Analysis and Evaluation of Fuel Injection Inspection Cover Part using FEA

Transcription

1 Analysis and Evaluation of Fuel Injection Inspection Cover Part using FEA Mr. Sandeep S N 1, Mr. Karthik S N 2, Kemparaju C R 3 & Madhusudan K 4 1 Asst. Professor, Dept of Mechanical Engg. CBIT-Kolar 2 Assistant Professor, Dept of Mechanical Engg. NHCE-Bangalore 3 Assistant Professor, Dept of Mechanical Engg. NHCE-Bangalore 4 Assistant Professor, Dept of Mechanical Engg. NHCE-Bangalore Abstract: The focus of present study is to evaluate suitable polymer for inspection cover part of diesel fuel injector. The material is selected using CES software as per the requirements and constraints of the component. The selected component modeled by using CATIA software and it is numerically analyzed for stress and strain using commercial FEA package. Prototype model of the component is built using FDM method, along with a tensile specimen for mechanical property evaluation. It was found satisfactory that the selected polymer material is suitable for the component and can be substituted instead of aluminum material. Keywords Fuel Injection, Inspection Cover, Tensile test I. INTRODUCTION The Inspection cover part acts as enclose of diesel fuel injection pump. The inspection cover part is present only in four stroke and six stroke diesel engine. It protects spilling of diesel out from pump housing when fuel sent to the injectors. Material used for inspection cover part is aluminium, the cost and weight of aluminum material is high and some of its mechanical and thermal properties are well above the component requirement. So it is replaced with polymer material. The application of polymeric materials in automobiles is constantly increasing and this trend is expected to continue. The key factors in selecting the polymeric materials in relation to other materials applied in automobiles are the today's appearance of automobiles, their functionality and more economic manufacture. 1.1 OBJECTIVE The objectives of the study are: To review the literature on polymers in automobiles. To collect data regarding the functional requirements and mechanical properties related to Inspection cover. To develop 3D model of inspection cover to carry out analysis for material substitution and part design validation. To develop prototype model. Mechanical properties evaluation. 1.2 PRODUCT SPECIFICATION: The specification of the fuel injection pump inspection cover part is taken from the Bosch manual. DOI: /IJRTER CU2SV 311

2 Fig 1: Inspection cover part Part name : Inspection cover Application : Enclosure for Pump Housing Specification requirements Temp : -20 to 140 C Risk factor : Sealing and Flatness Material : Aluminum (ENAC 47100) Present Process : PDC 1.3 FUNCTIONAL REQUIREMENTS The functional requirements of inspection cover part are taken from the Bosch manual. The functional requirements are; Needs to be stiff to provide leak free joint with pump housing; Not to buckle/crack under sustained loading; Withstand temperature range of 20 to 140 C; Withstand torque range of 5 Nm; Achieve flatness within 0.50 mm on mounting surface to provide leak free joint with Gasket; Corrosion resistance to water and oils (diesel, lubricating oil etc.). 1.4 Data analysis: Material : Al - EN AC Chemical symbol : EN AC-Al Si12 Cu1(Fe) General properties Density : 2650 kg/m3 Price : 1.67 to 1.83 USD/kg 1.5 Mechanical Properties: Young s Modulus : 75 GPa Poisson s Ratio : 0.33 Tensile strength : 250 MPa Elongation : 1-4 % Brinell Hardness : Thermal Properties: Temperature: -273 to 200 o C 1.7 Outcome of present material analysis: Withstand service temperature for present aluminum material is -273 to 200 o C, whereas the functional requirement is -20 to 140 o C. Cost and weight of the aluminum material is All Rights Reserved 312

3 II. MATERIAL SELECTION Material selection is a step in the process of designing any physical object. In the context of product design, the main goal of material selection is to minimize cost while meeting product performance goals. Systematic selection of the best material for a given application is carried out in CES (Cambridge Engineering Selector) software. Material selection process helps narrow the range of material as the design nears completion. When the range of materials has been narrowed, it will be easier for designers or engineers to choose the most suitable material. The selected material using this software is ABS polymer. III. MODEL CONSTRUCTION For creating a CAD model we want dimensions of inspection cover part. For this, used inspection cover part is taken and the dimensions are measured using measuring instruments. Radial gauge is used for measuring groves on cover part. Modeling of inspection cover part of a diesel injection pump is done with help of CATIA V5 R20 software. Fig 2: CAD model of inspection cover part IV. ANALYSIS Analysis has been performed by using ANSYS 14.4 by applying the boundary conditions and the torque. For applying torque, bolts are created and assembled to the inspection cover model in CATIA V5 R APPLYING MATERIAL Table 1: ABS material properties Property Values Young s Modulus 2.9GPa Poissons Ratio 0.35 Density 1.04g/cc Tensile Yield Strength 44MPa Compressive Yield Strength 44MPa Tensile Ultimate Yield Strength All Rights Reserved 313

4 4.2 BOUNDARY CONDITION: Fig 4: Displacement fixed in X direction Fig 5: Displacement fixed in Z direction Fig 6: Displacement fixed in Y direction Fig 7: Applied torque on two faces of bolt 4.3 FE MODEL Fig 8: Discretised model Fig 9: Total deformation and Von-mises stress at 5Nm torque of ABS material inspection cover All Rights Reserved 314

5 Fig 10: Total deformation and Von-mises stress at 6Nm torque of ABS material inspection cover part V. PROTOTYPING A MODEL Prototyping is an important stage in any product development process and the prototype can be defined as an approximation of a product (or system) or its components in some form for a definite purpose in its implementation. Prototype model of inspection cover part is created using Fused Deposition Modelling. Fig 11: Prototype model 4.4 TENSILE TEST SPECIMEN Standard tensile test specimen is created as per ASTM standard and it is subjected to standard tensile test to obtain the parameters. Fig 12: Tensile specimen model VI. HARDNESS TEST RESULTS Hardness test was done on the inspection cover part prototype model. Type of hardness test used here is Rockwell hardness and the value obtained is All Rights Reserved 315

6 Description Values Initial gauge length 50 mm Final gauge length mm Peak load kn Tensile strength N/mm 2 Yield stress N/mm 2 % of Elongation 2.50% Table2: Tensile test results VII. DISCUSSIONS From the static analysis results, it is found that the maximum displacement of 8.275e-4 mm and 9.930e-4 mm are obtained for EN AC material at 5 Nm and 6 Nm torque respectively. The maximum displacement of mm and mm is obtained for ABS material at 5 Nm and 6 Nm respectively. This shows that deformation is less in ABS and it will not affect its application. From tensile test results, we came to know that the maximum load it can withstand is 40.40KN which is well above the requirements of 5Nm torque. Von-mises stress is used as a criterion in determining the failure of ductile materials. The failure criteria states that the von-mises stress should be less than the yield stress of the material. Vonmises stress for ABS material is MPa and MPa at 5Nm and 6Nm torque respectively. And the yield stress value is MPa, results shows that von-mises stress is less than that of yield stress of inspection cover part. VIII. CONCLUSION In this work, the design and analysis of ABS inspection cover part of fuel injection pump are performed. The static results shows that the maximum displacement of ABS material is within the functional requirement of inspection cover part. From the results of tensile test we can say that it can with stand the applied torque. From the Von-mises and Yield stress value we can say that ABS material for inspection cover part passes the failure criteria i.e. von-mises stress value is less than the yield stress value. And it is concluded that, the mechanical properties of ABS material will suits its functional requirements. So it can readily substitute in place of aluminum material. REFERENCES 1. Nada Strum berger, Polymeric materials in automobiles University of Zagreb M.F. Ashby and D. Cebon, Materials selection in mechanical design Cambridge CB2 1PZ, UK Mansor M.R., Material selection of thermoplastic matrix for hibrid natural fiber/glass fiber polymer composites using analytic hierarchy process method, UPM Serdang, Selangor, MALAYSIA, Pankaj Saini, Design and analysis of composite leaf spring for light vehicles, Moradabad Institute of Technology, Moradabad, Uttar Pradesh, INDIA, Pradeep Kumar Uddandapu, "Impact analysis of car bumper by varying speeds using materials abs plastic and poly ether imide by fem software solid works, K.S.R.M. college of Engg., Kadapa, Andhra Pradesh, India, D.V.Pawar, Desin and analysis of plastic fuel tank for three wheeler vehicle GenbaSopanraoMoze college of Engg., Pune, India, J. Reddaiah, Desing and analysis of master cylinder of hydrolic braking system using ansys, Ravi Lidoriya, Design and analysis of aluminum alloy wheel using peek material, Central Institute of Plastic Engineering and Technology, Lucknow, India, T.Rangaswamy, Optimal design and analysis of automotive composite drive shaft, PSG College of Technology, Coimbatore, India, Tulasiram Nasikai, Design and analysis of vehicle chassis frame, Nova College of Engineering and technology, Vegavaram (V), Jangareddy gudem (M), West Godavari (D), Andhra Pradesh, India, Bosch Diesel fuel-injection pumps All Rights Reserved 316