ML20012C169
| ML20012C169 | |
| Person / Time | |
|---|---|
| Site: | South Texas  |
| Issue date: | 02/26/1990 |
| From: | Horne J COOPER INDUSTRIES, INC. |
| To: | |
| Shared Package | |
| ML20012C136 | List: |
| References | |
| REF-PT21-90 AM-1852-C-1A, NUDOCS 9003200224 | |
| Download: ML20012C169 (47) | |
Text
{{#Wiki_filter:- - _.._ - . . _ - . - - 9 I g Cooper-Besomer Reciprocating Products, Division Cooper Industries, Inc. l
- \
d a Applied Mechanics Report AM-1852-C-1A l I ! Final Report ( Finite Element Analysis of the KSV-4-2A Master Connecting Rod l Prepared by: l John M. Horne, Manager Analytical and Ccrnpressor Engineering Grove City, Pennsylvania February 26, 1990 I j#h I 9003200224 900308 B p .. DR ALOCKODOOy,gg8
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L i l' ' Historv On Novemoer 28, 1989 the No. 22 Diesel Generator (XSV-20-T, SN-7193) at Houston . Lighting and Power, South Texas Project, experienced failure of the master ! E < connecting rod on throw #4 Examination of the failed cmponents indicated the r rod failed by fatigue, originating at a point wnere an over drilled lubricating h sil hole partially penetrated the surface of the articulated pin bore. The hole had been tapped and plugged, Dut the reenterant corner had not been I. removed, nor had the edges of the hole been radiused to removed damaged j material. Examination of quality control records revealed no other rods had l been salvaged in this manner, but two others had been drilled completely l
- through, with the edge of the hole radiused. ;
Visual checks on spare rods and on others which had been temporarily removed from various engines revealed some rods wnich had the center oil hole extending past the transverse hole, but not into the articulated pin bore. The deepest I of these found to date is about 1/8 inch from the surface. A three dimensional j I finite element analysis was done to detemine the effect of these partially aver drilled holes on the stresses in the connecting rod. the results of that analysis. his report covers j j Loading The total loading on this master rod can be divided into three catagories;' assembly, firing, and inertia. The assembly load is dae to the interference j fit of the crankpin bearing shells in the rod, produemg a nminal radial : pressure of 833 psi in the crankpin bore of the rod. Firing loads always act ! in a downward direction, and thus are transferred directly to the crankpin in ; the area closest to the load application. These loads produce relatively low 3 cmpressive stresses in the lower portion of the master rod, in a direction I E normal to the bearing surface. ! Inertia loads, on the other hand, act in both upward and downward directions, j The peak downward inertia loads occur near the bottom center position of the j crank throw, and produce stresses similar to those from the firing load, but; i l lower in magnitude. The pesk upward inertia forces occur near the top center [' position of the crank. Their reactions occur in the lower half of the crankpin bearing, a that tangential stresses are produced in the articulated pin bales and around the crankpin bore of the master rod as the loacs are transferred to the bearing reaction area. Since the KSV is a "4 Stroke Cycle" engine, the r ;I peak upward inertia forces occur twice in the complete power cycle of each ! cylinder, at the end of the exhaust stroke and again at the end of the i empression stroke. On the exhaust stroke the pressure on the piston is very i I- low, so the net load is upward and very nearly equal to the inertia load. On the empression stroke, the force frca empression pressure at top center is i equal to or greater than the inertia force, so the net load is sero or q downward. The two cylinders on any crank throw fire on alternate revolutions of the _, crankshaft, 30 there is no significant interaction between the peak upward loads of the two cylinders. The maximum upwarc inertia load frce either cylinder will be 44.6 kips at 600 rpm. When the marter rod is at the top center.on the exnaust stroke, there is a downwarc load of 65 kips at the 1 articulated pin.
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Page Two '
- February 26, 1990 Procedure A three dimensional solid model of the lower end of the connecting rod was developed with the aid of the Conceptstation software developed by Aries Technology, Inc. Only one-half of the rod was modeled, since it is symmetrical I- about its axial center plane. This model is shown in Figure 1. Small details, such as the lubricating oil holes, could not be included in this model, because of problem size constraints. A finite element mesh was generated in this model
-I: using second order tetrahedral elements (Figure 2). Two load cases were applied to this model:
1 Assembly load - A uniform radial pressure of 960 psi was applied to the crankpin bore. This value was chosen based on the high limit of the
- interference fit between the crankpin bearing shell and the rod.
- 2. Master rod upward inertia force plus the assembly load - The model was held at the shank, and a unifonn pressure was applied to a portion of the g~
crankpin bore directly opposite the snank. This pressure was selected to produce a total force of 22.5 kip on the model (45 kip on the total rod). The 960 psi assembly pressure was also applied to the entire crankpin-bore. In both cases the model was restrained at the center cutting plane, in the
- direction perpendicular to the plane to account for symmetry. Both load cases were analysed using the linear static subset of the ANSYS finite element analysis program which is furnished with the Aries package. Previous work on a two dimensional model of this rod showed that the articulated rod upward inertia force case did not produce significant stresses in the area of the rod near the lubricating oil holes.
g Three small section models were constructed of the portion of the rod between g the crankpin and articulated pin bores. These included the lubricating oil hole drilling in that area. One model had the central 3/8 inch hole drilled to within 5/16 inch of the articulated pin bore, the second was drilled to within 1/16-inch of the bore, and the third had the drill tip just breaking through
- I- the surface (Figure 3, 4, and 4A). The finite element mesh for the "1/16" model is shown in Figure 5, and the mesh for the " break-through" model is in I Figure SA. Because of model size limitations, the outer one-third of the model width was removed. A check run was made on the full width model for one case, using a larger computer system, to insure this assumption did not compromise the validity of the results.
The deflection results from the full rod model at the two section cutting planes were used as input to the small section models. The assembly load pressure was also applied to the crankpin bore side of the models. An additional load case was run for the "1/16" and " break-through" models, using an added pressure of 1625 psi on both the crankpin and articulated pin bores in conjunction with the nmster rod inertia deflections, to represent the added I'. effeet of the downward load at the articulated pin. I
;I
I Pago Thres' ' February 26, 1990 , I A Modified Goocman Diagram procecure was usea to calculate the Cyclic Failure I Factor (safety factor against fatigue failure) in the area near the over crilled oil hole. In all cases, both the maximum principal and the Von Mises stresses were examined, and the larger of the two used for analysis. The average of the assembly load only and the master rod inertia plus assembly load cases was used as the mean stress value,and the difference oetween the maximum and mean stresses was used as the stress amplitude. A further review of the " break througn" model in figures 4A and SA in comparison with the failed rod indicated this model did not truly represent the failure case, in that the actual drill point penetration was slightly less than this model, and the finite element mesn at the drill point was not fine enougn to represent the reenterant corner geometry. For this reason a further study was done, using a smaller section model with arbitrary loading, to characterize the stress concentration effects of the "1/16 inch ligament" case and the faileo case. The uncrillea, "1/16 inen ligament", and " break-througn" models are snown in figures 29 througn 32. An aroitrary pressure of 10,000 psi was 3pplied to the rignt-hard face cf eacr. cf the models, ano the left-hand face I' was neld. The cimensions of all three moaels were icentical, except for the drilled hole. 1 Results Figures 6, 7, and 8 show the stress results for-the full rod model with the The three nodes selected are on l I master rod inertia plus assemoly load case. the articulated pin bore and rod center cutting plane close to the point where an over drilled oil hole would intersect the articulated pin bore. Thus these represent the "ncminal" stress in the rod at this point. These values range frca 6.04 to 9 44 ksi. The maximum stress value in the full rod model is 15.14 kai which occurs in the articulated pin bore at the narrowest point, as shown in Figure 9 l u Figure 10 and 11 snown a ccuparison of stresses in the full width section model and the model with the outer 1/3 removed. Note that in the narrower model the maximum principal stress is 12% higher, wnile the Von Mises stress is 7% lower. All further work was based on the narrower model. Figures 12 and 13 show the stress results on the section model with the small I central oil hole drilled to within 5/16 inch of the surface. The maximum stress occurs at the edge of the 7/8 inch central oil hole, in the articulated l pin bore, with Von Mises values of 18.4 ksi for the assemoly case and 23 9 ksi I for the master rod inertia plus assemoly case. Figures 14 and 15 snow an enlarged view of the smaller oil holes in this model, with the stress contouring range reduced to provide better resolution in that area. The g maximum stresses occur at the intersection of the small central hole and the E transverse hole, with values slightly less than 12.0 for botn load cases. I I I
Page Four February 26, 1990
- I Figures 16,17, and 18 ksi show the results on the section rodel with the small
_1 central oil hole drilled to within 1/16 inch of the surface. The maximum values occur at the larger oil hole, and are similar to the previous case. The third run, with the articulated rod force added, shows slightly lower maximum
,g values. Figures 19, 20, and 21 show an enlarged view of the smaller oil holes-3- in this model, with the reduced stress contouring ranges. At the intersection of the radial and transverse oil holes the maximum principal stresses in this model are 17 3 ksi for the assembly load case, and 20.0 ksi for the master rod I inertia plus assembly load. Addition of the articulated rod force reduces the stress at this point. The addition of the articulated rod load increases the maximum stress near the drill tip slightly.
I. The three nodes near the drill tip with the largest stress values, with articulated rod force included, were selected for failure analysis, with the following results (See Figures 21 A, 21B, and 21C for node locations): I. Maximum Principal Stresses - ksi. Node Assembly Maximum Mean Amplitude CFF 641 3.17 16.30 9.74 6.57 3 31 278 3 82 18.70 11.26 7 74 2.83 277 3 85 17 30 10 58 6.73 3,16 II. -Von Mises Stresses - kai. Node Assembly Maximum Mean Amplitude CFF 641 3 26 16.90 10.08 6.82 3 19 278 3 28 17.00 10.14 6.86 3 17
; 277 3.72 17.20 10.46 6.76 3 17 The 18.70 Kai maximum stress value, when compared to the average nominal value
.g of 7.74 ksi frm the full rod model, indicates a stress concentration factor of l 2.42.
Figures 22, 23, and 24 show the results on the section model with the drill tip just breaking through the surface of the articulated pin bore. Figures 25, 26, and 27 show the results for the most highly stressed node at the " break-through" point. The minimum cyclic failure factor at this node is 3 03 based on the maximum principal stress, with articulated rod force included. Figure 28 shows the lowest CFF values plotted on a Modified Goodman diagram. Figures 29, 30, and 31 show the results of the small section submodel study used to determine effective stress concentration factors. Figure 33 shows the ncxninal stress in the undrilled model at the node closest to the maximum stress point on the two drilled models, while figures 34 and 35 show those maximum
'I ' stress nodes in the crilled models. In all cases the minimum principal stress is the significant value, since the model is loaded in ecxnpression.
_Page Five February 26, 1990 ^ The stress concentration factors predicted by these submodels are: Submodel Principal Stress SCF
-psi Without hole -35200 ---
1/16 inch ligament -84700 2.41 Hole broken through -160000 4 55
- I-.
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Discussion of Results
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The stress results from the full rod model (Figures 6 through 9) are very similar to those obtained from a two dimensional finite elment model of this same rod as shown in Report AM-1852-C, February 4, 1987. The differences in
-g maximum stress level between the full width section model in Figure 12 and the
^g narrower model in Figure 13 are minor, and the stresses in the articulated pin bore of the narrow section model, Figure 13, away from the oil hole, are similar to those in the full rod model for the same loading condition. All of
>a
.g these factors tend to validate the assumptions made in arriving at the final-section models.
The maximum stresses in all of tM section models occur at the junction of the 7/8 inch central oil hole and the articulated pin bore. These stresses are somewhat' conservative, since the model has a sharp corner at this point, while the actual part is radiused. The cyclic failure factor at this point is 2.71 I based on maximum principal stresses.
- g. When the small central oil hole is 5/16 inch from the surface, the highest
~g stresses in that region are at the intersection of this hole with the transverse oil hole, rather than at the drill tip.- The stresses at the hole intersection are quite moderate, with cyclic failure factors greater than 4.0.
I With the hole tip 1/16 . inch from the surface the stresses in the thin ligament at the drill tip increase, but they are still less than the values at the 7/8 inch oil hole. The results with the articulated rod downward load added to the master rod inertia load are conservative, since the load was applied to the
.I entire surface of the model, while the actual part has a slot in the articulated' pin bushing at the oil holes. The 1/16 inch value was chosen for
. g' the analysis since this was the closest the drill point could credibly ccne to g the surface without being noticed by the machinist and the inspector. If the drill point were less than 1/16 inch frcm the surface it would tend to create a
" blister" in the articulated pin bore.
The original results with the drill tip breaking through the surface (Figure 4A model) indicated lower stresses, and thus a higher cyclic failure factor, than the "1/16 ligament case", assuming the " break-through" is smooth with no torn or cracked edges. This case does not truly represent the failed rod however, since the mesh is not fine enough to model the reenterant corner. The case with the hole drilled completely through and radiused was not run, but the
.I above results indicate the stresses would be lower than the "1/16 ligament case". This hole then becomes identical to the two holes near the cutside of the rod, and experience over the entire design life of the KSV engine indicates the stresses at that point are acceptable.
I
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Paga Six February 26, 1990 L The stress concentration factor for the "1/16 ligament case", calculated from the small section submodel results, is in good agreement with the data
.. I from the larger section model. The results from the small section submodel representing the " break-through" case indicate the stresses are 1.89 times those of the "1/16 ligament case". This would imply a cyclic failure factor of 1.50 for the " break-through" case. This low CFF value, in cmbination with the ,
observed machining cracks at the break through point, would certainly explain ' the failure of the connecting rod at the South Texas Project. A finer finite I element mesh might shown an even higher geometric stress concentration factor at this point. All of the stress results are based on normal engine operation at 600 rpm. On-rare occasions during engine testing, the speed could approach the overspeed shutdown setting of 660 rpm. The engine load would be nearly ::ero under this
-E. condition, but inertia forces woule increase in proportion to the sq,re of the 3 speed. For the "1/16" ligament model at node 278, this would tend to produce a mean stress of 12.44 ksi and an amplitude of 9 37 ksi, for a CFF of 2.42.
~his is conservative, since the downward load component frm the articulated
'I rod pin would actually be much lower under this condition.
All of the calculated cyclic failure factors for this rod are well above.the ! I normal design valve of 2.0, except for the rod which failed at the South Texas Project. 1 Conclusion Any of the KSV-4-2A connecting rods which have the central 3/8 inch lubricating
. oil hole drilled past the transverse oil hole, but not through the surface of the articulated pin bore, will have a minimum cyclic failure factor of 2.83 near the tip of the hole, under normal operating conditions. The CFF will be-I greater than 2.42 under the worst credible operating condition (overspeed trip setting). Rods which have the hole drilled through and radiused will have a higher CFF. Thus all of these rods presently installed in KSV engines are safe for continued operation, g
wh John M. Horne, Manager Analytical and Compressor Engineering JMH/sas Attach. I I
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;UIT ' UNDO 5ACKUP :WMDCDPY : GRID ' AXIS ~UIEWPORT SETUP !CAI.C MEASUREiINFO WINDOW 1
l l NODE 277 - STRESS FESULTS l I r- , - .yp l
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i i OPEN SETUP ~ DT5 PLAY l FEM INFO MERI _ PICK ' STRESSES AT NODE 205 RESULT E. INTO-] 54 0-0.00 G EMIEE I
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. WINDOW I Blind hole broken thru into bore l
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4 1 k:) 43, y ( Command: E I _.Q UIT!UNDOiBACKUP:H ARDCOP Y ! GR ID i AXIS lUIEWPORT [5ETUP 1C ALC ! MEASURE! INFO WINDOW KSU-4-2A POWER PISTON ROD Without holes l l I t hDu t " D l t! TO s1 n wt ne l
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I Command: E OUIT; UNDO!EACKUP TARDCOPY GRID AXIS;UIEWPORT;5ETUP~ CALC MEASURE; INFO _ WINDOW MSU-4-2A POWER PISTON R0D Bland hole within 1/16 of bore I . . q , p ,; , ne I l l
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l Command:
. QUIT!UND0!EACKUP HARDCOPY: GRID: AXIS ;UIEWFORTISETUP !C ALC MEASURE! INFO . WINDOW 6(SU-4-2A POWER P!STON ROD Blind hole broken thru into bere
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