FEMFAT Boundary Layers
description
Transcript of FEMFAT Boundary Layers
Presentation by
Mr. Sumedh Kousadikar
Mr. Santosh Kumar
Mr. Atul Patil
January 22 , 2013 Pune, India
Bending fatigue life evaluation of
Crankshaft with induction hardening effect
via FEMFAT boundary layers
R&D CDFD Engineering
Bharat Forge Ltd. Pune, India
FEMFAT USER CONFERENCE 2013
Presentation Sequence
• Introduction
• Kalyani Group & Bharat Forge Overview
• Objective & Methodology
• Approach 1: Introducing hardness effect via Boundary layer
• Approach 2: Hardness effect via Boundary layer & Forge factor
• Correlation between FEMFAT & physical test results
• Conclusion & Future Work
R & D CDFD ENGG CMMI (ML-3)
• Bharat Forge Overview
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Global Footprint
BFL
Capacity over 760,000 Tons per annum
Crankshaft machining capacity of 1,200,000 Nos.
Capacity to machine 500,000 FAB & 750,000 steering knuckles
Skilled workforce of 7000 Worldwide.
CAPACITY
60,000 tons
CAPACITY
200,000 Tons
CAPACITY
365,000 Tons
CAPACITY
135,000 Tons
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5
6 4
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CDP BHARAT FORGE
Ennepetal, Germany
BHARAT FORGE DAUN
Daun, Germany
BF ALUMINIUMTECHNIK
Dresden, Germany
BF AMERICA
Lansing
BHARAT FORGE KILSTA,
Sweden
FAW BF (Changchun) Co. Ltd.
Changchun, China
• Strong Foray in the largest
auto market USA
• Strong customer
relationship
• Dual Shore manufacturing
• Manpower: 83 People
• Production base close to the
customer
• Proximity to large marquee
Customers
• Dual Shore manufacturing
• Manpower: 1060 People
• JV with FAW in China with
52% stake
• Foothold into fastest
growing market
• Dual Shore Manufacturing
• Manpower: 1500 People
• Worlds largest single
location forging facility
• Technologically advanced,
flexible forging & machining
facility
• Proximity to fast growing
Auto markets of China &
India
• Dual Shore manufacturing
• Manpower: 4700 People
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GLOBAL PRESENCE - Automotive
GLOBAL & DOMESTIC CLIENTS
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Global & Domestic – Non Automotive
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New Verticals… Greater Focus… India’s Growth
Non - Auto Business
Energy Transportation Construction & Mining
Railways
Aerospace Oil & Gas
Supporting global core infrastructure sectors
Marine
Construction
Wind Thermal Hydro Nuclear
Power
Metal & Mining
General
Engineering
FEMFAT USER CONFERENCE 2013 R & D CDFD ENGG CMMI (ML-3) 6
Crankshaft manufacturing process involves forging, heat treatment, machining, grinding,
shot blasting & induction hardening.
Forging Machining Induction hardening Fatigue testing
& Validation
Fatigue testing of crankshaft is a complex engineering process, which requires lot of
theoretical calculations, practical work, time & cost.
Crankshaft fatigue life can be improved by optimizing design & process parameters. But
it’s physical test validation needs lot of testing time & other expenses. So to reduce these
complexities, it is important to virtually simulate the crankshaft fatigue testing process &
predict the fatigue life.
Introduction
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Bending fatigue life evaluation of crankshaft with induction hardening effect via FEMFAT
boundary layers.
Crankshaft bending fatigue life correlation between FEMFAT & physical test results.
Methodology:
Import ANSYS stress
results into FEMFAT &
apply different IH
process parameter effect
via boundary layers
Conduct FE analysis Predict fatigue life
& validate results
Objective & Methodology
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Following input parameters are taken for bending fatigue life evaluation of five different
capacity crankshafts.
The load spectra applied is actual (B50) mean fatigue strength of crankshaft.
All analysis are performed on load ratio (R=-1) fully reverse condition.
Other parameters like technological size influence, forge factor, are activated based on pin
diameter of crankshaft.
Crankshafts Input data for FEMFAT Analysis
S.N. Crankshaft Material Pin Dia(Ø) mm UTS (MPa) YS (Mpa) Surface Hardness
(HRc) Surface finish
(Ra) µ
1 A Micro alloyed 70 780-930 450 52 0.25
2 B Micro alloyed 90 750-900 450 53 0.25
3 C Q & T 94 930-1080 760 50 0.25
4 D Micro alloyed 95 850-1000 550 55 0.25
5 E Micro alloyed 100 850-1000 550 56 0.25
Input data for analysis
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Following parameters are considered for analysis, Material: Micro alloyed steel. Applied stress level 875 MPa UTS 850 MPa Pin Diameter: 94 mm Technological size influence ON Forge Factor ON Surface Roughness 0.2 µ Stress ratio R=-1 B50 fatigue life
FEMFAT fatigue
life Expected
fatigue life % of variation
5.82E+03 10E+06 99.94%
Fatigue life Requirement:
10Million no. of cycles for 875 MPa
Without Induction hardening effect
Fatigue life analysis using FEMFAT
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Similarly fatigue life evaluated for other sizes of crankshafts as shown below.
BENDING FATIGUE TEST CORRELATION
Sr No. Crankshaft B50 physical
test (MPa) Pin Diameter
(mm) Number of cycles
Calculated cycles by FEMFAT
% Difference
1 A 875 70 10E+06 2.38E+04 99.76%
2 B 757 90 10E+06 2.69E+05 97.31%
3 C 880 94 10E+06 5.56E+04 99.44%
4 D 875 95 10E+06 4.47E+04 99.55%
5 E 875 100 10E+06 2.99E+04 99.70%
Without hardening Influence, the fatigue life achieved is very small as compared to
expected no. of cycles (10 Millions)
Fatigue life analysis using FEMFAT
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Hardness 55 HRC
Fatigue life Requirement:
10Million no. of cycles for 875 MPa Achieved fatigue life: 9.1 Million cycles
Result correlates well
Approach 1: Introducing hardness effect via Boundary layer
One of the crankshaft is simulated for fatigue life evaluation using FEMFAT with introducing
hardness effect in terms of UTS at 3mm boundary layer.
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Following parameters are considered for analysis Material: Micro alloyed steel. Pin Diameter: 94 mm Technological size influence ON Forge Factor ON (default taken as 1) Surface Roughness 0.2 µ Stress ratio R=-1 B50 fatigue life Mechanical properties (YS, UTS 850 MPa) Applied stress level 875 MPa
Following parameters are considered for analysis Material: Micro alloyed steel. Pin Diameter: 94 mm Technological size influence ON Forge Factor ON introduced as 1.9 Surface Roughness 0.2 µ Stress ratio R=-1 B50 fatigue life Mechanical properties (YS, UTS 850 MPa) Applied stress level 875 MPa IH Boundary layer ON
Approach 2: Introducing hardness effect via Boundary layer & Forge factor
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Forge factor in the FEMFAT depends on geometrical complexities of forging components. we
have related forge factor with pin diameter of crankshaft.
For most of the crankshafts trend observed, as pin diameter increases forge factor decreases.
For few exceptional cases, e.g. if pin diameter is more with less counterweight masses
forge factor varies proportionally with geometry of crankshaft.
y = -0.0015x2 + 0.2175x - 5.5546
0.5
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1.5
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2.5
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60 70 80 90 100 110
Fo
rge
Facto
r
Pin diameter
Pin diameter Vs. Forge factor
Crankshaft
Dia 70
Dia 90
Significance of forge factor during fatigue life evaluation
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BENDING FATIGUE TEST CORRELATION
Sr No. Crankshaft B50 physical
test (MPa) Pin Diameter Forge factor Number of cycles
Calculated cycles by FEMFAT with Forge
factor
% Difference With forge factor
1 A 875 70 2.45 10E+06 1.02E+07 -2.0%
2 B 757 90 2.06 10E+06 9.77E+06 2.3%
3 C 880 94 1.92 10E+06 9.92E+06 0.8%
4 D 875 95 1.78 10E+06 1.02E+07 -2.0%
5 E 875 100 1.45 10E+06 9.95E+06 0.5%
Following crankshafts are simulated for fatigue life evaluation using FEMFAT,
with combination of boundary layer & forge factor effect.
Results shows good correlation between FEMFAT & physical test
Comparisons of fatigue life evaluated by FEMFAT and physical test
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Crankshafts are simulated for fatigue life evaluation using FEMFAT by introducing
processing parameter effect, boundary layer with different hardness ranges & forge factor.
This study shows good correlation with physical test.
This study will be beneficial for virtual estimation of crankshaft fatigue life. This will help
to reduce product development time, cost & efforts.
Correlation for fatigue life between physical test and virtual test will be useful for
crankshaft design & manufacturing process optimization.
Future Work:
To study the effect of different process parameters (hardness, surface finish, case
depth, residual stresses) on fatigue life of crankshaft using FEMFAT and its
experimental validation.
Conclusion & Future Work
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www.bharatforge.com
Thank You
Any Questions?
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