基于多场耦合分析的柴油机气缸盖结构仿真研究及疲劳寿命预测
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摘要
气缸盖是影响柴油机整体性能的关键部件，工作时承受着高强度的机械负荷和热负荷，由于其结构内部及冷却液流动情况十分复杂，导致温度和应力分布很不均匀，很容易产生应力集中现象，严重时会发生疲劳破坏。本文以柴油机缸盖为研究对象，以流体动力学、传热学等有限元理论为分析基础，建立了缸盖、机体、螺栓、气缸垫、冷却水腔的有限元模型，采用非线性接触分析方法对缸盖进行了流固耦合、热机耦合仿真分析。通过对冷却液流动与传热情况及缸盖在预紧工况、预紧-爆发工况、热应力工况、热机耦合工况下的应力场的分析，找出缸盖应力集中主要区域，并以此为依据对缸盖结构进行了多方案改进设计。通过对比改进后缸盖耦合分析结果，选取最能够增强冷却效果、降低缸盖温度、缓解应力集中问题的设计方案，采用疲劳分析软件，计算缸盖疲劳寿命，探索了机械载荷、热负荷对缸盖疲劳强度的影响。
论文应用前处理软件Hypermesh对缸盖、机体、螺栓、气缸垫、水腔等三维实体模型进行了适当简化，并分别划分了接触分析所需的固体域网格及流体分析边界层网格。把缸盖和水腔耦合模型导入流体动力学软件CFX，运用整场离散、整场求解方法，对气缸盖及冷却液进行了直接耦合传热分析。分析结果显示，冷却液流速合理，基本达到缸盖冷却要求。但缸盖上水孔布置不太合理，导致缸盖冷却不充分，尤其是两排气道之间鼻梁区及排气道靠近缸盖顶板处冷却液流速偏低，冷却效果较差，这也解释了缸盖在排气道侧温度偏高的原因。
论文把流场分析得出的缸盖温度映射到ANSYS分析模型中，计算了缸盖在热应力工况、预紧力工况、预紧力-爆发工况、热机耦合工况下的应力场。计算结果显示，在预紧力和爆发压力作用下，最大应力值都位于螺栓支撑凸台附近，由此可知，缸盖只承受机械载荷作用时，应力集中主要出现在预紧力作用区域。而在热应力及热机耦合两种工况下，应力集中区域基本相同，主要分布在缸盖底板水道壁面、火力面鼻梁区及两排气道之间的鼻梁区附近，而这些区域在单纯机械负荷作用下的应力值较低，证明了热负荷对其应力水平起主导作用。
通过对计算结果的分析，论文提出五种缸盖结构改进方案，探索了降低底板厚度、增大入水孔直径、底板加工卸载槽、增大底板冷却水孔直径等结构改进形式对冷却液冷却效果、缸盖温度场及各种工况下的应力分布的影响。通过与原方案对比，发现缸盖入水孔直径增大以后，冷却液流动更加合理、冷却效果增强，缸盖温度明显降低；而在底板处加工卸载槽以后，由于火力面的承热面积增加，使缸盖最高温度有所升高。应力计算结果显示，对缸盖进行上述改进后，虽然使缸盖承受了更大的机械载荷，但热负荷作用下的应力值呈下降趋势。增大缸盖底板冷却水孔直径后，进气道壁面温度下降明显，但缸盖最高温度反而略有增加，这主要是由于上水孔流出的冷却液很大一部分经冷却水孔直接流向出水口，而减少了排气道侧的冷却液流量，冷却效果下降。
论文把应力计算结果导入到疲劳分析软件FE-safe中，选取应力计算结果最优方案与原缸盖结构进行对比，分别计算了缸盖在机械载荷和热负荷作用下的疲劳寿命。结果证明，改进方案降低了缸盖应力集中区域的应力应变水平，疲劳循环次数增多，寿命加强。火力面鼻梁区、两排气道之间的鼻梁区、螺栓支撑凸台等区域容易发生疲劳破坏，寿命相对较小，这些区域在缸盖抗疲劳设计过程中应重点考虑。通过对比发现，在机械载荷工况下，预紧力对缸盖疲劳寿命起到主导作用；而在热机耦合工况下，热应力对缸盖底板处的疲劳寿命影响较大。
The cylinder head is one of the key parts for the diesel engine. When it is working, thecylinder bears high temperature and pressure. Besides, because of its complex geometricshape and flow situation in water jacket, heat stress and mechanical stress distribution is notuniform, it is easy to produce the stress concentration phenomenon which can cause seriousfatigue damage. The paper takes a diesel engine as the research object, based on some theoriesof finite element analysis such as the fluid dynamics theory, heat transfer theory and so on.Multi-physics field coupling analysis was taken on the the model which is combined bycylinder head, engine body, bolts, cylinder cushion, and other parts using nonlinear contactanalysis method. In order to calculate the stress and strain field results in the workingconditions such as the prestressing force, explosion pressure, heat load and the thermalmechanical coupling conditions. Then the paper explored the influence on the cylinder headfatigue strength cased by mechanical stress and thermal stress, found out the main stressconcentration areas. At last, the paper put forward some structure improvement measuresbased on the results above to forecast the fatigue life of the cylinder head using fatigueanalysis software FE-safe.
The paper built both the finite element assembly model and fluid analysis model afterof the simplification for the cylinder head, engine body, water jacket and cylinder cushionwith the specialized processing software Hypermesh. And then I put the mesh to the Fluiddynamics software CFX, took the directly coupled heat transfer analysis the based on thetheory of disperse integrally and solve integrally. The analysis results showed that watervelocity is reasonable, and can basically meet with cylinder head cooling requirements. Butthere are also some shortcomings in the water inlets, especially in the area near the two exhausting channels, the water velocity is too slow, this also explains the cause of the hightemperature in exhausting channels.
Then the paper mapped the cylinder head temperature made in flow analysis to theanalysis model, calculated the stress field in the four working conditions such as theprestressing force, explosion pressure, heat load and the thermal mechanical couplingconditions, The results indicated that the stress concentration is mainly distributed close to thebolt support convex platforms when it bears bolt prestressing force and explosion pressure.We can conclude that stress concentration occurs in Mechanical load condition. Besides, onthe thermal stress and heat coupling conditions, stress concentrated areas are almost the same,which are mainly distributed in the cylinder water channel floor , nose bridge surface betweentwo exhaust ports in fire floor, near the water-jacket fillets between close to cylinder boltholes in cylinder base floor. so the results confirms that thermal stress takes a key role in theseregions..
This paper puts forward five improvements of cylinder head such as the change ofbottom thickness, inlet diameter, processing discharge groove which can influence thecylinder head temperature distribution and cooling liquid cooling effect. Then analyzed theheat transfer effect and stress distribution in various working conditions, through thecomparison with the original model, we found that the cooling fluid flow more reasonable,and cylinder head temperature has reduce. After the improvement of processing dischargegroove, the highest temperature raised because of the increase of heated area. In addition, nodoubt that the mechanical load had increased after the thinning improvement of cylinderbaseboard, but heat load stress and strain reduced significantly to the contrary. When thediameter of cooling hole increased, the intake surface temperature dropped significantly,while the highest temperature increased on the contrary. It is mainly because that most of thecooling water has gone to the output directly through the cooling hole, which reduced thecooling effect in the region of exhaust channel.
Finally, the paper exported stress results into the fatigue analysis software FE-safe tocalculate the cylinder head fatigue life of the optimal case. The results show that high stress and strain are located in the regions such as the nose bridge surfaces both in fire floor andbetween two exhaust ports and bolt support convex platforms, where we should make aspecial consideration in diesel engine design. By comparison, the paper also found that thefatigue cyclic numbers and service life have both increased after improvement. Through thecomparison with the original model, we find that pretightening force plays an important rolein the mechanical load conditions; while the thermal stress has a key effect on the fatigue lifein the bottom floor of cylinder head.
论文应用前处理软件Hypermesh对缸盖、机体、螺栓、气缸垫、水腔等三维实体模型进行了适当简化，并分别划分了接触分析所需的固体域网格及流体分析边界层网格。把缸盖和水腔耦合模型导入流体动力学软件CFX，运用整场离散、整场求解方法，对气缸盖及冷却液进行了直接耦合传热分析。分析结果显示，冷却液流速合理，基本达到缸盖冷却要求。但缸盖上水孔布置不太合理，导致缸盖冷却不充分，尤其是两排气道之间鼻梁区及排气道靠近缸盖顶板处冷却液流速偏低，冷却效果较差，这也解释了缸盖在排气道侧温度偏高的原因。
论文把流场分析得出的缸盖温度映射到ANSYS分析模型中，计算了缸盖在热应力工况、预紧力工况、预紧力-爆发工况、热机耦合工况下的应力场。计算结果显示，在预紧力和爆发压力作用下，最大应力值都位于螺栓支撑凸台附近，由此可知，缸盖只承受机械载荷作用时，应力集中主要出现在预紧力作用区域。而在热应力及热机耦合两种工况下，应力集中区域基本相同，主要分布在缸盖底板水道壁面、火力面鼻梁区及两排气道之间的鼻梁区附近，而这些区域在单纯机械负荷作用下的应力值较低，证明了热负荷对其应力水平起主导作用。
通过对计算结果的分析，论文提出五种缸盖结构改进方案，探索了降低底板厚度、增大入水孔直径、底板加工卸载槽、增大底板冷却水孔直径等结构改进形式对冷却液冷却效果、缸盖温度场及各种工况下的应力分布的影响。通过与原方案对比，发现缸盖入水孔直径增大以后，冷却液流动更加合理、冷却效果增强，缸盖温度明显降低；而在底板处加工卸载槽以后，由于火力面的承热面积增加，使缸盖最高温度有所升高。应力计算结果显示，对缸盖进行上述改进后，虽然使缸盖承受了更大的机械载荷，但热负荷作用下的应力值呈下降趋势。增大缸盖底板冷却水孔直径后，进气道壁面温度下降明显，但缸盖最高温度反而略有增加，这主要是由于上水孔流出的冷却液很大一部分经冷却水孔直接流向出水口，而减少了排气道侧的冷却液流量，冷却效果下降。
论文把应力计算结果导入到疲劳分析软件FE-safe中，选取应力计算结果最优方案与原缸盖结构进行对比，分别计算了缸盖在机械载荷和热负荷作用下的疲劳寿命。结果证明，改进方案降低了缸盖应力集中区域的应力应变水平，疲劳循环次数增多，寿命加强。火力面鼻梁区、两排气道之间的鼻梁区、螺栓支撑凸台等区域容易发生疲劳破坏，寿命相对较小，这些区域在缸盖抗疲劳设计过程中应重点考虑。通过对比发现，在机械载荷工况下，预紧力对缸盖疲劳寿命起到主导作用；而在热机耦合工况下，热应力对缸盖底板处的疲劳寿命影响较大。
The cylinder head is one of the key parts for the diesel engine. When it is working, thecylinder bears high temperature and pressure. Besides, because of its complex geometricshape and flow situation in water jacket, heat stress and mechanical stress distribution is notuniform, it is easy to produce the stress concentration phenomenon which can cause seriousfatigue damage. The paper takes a diesel engine as the research object, based on some theoriesof finite element analysis such as the fluid dynamics theory, heat transfer theory and so on.Multi-physics field coupling analysis was taken on the the model which is combined bycylinder head, engine body, bolts, cylinder cushion, and other parts using nonlinear contactanalysis method. In order to calculate the stress and strain field results in the workingconditions such as the prestressing force, explosion pressure, heat load and the thermalmechanical coupling conditions. Then the paper explored the influence on the cylinder headfatigue strength cased by mechanical stress and thermal stress, found out the main stressconcentration areas. At last, the paper put forward some structure improvement measuresbased on the results above to forecast the fatigue life of the cylinder head using fatigueanalysis software FE-safe.
The paper built both the finite element assembly model and fluid analysis model afterof the simplification for the cylinder head, engine body, water jacket and cylinder cushionwith the specialized processing software Hypermesh. And then I put the mesh to the Fluiddynamics software CFX, took the directly coupled heat transfer analysis the based on thetheory of disperse integrally and solve integrally. The analysis results showed that watervelocity is reasonable, and can basically meet with cylinder head cooling requirements. Butthere are also some shortcomings in the water inlets, especially in the area near the two exhausting channels, the water velocity is too slow, this also explains the cause of the hightemperature in exhausting channels.
Then the paper mapped the cylinder head temperature made in flow analysis to theanalysis model, calculated the stress field in the four working conditions such as theprestressing force, explosion pressure, heat load and the thermal mechanical couplingconditions, The results indicated that the stress concentration is mainly distributed close to thebolt support convex platforms when it bears bolt prestressing force and explosion pressure.We can conclude that stress concentration occurs in Mechanical load condition. Besides, onthe thermal stress and heat coupling conditions, stress concentrated areas are almost the same,which are mainly distributed in the cylinder water channel floor , nose bridge surface betweentwo exhaust ports in fire floor, near the water-jacket fillets between close to cylinder boltholes in cylinder base floor. so the results confirms that thermal stress takes a key role in theseregions..
This paper puts forward five improvements of cylinder head such as the change ofbottom thickness, inlet diameter, processing discharge groove which can influence thecylinder head temperature distribution and cooling liquid cooling effect. Then analyzed theheat transfer effect and stress distribution in various working conditions, through thecomparison with the original model, we found that the cooling fluid flow more reasonable,and cylinder head temperature has reduce. After the improvement of processing dischargegroove, the highest temperature raised because of the increase of heated area. In addition, nodoubt that the mechanical load had increased after the thinning improvement of cylinderbaseboard, but heat load stress and strain reduced significantly to the contrary. When thediameter of cooling hole increased, the intake surface temperature dropped significantly,while the highest temperature increased on the contrary. It is mainly because that most of thecooling water has gone to the output directly through the cooling hole, which reduced thecooling effect in the region of exhaust channel.
Finally, the paper exported stress results into the fatigue analysis software FE-safe tocalculate the cylinder head fatigue life of the optimal case. The results show that high stress and strain are located in the regions such as the nose bridge surfaces both in fire floor andbetween two exhaust ports and bolt support convex platforms, where we should make aspecial consideration in diesel engine design. By comparison, the paper also found that thefatigue cyclic numbers and service life have both increased after improvement. Through thecomparison with the original model, we find that pretightening force plays an important rolein the mechanical load conditions; while the thermal stress has a key effect on the fatigue lifein the bottom floor of cylinder head.
引文
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