Browsing by Author "Freitas, M."
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- An algorithm for fatigue crack growth applied to mixed and biaxial mode loadingsPublication . Baptista, Ricardo; Infante, V.; Freitas, M.Fatigue is still one of the main concerns when dealing with mechanical components failure. While it is fundamental to experimentally determine the fatigue material behavior using standard specimens, testing large and complex component geometries can be complicated. In these cases, the Finite Element Method can be a cost-effective solution but developing fatigue crack growth models is still a complicated task. In order to solve this problem, an algorithm for automatic crack propagation was developed. Using three different modules, the algorithm can generate a complex Finite Element Method model including a fatigue crack; solve this model considering complex loading conditions, by applying the superposition method; and calculate the fatigue crack propagation rate, using it to update the original model. In order to benchmark this solution two different problems were analyzed, a modified compact tension specimen and a cruciform specimen. By modifying the compact tension specimen hole location and simulating an initial crack, it was possible to understand how mixed mode conditions influence the fatigue crack path. Different load ratios and initial crack directions on the cruciform specimen were analyzed. Increasing the load ratio will increase the crack deflecting angle. The obtain solutions were compared with experimental results, showing good agreement. Therefore the developed algorithm can be used to predict the fatigue crack growth behavior on complex geometries and when different types of loads are applied to the component.
- Crankshaft failure analysis of a boxer diesel motorPublication . Fonte, M.; Anes, V.; Duarte, P.; Reis, L.; Freitas, M.This paper reports a failure mode analysis of a boxer diesel engine crankshaft. Crankshafts are components which experiment severe and complex dynamic loadings due to rotating bending combined with torsion on main journals and alternating bending on crankpins. High level stresses appear on critical areas like web fillets, as well as the effect of centrifugal forces and vibrations. Since the fatigue fracture near the crankpin-web fillet regions is one of the primary failure mechanisms of automotive crankshafts, designers and researchers have done the best for improving its fatigue strength. The present failure has occurred at approximately 2000 manufactured engines, and after about 95,000 km in service. The aim of this work is to investigate the damage root cause and understand the mechanism which led to the catastrophic failure. Recommendations for improving the engine design are also presented.
- Crankshaft failure analysis of a motor vehiclePublication . Fonte, M.; Li, Bin; Reis, L.; Freitas, M.A case study of a crankshaft catastrophic failure of a motor vehicle and its failure analysis is presented. The crankshaft suffered a mechanical seizure on the crankpin no. 2 after 3 years in service. It was repaired and after 30,000 km the vehicle had a damage again, with a catastrophic failure on the same crankpin. A transversal macrograph of the crankpin revealed that the crankpin was rectified and filled with a metal alloy for the same nominal diameter. Two fatigue cracks growing to the center of the crankpin where the final fracture occurred. The symmetric semi-elliptical crack front profile confirms the effect of a pure mode I under alternating bending. The catastrophic failure was a consequence of the inadequate repairing by a non-authorized manufacturer.
- Design optimization of cruciform specimens for biaxial fatigue loadingPublication . Baptista, Ricardo; Cláudio, Ricardo; Reis, L.; Guelho, I.; Freitas, M.; Madeira, J. F. A.In order to correctly assess the biaxial fatigue material properties one must experimentally test different load conditions and stress levels. With the rise of new in-plane biaxial fatigue testing machines, using smaller and more efficient electrical motors, instead of the conventional hydraulic machines, it is necessary to reduce the specimen size and to ensure that the specimen geometry is appropriated for the load capacity installed. At the present time there are no standard specimen’s geometries and the indications on literature how to design an efficient test specimen are insufficient. The main goal of this paper is to present the methodology on how to obtain an optimal cruciform specimen geometry, with thickness reduction in the gauge area, appropriated for fatigue crack initiation, as a function of the base material sheet thickness used to build the specimen. The geometry is optimized for maximum stress using several parameters, ensuring that in the gauge area the stress is uniform and maximum with two limit phase shift loading conditions. Therefore the fatigue damage will always initiate on the center of the specimen, avoiding failure outside this region. Using the Renard Series of preferred numbers for the base material sheet thickness as a reference, the reaming geometry parameters are optimized using a derivative-free methodology, called direct multi search (DMS) method. The final optimal geometry as a function of the base material sheet thickness is proposed, as a guide line for cruciform specimens design, and as a possible contribution for a future standard on in-plane biaxial fatigue tests.
- Development of a Very High Cycle Fatigue (VHCF) multiaxial testing devicePublication . Vieira, M.; Freitas, M.; Reis, L.; Ribeiro, A.M.R.; Fonte, Manuel.The very high cycle region of the S-N fatigue curve has been the subject of intensive research on the last years, with special focus on axial, bending, torsional and fretting fatigue tests. Very high cycle fatigue can be achieved using ultrasonic exciters which allow for frequency testing of up to 30 kHz. Still, the multiaxial fatigue analysis is not yet developed for this type of fatigue analyses, mainly due to conceptual limitations of these testing devices. In this paper, a device designed to produce biaxial fatigue testing using a single piezoelectric axial exciter is presented, as well as the preliminary testing of this device. The device is comprised of a horn and a specimen, which are both attached to the piezoelectric exciter. The steps taken towards the final geometry of the device are presented. Preliminary experimental testing of the developed device is made using thermographic imaging, strain measurements and vibration speeds and indicates good behaviour of the tested specimen.
- Failure analysis of a crankshaft of a helicopter enginePublication . Afonso Fonte, M.; Freitas, M.; Infante, V.A detailed analysis of a crankshaft failure belonging to a helicopter engine is presented. The main objective of this work was to analyze the characteristics of the failure and determine the root cause of the failure of the crankshaft. In order to determine the causes of the crankshaft failure, a material analysis was performed, followed by a detailed observation of the failure mechanisms through macroscopic, microscopic and microstructural examinations of the fracture surface. A preliminary observation of the fractured crankshaft indicates that this failure occurred by a fatigue process where the fracture surface shows obvious signs of cyclic propagation mechanisms. The existence of a large number of beachmarks indicates significant crack growth characterized by the effect of successive starts and stops of the engine by the operating conditions. These beachmarks cover about two-thirds of the total area of the fracture surface and the uniform geometric pattern of the crack front, along the entire propagation zone, allows to conclude that the fatigue process occurred from a loading state consisting essentially of cyclic bending stresses between the crankweb and the main journal of the crankshaft. No original defect was observed either on the surface or inside the material that could be the source of the crack initiation and growth and subsequent final fracture of the component. The analysis of the shell bearings applied to the main journal revealed a significant damage, with fractured location lugs, that are believed to be at the origin of the crack initiation of the crankshaft.
- Failure analysis of cylinder head studs of a four stroke marine diesel enginePublication . Fonte, M.; Reis, L.; Infante, V.; Freitas, M.After about seven years in service, four cylinder head studs, which tight the block and cylinder heads of a marine main engine, have fractured. Meantime, they were changed for new ones without to determine the root cause of failure. The aim of this research work is to carry out a failure analysis in order to avoid recurrent damages in that engine. The fracture morphology and thread roots of fractured studs were carefully observed by optical devices. Thread material defects and corrosion were not found. However, the thread roots, where the stress concentration are higher, can be pointed as the local of fatigue crack initiation. As is well-known, all cylinder head stud bolts are pre-tensioned in order to increase the mean stress σm and reduce the stress amplitude σa. The steel alloy quality and design are of primordial importance for improving the lifetime of studs, and this is supervised by the Classification Societies (CS), as is indicated by an engraved stamp on each stud end, that certifies each one of them. The pre-tightening of the studs was calculated, and results point as root cause of failure a significant high stress concentration mainly at the second thread root of the studs, close to the bottom side of the nut, which are critical stress zones.
- Failure mode analysis of a damaged diesel motor crankshaftPublication . Afonso Fonte, M.; Reis, L.; Freitas, M.A case study of a catastrophic failure of a diesel motor crankshaft is presented. The aim of this failure analysis is to investigate the root cause of this important mechanical component. This crankshaft belonged to a particular vehicle (140 cv, at 4000 rpm, 1968 cm3 displacement) that fractured after 180,000 km and 8 years in service. The motor was disassembled, and the crankpin No. 3 and the main bearing cap No. 4 were broken. Defects of material and machining defects were not found at the crack initiation sites by optical and SEM microscope. Results shown that the crankpin and the main bearing cap clearly failed by fatigue, and the root cause seems to be related with deficient tightening of the main bearing cap No. 4, which fractured due to a crack developed on the its outer side. The main journal No. 4 did run out of support, and the crankthrow No. 3 increased the alternating stress amplitude, whereby an inevitable catastrophic crankshaft failure happened.
- Failure mode analysis of a diesel motor crankshaft.Publication . Fonte, M.; Infante, V.; Reis, L.; Freitas, M.A failure mode analysis of a diesel motor (110 kW) crankshaft from an automobile vehicle is presented. After 120,000 km in service, an abnormal vibration was detected which was increasing with the time. The diesel motor was first disassembled for determining the root cause, however without success. No defect was detected, but since a suspicion of damage was present, and being this failure recurrent in this type of diesel motor series, the crankshaft was disassembled again. Then the crankshaft was subjected to a simple vibration analysis and a preliminary indication of possible existence of a crack was concluded. The crankshaft was then replaced by a new one, and the old was subjected to a failure analysis for determining the root cause. A crack was found at the crankpin web-fillet and after a complete opening of the crack, the failure analysis showed that fatigue was the dominant failure mechanism. Observations were carried out by optical and Scanning Electronic Microscope. Material defects at the crack initiation zone were not found. The root cause of damage seems to be a misalignment of the main journals and a weakness of design close to the gear at the region where the crack was initiated. Therefore, probably a poor design and a deficient assembling of the crankshaft helical gear coupled to the main journal end was the first cause of the failure.
- Failure mode analysis of two crankshafts of a diesel single cylinder enginePublication . Fonte, M.; Duarte, P.; Reis, L.; Freitas, M.; Infante, V.This paper reports an investigation carried out on two damaged crankshafts of single cylinder diesel engines used in agricultural services for several purposes. Recurrent damages of these crankshafts type have happened after approximately 100 h in service. The root cause never was imputed to the manufacturer. The fatigue design and an accurate prediction of fatigue life are of primordial importance to insure the safety of these components and its reliability. This study firstly presents a short review on fatigue power shafts for supporting the failure mode analysis, which can lead to determine the root cause of failure. The material of these damaged crankshafts has the same chemical composition to others found where the same type of fracture occurred at least ten years ago. A finite element analysis was also carried out in order to find the critical zones where high stress concentrations are present. Results showed a clear failure by fatigue under low stress and high cyclic fatigue on crankpins.