Analysis of Fatigue Cracks of Diesel Engines Cylinder Heads using a Two-Layer Viscoplasticity Model and Considering Viscousity Effects

Loading conditions and complex geometry have led the cylinder heads to become the most challenging parts of diesel engines. One of the most important durability problems in diesel engines is due to the cracks valves bridge area. The purpose of this study is a thermo-mechanical analysis of cylinder heads of diesel engines using a two-layer viscoplasticity model. The results of the thermo-mechanical analysis indicate that the maximum temperature and stress exist in the valves bridge. The results of the finite element analysis correspond with the experimental tests, carried out in references, and illustrate the cylinder heads cracked in this region. The results of the thermo-mechanical analysis show that when the engine is running the stress in the region is compressive caused by the thermal loading and combustion pressure. When the engine shuts off the compressive stress turns into the tensile stress because of assembly loads. The valves bridge is under the cyclic tensile and compressive stress and then is under low-cycle fatigue. After several cycles the fatigue cracks will appear in this region. The lifetime of this part can be determined through finite element analysis instead of experimental tests. Viscous strain is more than the plastic strain which is not negligible.