Eventos Anais de eventos
COBEM 2023
27th International Congress of Mechanical Engineering
Integrated Product Development Methodology Applied to a Resonant Fatigue Testing Bench for Shafts and Crankshafts
Submission Author:
Artur Cantisano , SP
Co-Authors:
Artur Cantisano, Luiz Fonseca, jefferson de oliveira gomes, Ronnie Rego, Tiago Colombo, Eduardo Garcia Muñoz
Presenter: Artur Cantisano
doi://10.26678/ABCM.COBEM2023.COB2023-2236
Abstract
Modern mobility has brought challenges to the automotive sector, as the requirements for increasing energy efficiency and reducing weight and CO2 emissions are becoming increasingly severe in all world markets. Of the existing technical strategies to achieve these goals, engine downsizing is currently one of the most applied methods. Engine downsizing is based on smaller and more fuel-efficient engines, without impairing their efficiency. Nonetheless, such downsizing approach has a direct impact on critical engine components, such as shafts and crankshafts. When downsized, these components are prone to higher requirements related to mechanical strength and performance. Due to the predominance of cyclic mechanical loads in the engine, shafts and crankshafts are especially prone to fatigue failure. Considering that the manufacturing chain of such components involves numerous sources of residual stresses, it is thus mandatory to carry out durability tests on these components, especially considering the trend of engine downsizing. Thus, the objective of this study is to present an IPD - Integrated Product Development Methodology to the development of a fatigue testing bench for shafts and crankshafts. The applied methodology followed steps of informational, conceptual, and detailed design, gathering industry requirements related to modern automotive engines. The testing bench was developed allowing tests of torsion and bending, which are the predominant efforts in these components, with the differential of allowing tests on both shafts and crankshafts of different geometries and sizes. The IPD methodology employed considered the need of a fast specimen exchange, with a control system that adjusts bending and torsional moments applied to the specimen automatically, a monitoring system against force peaks and automatic shutdown at the end of the test. In total, more than 100 bending fatigue tests were carried out in the developed testing bench, totaling 733 million cycles, with an average of 550 N.m of bending moment. In torsion, 13 tests were performed, with 150 N.m of torque, totaling 1.57 million cycles. The development of the testing bench using the IPD methodology also allows an expansion of the investigations carried out with an increased robustness and reliability combined with a reduction of testing costs.
Keywords
crankshafts, Shafts, fatigue, resonance, Integrated Product Development
