dòng)“端腹板e(cuò)nd
web”平衡特性
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自動(dòng)計(jì)算質(zhì)心位置平衡一階不平衡力矩四缸機(jī)-不平衡力/力矩Copyright
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Reserved.16FyFzMxMyMz四缸機(jī)-不平衡力/力矩階次分析缸體彎矩-Mx輸出缸體瞬時(shí)彎矩和整體最大彎矩(Mx,My)評(píng)價(jià)缸體載荷設(shè)定設(shè)計(jì)標(biāo)準(zhǔn)缸體彎矩隨著軸向位置和曲軸轉(zhuǎn)角的變化缸體彎矩隨著軸向位置的變化(在最大彎矩角度)Copyright
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Reserved.17輸出機(jī)體所有受力情況輸出間隔1°曲軸轉(zhuǎn)角的,從所有軸承、氣缸傳遞給機(jī)體的力,包括活塞受側(cè)向力時(shí)的軸向坐標(biāo),以表格型式給出??捎糜诎l(fā)動(dòng)機(jī)機(jī)體的有限元NVH計(jì)算Copyright
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Reserved.18帶雙平衡軸的四缸直列機(jī)曲軸系平衡軸平衡軸齒輪使用GT-SUITE
OPTIMIZER計(jì)算的平衡重Copyright
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機(jī)體振動(dòng)
–
懸置分析與設(shè)計(jì)Copyright
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Reserved.20懸置位置坐標(biāo)(坐標(biāo)系,懸置裝配方向)在本地坐標(biāo)系下的懸置剛度、阻尼特性作為受懸置約束以及受不平衡力及力矩作為激勵(lì)的剛體慣量的缸體-傳動(dòng)系機(jī)體6自由度運(yùn)動(dòng),質(zhì)心、支承點(diǎn)(或任意點(diǎn))運(yùn)動(dòng)及受力發(fā)動(dòng)機(jī)+路面激勵(lì)對(duì)懸置作用力缸體運(yùn)動(dòng)(模態(tài))頻域特性和模態(tài)圖4缸直列機(jī)-曲軸、機(jī)體和缸體模型懸置底盤Copyright
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Reserved.21四缸機(jī)-5000
RPM支承位移壓力+慣性力Mount2Mount1Mount3Mount4Initial
settling
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RPM支承位移Mount2Copyright
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Reserved.244.曲軸扭振Copyright
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Reserved.25曲軸扭轉(zhuǎn)慣量/剛度建模時(shí)域扭振分析頻域(FD)扭振分析自由振動(dòng)分析(自然頻率和模態(tài)圖)受迫振動(dòng)頻響分析外部部件耦合到曲軸,包括另外的軸系部件,驅(qū)動(dòng)軸系,齒輪系等可以耦合到模型中,(時(shí)域或頻域分析)也可以包含其他的子系統(tǒng)粘彈性橡膠阻尼模型曲軸扭振建模Copyright
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Reserved.26扭轉(zhuǎn)曲軸慣量:每個(gè)主軸頸,曲柄臂,曲柄銷定義一個(gè)位于各自中心的慣量根據(jù)幾何及材料密度自動(dòng)計(jì)算部件慣量,但用戶可以通過(guò)輸入慣量作出修正剛度:
扭轉(zhuǎn)剛度根據(jù)材料屬性及等效長(zhǎng)度計(jì)算+按BICERA推薦算法計(jì)算的曲柄臂等效剛度/長(zhǎng)度可以選用用戶自定義剛度阻尼:材料(遲滯)阻尼比外部阻尼(摩擦)曲軸扭振模型飛輪慣量軸頸慣量曲柄銷慣量曲柄臂慣量附加轉(zhuǎn)動(dòng)慣量集中慣量扭轉(zhuǎn)柔度+材料阻尼Copyright
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Reserved.29輸入剛度(軸頸中心到曲柄銷中心距),或BICERA方法*:等效長(zhǎng)度(EL)從實(shí)驗(yàn)數(shù)據(jù)查參數(shù)化曲柄臂模型得到等效長(zhǎng)度“矩形化”曲柄臂vs.基本曲柄臂尺寸比查表EL(曲柄半徑,曲柄臂厚,軸頸直徑,曲柄臂寬)根據(jù)最大軸頸/銷直徑超過(guò)臂寬修正根據(jù)曲柄銷與軸頸直徑比與重疊的修正可選項(xiàng)(曲柄臂幾何對(duì)象):對(duì)軸頸和曲柄銷孔徑,銷的偏心距修正軸頸、曲柄臂與曲柄銷連接部圓角修正曲柄臂切口修正*
The
British
Internal
Combustion
Engine
Research
Association,
A
Handbook
of
Torsional
Vibrations,
E.J
Nestorides,
Ed.
(1958)曲柄臂扭轉(zhuǎn)變形參數(shù)Copyright
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Reserved.31通過(guò)與運(yùn)動(dòng)方程聯(lián)合求解所有自由度的扭振自動(dòng)調(diào)整計(jì)算步長(zhǎng),雙精度求解,允許長(zhǎng)時(shí)間瞬時(shí)計(jì)算穩(wěn)態(tài)分析,預(yù)定義的車速變化的瞬態(tài)或根據(jù)負(fù)載加速的瞬態(tài)分析,允許發(fā)動(dòng)機(jī)轉(zhuǎn)速變化其余的部件模型與剛性分析(不平衡力,平衡軸,軸承缸體振動(dòng)和支承)相同曲軸扭振–時(shí)域仿真II角位移、角速度、角加速度局部應(yīng)力,扭轉(zhuǎn)變形曲拐角變形(傳遞誤差)中間扭矩,曲軸扭矩工作應(yīng)力(扭轉(zhuǎn)應(yīng)力+橫向剪切應(yīng)力,彎曲應(yīng)力)隨時(shí)間變化,平均值,最大、最小值,幅值時(shí)域得到的結(jié)果進(jìn)行頻域分析Copyright
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Reserved.曲軸扭振–
時(shí)域計(jì)算Angle
Shifts
(error)Angular
VelocityTorque
before
Throw
Crankpin
Shear
Stress34曲軸扭振–
頻域分析ICopyright
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頻域分析IICopyright
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Reserved.36受迫振動(dòng)分析(接前)隨發(fā)動(dòng)機(jī)轉(zhuǎn)速變化的曲柄銷處各諧次扭矩圖幅值響應(yīng)圖(各諧次角度,角速度,角加速度,扭矩,扭轉(zhuǎn)剪切應(yīng)力等).基于階次/頻率、轉(zhuǎn)速的等高線圖時(shí)域圖參數(shù)提取:瞬時(shí)角度,角速度,角加速度,扭矩,可以輸入速度和隨時(shí)間變化或者頻率相關(guān)的扭矩激勵(lì)不規(guī)則轉(zhuǎn)速循環(huán)扭振阻尼功率瞬時(shí)計(jì)算自由頻域扭振–前4個(gè)模態(tài)Copyright
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PLOTS
vs.RPM:選擇節(jié)點(diǎn)和響應(yīng)階次作圖選項(xiàng):選擇節(jié)點(diǎn)頻率或階次頻率或階次選擇XY軸Copyright
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對(duì)轉(zhuǎn)速的諧次響應(yīng)作圖Copyright
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Reserved.40強(qiáng)制頻率扭振分析–階次/頻率、轉(zhuǎn)速云圖VS
ORDER
-
AFTER
LAST
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ORDER
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AFTER
MIDDLE
CYLINDERVS
FREQUENCY
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AFTER
MIDDLE
CYLINDERVS
FREQUENCY
-
AFTER
LAST
CYLINDER2nd
Nat.
Freq.Copyright
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Nat.Freq.共振轉(zhuǎn)速自動(dòng)偵測(cè)Copyright
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Reserved.43Speed橡膠阻尼器建模橡膠阻尼采用Maxwell-Reichart型Solid模模型假定剛度、阻尼是頻率的函數(shù)
(Keff(f),Ceff
(f), -
函數(shù)關(guān)系由試驗(yàn)測(cè)得)
,Maxwell
模型的剛度和阻尼參數(shù)
(k0
k1
k2k3 c1
c2
c3
}
通過(guò)最小方差方法自動(dòng)擬合時(shí)域頻域物理描述是一致Copyright
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k1
k2
k3c1
c2
c3Keff,(f),
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(f)Keff
(f)Ceff
(f)Copyright
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(f)Φeff
(f)
(Phase
or
loss
angle)Φeff
(f)
(Phase
or
loss
angle)Data
Set
1Data
Set
2Co(pyrPigh=t
(0C)
,2011
CPD-a=dapc0o
J.APA5N
CPo.,mLTDa.
Axll
,RighPts=RePsermveda.475.軸承油膜分析遷移率Mobility或者阻抗法Impedance
MethodMobility
and
Impedance兩種方法互為鏡像Mobility用于剛性,扭轉(zhuǎn)或準(zhǔn)靜力學(xué)彎曲曲軸動(dòng)力學(xué)的主軸承(即軸承反力已知)和連桿軸承Impedance狀態(tài)已知,用于主軸承的全動(dòng)力學(xué)求解求解反作用力)(軸頸詳細(xì)油膜輸出軌跡,最小油膜厚度最大壓力及其位置流率(液壓動(dòng)力學(xué),Martin,Martin-Xu等模型)油膜范圍 x
lines)Copyright
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(Using
Fits
of
Goenka,1984)Mobility48Max.Pres.
LocationMax
PressureFilm
ExtentCopyright
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第二主軸承,
5000
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方法求解四缸機(jī)–第二主軸承,5000
RPM50詳細(xì)油膜展開/壓力圖
(軸承,軸頸,連桿系統(tǒng))油膜展開圖——曲軸轉(zhuǎn)角(水平軸.)軸承圓周(垂直軸.)云圖油壓進(jìn)行了歸格化處理?;疑糠直硎?80°油槽GROOVECopyright
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Film
Thickness
Maximum
Oil
PressureOil
Volume
FlowRateAttitude
AngleConrod
Large
End方法與其他工具的對(duì)比TOOL
ATOOL
CCopyright
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A方法的對(duì)比:三缸機(jī)主軸承載荷GT-SUITECopyright
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Tool
A方法的對(duì)比:三缸機(jī)主軸承質(zhì)心軌跡6.曲軸3-D彈性(彎曲)模型Copyright
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3D剛體運(yùn)動(dòng)上準(zhǔn)靜力學(xué)模式下,線性化彈性位移根據(jù)相當(dāng)配置得出3-D
梁有限元方程Copyright
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帶寬優(yōu)化算法動(dòng)力學(xué)計(jì)算中考慮小尺度旋轉(zhuǎn)和大位移在梁的任意位置進(jìn)行應(yīng)力計(jì)算(軸向和剪切應(yīng)力,彎曲和扭曲力矩),使用簡(jiǎn)化積分算法梁節(jié)點(diǎn)可以指定速度梁剛體慣性負(fù)荷采用準(zhǔn)靜力學(xué)方程梁的有限元圖2,3,或4節(jié)點(diǎn)有限元方法可用于各種結(jié)構(gòu)如軸頸、曲柄臂、曲柄銷的建模Copyright
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Beam
FE
模型ElementsNodes3D曲柄臂固體FE模型柔度用于自動(dòng)創(chuàng)建當(dāng)量的3D梁FE模型Compliance
for
3
load
cases3D
FE
AnalysisCopyright
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pin)過(guò)度盤當(dāng)量梁屬性ElementsNodes3D
FE
分析3D
Load
Case
CompliancesCopyright
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[N-m]7.曲軸應(yīng)力恢復(fù)與后處理選項(xiàng)基本的3D梁?jiǎn)卧敵?,即,恢?fù)的剪切,力矩,扭矩,應(yīng)變
(隨時(shí)間變化,平均值,最小值,最大值,幅值)主軸和曲軸銷倒角的應(yīng)力集中基于用戶定義的應(yīng)力/彎矩比可選疲勞壽命計(jì)算主軸和曲軸銷倒角的應(yīng)力集中
(IACS
M53)船用發(fā)動(dòng)機(jī)曲軸認(rèn)證通過(guò)/不通過(guò)的標(biāo)準(zhǔn)基于彎曲和扭轉(zhuǎn)載荷的合力)EFRMEAN
TFSs
AMPss
=(1
-
sCopyright
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FE應(yīng)力使用強(qiáng)度數(shù)據(jù)和疲勞分析&Goodman圖(EFR應(yīng)力疲勞法)對(duì)于曲拐外載荷產(chǎn)生簡(jiǎn)單的列-格式化ASCII文件,可以為第三方疲勞分析軟件所用EFR
Stress/Fatigue
Methodology
IUnit
Load
Case
Detailed
3D
FE
AnalysisForces/Moments
from
CranktrainDesign
Analysis單位載荷3D-FEA節(jié)點(diǎn)應(yīng)力,乘以曲軸分析(梁有限元求解)得到的曲拐力和力矩,再線性疊加σi,j,k,m,s=
ΣnFk,nC
σ
n
i,j,m,sCopyright
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=
stress
factor(nodal
stress
for
unit
loadFn)Fn
=Instantaneous
forceormomentn=
unit
load
case
indexi=
stress
tensor
indexj=
FEnode
indexk=
crank
angle
(step)
indexm=
stress
concentration
zone
indexs
= solution
(crankthrow)indexC
F根據(jù)應(yīng)力和強(qiáng)度不同進(jìn)行可靠性計(jì)算EFR
Stress/Fatigue
Methodology
IIσ
EFR,ma
,m,s=
maxi
(σEFR,j,m,s)σ
EFR,max,s=
maxm
(σEFR,max,m,s)σ
EFR,max
=
maxj(σEFR,max,,s)σEFR,j,m,s
=
σamp,j,m,s/(1-
σmean,j,m,s/
σtfs)曲拐和曲軸,應(yīng)力集中區(qū)中最大EFR應(yīng)力EFR(Equivalent
Fully-Reversed)StressSPS和應(yīng)力矢量的循環(huán)最大,最小,平均和幅值
Von
Mises“amplitude”stress*主應(yīng)力篩選(SPS)σj,k,m,s單位載荷應(yīng)力疊加(瞬態(tài)應(yīng)力矢量)σi,j,k,m,s=
ΣnFk,nC
σn
i,j,m,sEFRCopyright
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=
1-UREFR*
“Von
Mises”
Stress
based
on
stress
cyclic
amplitude
tensorσ
max,j,m,s=
maxk(σj,k,m,s)σ
min,j,m,s=
mink(σj,k,m.s
)σ
mean,j,m,s=avgk(σj,k,m,s
)σ
amp,j,m,s
=
(σmax,j,m,s-
σmin,j,m,s)/2參考.對(duì)象自動(dòng)化過(guò)程ShaftStressAnalysis:
Master
Reference
ObjectShaftStressConcZones:
FE
Node
data
&
CS
Zone
DefinitionCrankUnitLoadcases:
Unitload
case
FEA
output
filesCopyright
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fillet
1LighteningpocketsCourtesy
of
Cummins,
Inc.Pin
fillet
2Oil
holeMain
Fillet
1Main
Fillet
2EFR
Stress/Fatigue
Methodology
IIICopyright
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Cylinder
In-line
CranktrainCopyright
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Orbits
–
Comparison
to
Tool
BTool
BCopyright
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BTool
BTool
BTool
BTool
BTool
BBearing
Loads
–
Comparison
to
Tool
BTool
BCopyright
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BTool
BTool
BTool
BTool
BTool
BComparisons
to
Tool
B(Bearings
-
Differences
in
%)BearingLoadMin.
Oil
FilmThicknessMax.OilPressureBearing
1-1.03-1.431.14Bearing
21.751.790.2Bearing
31.051.18-1.63Bearing
40.059-0.251.27Bearing
50.721.09-1.73Bearing
61.732.113.51Bearing
7-1.87-2.651.27Copyright
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to
In-house
Tool(Fillet
EFR
Stress
-
Differences
in
%)Crankpin
FilletJournal
FilletWeb
1L-1.94-0.98Web
1R-4.69-3.81Web
2L-3.04-2.48Web
2R-4.01-3.21Web
3L-3.48-2.81Web
3R-0.78-0.93Web
4L-1.74-0.85Web
4R-1.91-1.94Web
5L-2.98-2.43Web
5R-1.91-1.37Web
6L-4.66-3.45Web
6R-0.95-0.93Copyright
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filletBackJournalFilletComparison
to
In-house
ToolEFR
Stress
&
Acceptability四個(gè)應(yīng)力集中區(qū)Front
JournalFilletFrontPin
filletFRONTJOURNALFILLETBACKJOURNAL
FILLETFRONTPINFILLETBACKPINFILLET%
Diff%
Diff%
Diff%
DiffMax.
Component
Stress0.860.380.800.48EFR
Stress
–SPS
Method0.480.430.600.44EFR
Stress
–VMS
Method0.450.400.300.26Unreliability-SPS
Method8.418.129.655.19Copyright
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Engine
ValidationCopyright
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Comparison
to
Tool
BV8Loa-d4s
0–
0T
0
rBp,
–mMaximum
Bearing
Force070000600005000040000300002000010000152
3
4Main
Bearing
NumberForce
(N)Cummins#1#2#3#4#5GTTool
BCopyright
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Comparison
to
Tool
BV8
-
4000
rpmMinimum
Oil
Film
Thickness1.00.50.02.52.01.53.0152
3
4Main
Bearing
NumberMOFT
(mm)Cummins主軸承軌跡–Tool
B,–GT-SUITE#1#2#3#4#5GTTool
BCopyright
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Comparison
to
Tool
Bv8
-
4000
rpmPeak
Oil
Film
Pressure200180160140120100806040200152
3
4Main
Bearing
Num
berPOFP
(Mpa)CumminsGTTool
BPeak
OilFilm
Pressure
Difference-1-24321012345Main
BearingNumberPOFP
Difference(%)峰值油膜壓力Copyright
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Comparison
to
Tool
Bv8
-
4000
rpmMainFillets
Stress0400350300250200150100501236784
5Web
#Stress
(Mpa)CumminsGTTool
BPin
Fillets
Stress3503002502001501005001236784
5Web
#Stress
(Mpa)CumminsGTTool
BFillets
EFR
StressCopyright
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M53標(biāo)準(zhǔn)分析船舶應(yīng)用校準(zhǔn)根據(jù)IACS的標(biāo)準(zhǔn)計(jì)算曲軸強(qiáng)度,評(píng)估疲勞安全性基于的假定是:曲軸銷和曲柄臂間,主軸和曲柄臂間是最大應(yīng)力區(qū)對(duì)曲軸系統(tǒng)中的每個(gè)曲柄臂都進(jìn)行分析Copyright
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集成仿真(和其他GT-SUITE產(chǎn)品)Copyright
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Cranktrain+ValvetrainCopyright
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,模擬曲軸,配氣機(jī)構(gòu)和其相互作用使用一個(gè)模型進(jìn)行曲軸和配氣機(jī)構(gòu)設(shè)計(jì)和相互作用分析更加準(zhǔn)確的捕捉下述特性:曲軸速度曲軸和配氣機(jī)構(gòu)扭轉(zhuǎn)動(dòng)力學(xué)相互作用齒輪系和鏈傳動(dòng)系的影響
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