Eventos Anais de eventos
COBEM 2023
27th International Congress of Mechanical Engineering
FAULT ANALYSIS IN ROAD SPRINTER OM611
Submission Author:
Magno Caetano , MG
Co-Authors:
Magno Caetano , Ronalty Rios, Claysson Vimieiro, JORDANA MARTINS
Presenter: Claysson Vimieiro
doi://10.26678/ABCM.COBEM2023.COB2023-1478
Abstract
The connecting rod, one of the main components of the engine, generates impressive results, since, together with the crankshaft, they manage to transform an alternating linear movement of the piston into a continuous circular movement. To fully perform its function, the connecting rod needs to be robust and resistant at the same time, to support the transmission of movement, and be light, so that the inertia of the system is reduced at each stage of the combustion engine cycle, improving its energy efficiency. The present study sought to understand the Sprinter Motor OM611 connecting rods on the market, the operating principle and the most common mechanical failures, and from this, understand what preventive measures could be taken so that they have a longer useful life without compromising the function performed. The main objective of this work is to identify the main mechanical failures of the connecting rod/crankshaft system through inspection, to present the possible causes, as well as to propose solutions and improvements in order to minimize them. FEA simulations will also be used to simulate the failure modes that the connecting rod/crankshaft system of forged pearlitic alloys AISI 4140 is subject to during engine operation, to substantiate the theoretical causes of mechanical failures raised through visual inspection. Simulations were carried out: (1) linear statics to evaluate excess efforts transmitted by the piston, failures in the web due to deformation, breakage in the transmission between the smaller eyelet and the web, breakage of the larger eyelet, failure of the threaded hole (2) fatigue analysis for evaluation of rupture failures at 45°, (3) fatigue analysis by fretting in the smaller eyelet. The results obtained may be used in future work, to improve the design and implement the use of lighter materials, suitable for the efficient operation of the system, and to support studies that involve maintenance failures, such as overheating due to lack of lubrication.
Keywords
connecting rod, Combustion engine, mechanical failures, FEA simulation
