Engine Flywheel failure avoidance through CAE optimization

Paper #:
  • 2017-01-1024

Published:
  • 2017-03-28
Abstract:
ABSTRACT Engine flywheel is subjected to combined thermal and inertial loads. The combined thermal and inertial load is too complex to understand without good CAE. During development, our engine flywheel had crack near its periphery in vehicle clutch slippage conditions. Attempt is made to understand the failure mechanism and propose design change through CAE. For a flywheel typical failure like crack is very critical for vehicle and occupant safety. On CAE simulation, it is understood that balancing hole specification is critical to crack initiation. It is proposed to change balancing hole dimensions to achieve the required level of performance over time. This activity also has an added advantage of reduced development cost and time which have an heightened emphasis due to globalization and expansion of automotive OEMs in their product line, so that they may participate and compete in lower priced niche markets. It has been observed that the outcomes in CAE are correlated well in physical experiments. Key learning: 1. Balancing hole have immense role in crack initiation 2. Stress continuity (in addition to stress values) is important 3. In a Vehicle, clutch slippage condition tends to increase the thermal stress due to increased thermal loads over the flywheel which eventually is reduced due to spinning
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