Functionality analysis of thermoplastic composite material to design engine components 2020-01-0774
Developing of innovative technologies and materials to meet the requirements of environmental legislation on vehicle emissions has paramount importance for researchers and industries. Therefore, improvement of engine efficiency and fuel saving of modern internal combustion engines (ICE) is one of the key factors, together with the weight reduction. Thermoplastic composite materials might be one of the alternative materials to be employed to produce engine components to achieve these goals as their properties can be engineered to meet application requirements. PEI-AS4 unidirectional thermoplastic composite is used to design engine connecting rod and wrist pin, applying commercial engine data and geometries. The current study is focused on some elements of the crank mechanism because the weight reduction of these elements affects not only the curb weight of the engine but the overall structure. As a matter of fact, by reducing the reciprocating mass, alternate force will be reduced and hence the size of the structural elements. Also, other elements of the engine can be designed for lightweighting but the crank mechanism elements maximize the effect, by reducing both loads and weight. Finite element analysis has been conducted for proper stress analysis and accordingly examine the design and parts functionalities. The FEM analysis is performed using Altair HyperMesh for mesh optimization to stress evaluation of standard engine components made of steel and the to redesign the parts using thermoplastic material to sustain the loads and stresses. Then the design modification has been considered to reduce loads and weight without service alteration. The simulation results reveal that available torque at crankshaft applying composite material has higher peak value due to the lower inertial force as consequence of weight reduction of connecting rod and wrist-pin.
Abbas Razavykia, Cristiana Delprete, Carlo Rosso, Paolo Baldissera