Abstract
During the start-stop cycle of marine diesel engines, the cylinder head bears the cyclic thermal stress and produces irreversible deformation. Previous studies mainly predicted the thermomechanical fatigue life of cylinder heads based on the strain fatigue damage criterion, but the multi-factor damage mechanism and law of thermal cycle load on the structural integrity of cylinder heads are not clear. A transient thermal cycle analysis method of the viscoelastic plastic Chaboche model was developed to quantitatively account for the marine engine cylinder head's local deformation and leakage failure. The Chaboche model combines the temperature-dependent nonlinear kinematic hardening equation and Norton-Bailey creep equation. A thermal cycling test of simulated cylinder head specimen was designed to cautiously verify the inelastic cyclic behavior of the multiaxial thermal and structural coupling effect. The model and numerical method are verified by the deformation and fatigue test of the specimen. Then the permanent deformation and leakage of the cylinder head and water-cooled valve seat are analyzed. The results show that multiaxial thermal cycle simulation verified the deformation prediction with an error of no more than 14%. Inelastic deformation induced by temperature cycling leads to gradual leakage failure in the exhaust nose bridge area of the cylinder head. The irreversible deformation gradually reduces the contact sealing force, and the cyclic loading plasticity that dominates is 8.36 times that of the creep deformation.
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig1_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig2_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig3_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig4_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig5_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig6_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig7_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig8_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig9_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig10_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig11_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig12_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig13_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig14_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig15_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig16_HTML.jpg)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig17_HTML.png)
![](http://media.springernature.com/m312/springer-static/image/art%3A10.1007%2Fs40430-022-03652-2/MediaObjects/40430_2022_3652_Fig18_HTML.png)
Similar content being viewed by others
Abbreviations
- \(C_{i}\) :
-
Kinematic hardening parameters
- \(E\) :
-
Young's modulus
- \(Q\) :
-
Saturation value of R
- \(R\) :
-
Isotropic hardening parameter
- \(R_{{{\text{th}}}}\) :
-
Restraint ratio
- \(T\) :
-
Temperature
- \(X\) :
-
Back stress tensor
- \(b\) :
-
Isotropic hardening parameter
- \(c\) :
-
Specific heat
- \(p\) :
-
Equivalent plastic strain
- \(\alpha\) :
-
Thermal expansion coefficient
- \(\varepsilon_{{\text{c}}}\) :
-
Creep strain
- \(\varepsilon_{{\text{p}}}\) :
-
Plastic strain
- \(\varepsilon_{{{\text{mech}}}}\) :
-
Mechanical strain
- \(\varepsilon_{{{\text{th}}}}\) :
-
Thermal strain
- \(\sigma\) :
-
Stress tensor
- \(\sigma_{0}\) :
-
Yield stress
- \(\lambda\) :
-
Thermal conductivity
- \(\gamma_{i}\) :
-
Kinematic hardening parameters
References
Pirker G, Wimmer A (2017) Sustainable power generation with large gas engines. Energy Convers Manag 149:1048–1065
Pierce D, Haynes A, Hughes J et al (2019) High temperature materials for heavy duty diesel engines: historical and future trends. Prog Mater Sci 103:109–179
Bree J (1966) Ratchet and fatigue mechanisms in sealed fuel pins for nuclear reactors. TRG Report, D
Thomas J, Verger L, Bignonnet A et al (2004) Thermomechanical design in the automotive industry. Fatigue Fract Eng Mater Struct 27(10):887–895
**g GX, Zhang MX, Qu S et al (2018) Investigation into diesel engine cylinder head failure. Eng Fail Anal 90:36–46
Ghodrat S, Kalra A, Kestens LA et al (2019) Thermo-mechanical fatigue lifetime assessment of spheroidal cast iron at different thermal constraint levels. Metals 9(10):1068
Compeau DR, Higgins CA (1995) ASTM E2368–10, standard practice for strain controlled thermomechanical fatigue testing. MIS Q 19(2):189–211
Hähner P, Rinaldi C, Bicego V et al (2008) Research and development into a European code-of-practice for strain-controlled thermo-mechanical fatigue testing. Int J Fatigue 30(2):372–381
Grieb MB, Christ HJ, Plege B (2010) Thermomechanical fatigue of cast aluminium alloys for cylinder head applications–experimental characterization and life prediction. Procedia Eng 2(1):1767–1776
Wu X, Quan G, MacNeil R et al (2015) Thermomechanical fatigue of ductile cast iron and its life prediction. Metall Mater Trans A 46(6):2530–2543
Lopez-Covaleda EA, Ghodrat S, Kestens LA (2020) Lifetime and damage characterization of compacted graphite iron during thermo-mechanical fatigue under varying constraint conditions. Metall Mater Trans A 51(1):226–236
Lekakh SN, Buchely M, O’Malley R et al (2021) Thermo-cycling fatigue of SiMo ductile iron using a modified thermo-mechanical test. Int J Fatigue 148:106218
Fissolo A, Amiable S, Ancelet O et al (2009) Crack initiation under thermal fatigue: an overview of CEA experience. Part I: Thermal fatigue appears to be more damaging than uniaxial isothermal fatigue. Int J Fatigue 31(3):587–600
Li Z, Li J, Chen Z, Guo J, Zhu Y et al (2021) Experimental and computational study on thermo-mechanical fatigue life of aluminium alloy piston. Fatigue Fract Eng Mater Struct 44(1):141–155
Szmytka F, Salem M, Rezai-Aria F et al (2015) Thermal fatigue analysis of automotive diesel piston: experimental procedure and numerical protocol. Int J Fatigue 73:48–57
Beesley R, Chen H, Hughes M (2017) A novel simulation for the design of a low cycle fatigue experimental testing programme. Comput Struct 178:105–118
Trampert S, Gocmez T, Pischinger S (2008) Thermomechanical fatigue life prediction of cylinder heads in combustion engines. J Eng Gas Turbines Power 130(1):012806
Googarchin HS, Sharifi SMH, Forouzesh F et al (2017) Comparative study on the fatigue criteria for the prediction of failure in engine structure. Eng Fail Anal 79:714–725
Zhang H, Cui Y, Liang G, Li L et al (2021) Fatigue life prediction analysis of high-intensity marine diesel engine cylinder head based on fast thermal fluid solid coupling method. J Braz Soc Mech Sci Eng 43(6):1–15
Yang W, Pang J, Wang L et al (2022) Thermo-mechanical fatigue life prediction based on the simulated component of cylinder head. Eng Fail Anal 135:106105
Szmytka F, Rémy L, Maitournam H et al (2010) New flow rules in elasto-viscoplastic constitutive models for spheroidal graphite cast-iron. Int J Plast 26(6):905–924
Hosseini E, Holdsworth SR, Flueeler U (2018) A temperature-dependent asymmetric constitutive model for cast irons under cyclic loading conditions. J Strain Anal Eng Des 53(2):106–114
Bartošák M, Španiel M, Doubrava K (2020) Unified viscoplasticity modelling for a SiMo 4.06 cast iron under isothermal low-cycle fatigue-creep and thermo-mechanical fatigue loading conditions. Int J Fatigue 136:105566
Norman V, Calmunger M (2019) On the micro-and macroscopic elastoplastic deformation behaviour of cast iron when subjected to cyclic loading. Int J Plast 115:200–215
Song J, Bing SUN (2018) Damage localization effects of the regeneratively-cooled thrust chamber wall in LOX/methane rocket engines. Chin J Aeronaut 31(8):1667–1678
Cho NK, Chen H, Boyle JT et al (2018) Enhanced fatigue damage under cyclic thermo-mechanical loading at high temperature by structural creep recovery mechanism. Int J Fatigue 113:149–159
Chaboche JL (1989) Constitutive equations for cyclic plasticity and cyclic viscoplasticity. Int J Plast 5(3):247–302
Chaboche JL (1991) On some modifications of kinematic hardening to improve the description of ratchetting effects. Int J Plast 7(7):661–678
Shi L, Wang ZG, Zhang SL (2015) Creep deformation of ductile cast iron cooling staves. Ironmak Steelmak 42(5):339–345
Ostergren WJ (1976) A damage function and associated failure equations for predicting hold time and frequency effects in elevated temperature, low cycle fatigue. J Test Eval 4(5):327–339
Ghahremaninezhad A, Ravi-Chandar K (2012) Deformation and failure in nodular cast iron. Acta Mater 60(5):2359–2368
Acknowledgements
The authors are grateful for the financial support by "National Key Research and Development Project of China No. 2017YFE0130800" and Project 52006136 of National Natural Science Foundation of China.
Author information
Authors and Affiliations
Corresponding authors
Ethics declarations
Conflict of interest
The authors declare that they do not have any commercial or associative interest that represents a conflict of interest connected with the work submitted.
Additional information
Technical Editor: João Marciano Laredo dos Reis.
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Zhang, H., Liang, G., Qiao, X. et al. Experimental and numerical study of inelastic behavior based on simulated cylinder head specimen under thermal cycling conditions. J Braz. Soc. Mech. Sci. Eng. 44, 372 (2022). https://doi.org/10.1007/s40430-022-03652-2
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s40430-022-03652-2