INTEGRITY ASSESSMENT OF AN AIRCRAFT CYLINDER ASSEMBLY WITH A CRACK
Keywords:
crack, aircraft cylinder head, stress intensity factor, integrity assessment
Abstract
The repeatability of the air-cooled piston engine cylinder assembly failure due to a crack in the cylinder head, as well as its severity from the aspect of crew and passenger safety were the main motives for our research. In this paper an integrity assessment of a cylinder assembly with a crack was performed. By modeling cracks of different lengths in the cylinder head and considering the values of stress intensity factors and J-integral values at a given crack length on the one hand and determining the critical values of these fracture mechanics parameters on the other hand, the stability of the crack was examined. As part of the research, the dependence of the crack length on the stress intensity factor was established. The methodology proposed in this paper can be adapted to assess the integrity of other similar structural elements.
References
[1] B. Krstić, B. Rašuo, D. Trifković, I. Radisavljević, Z. Rajić, M. Dinulović, Failure analysis of an aircraft engine cylinder head, Engineering failure analysis, 32 (2013), 1-15, doi: https://doi.org/10.1016/j.engfailanal.2013.03.004
[2] M. Azadi, A. Mafi, M. Roozban, F. Moghaddam, Failure Analysis of a Cracked Gasoline Engine Cylinder Head, Journal of Failure Analysis and Prevention, 12 (2012) 3, 286-294, doi: https://doi.org/10.1007/s11668-012-9560-6
[3] P.M. Tripathi, S. Prakash, R. Singh, K.S. Dwivedi, The Finite Element Analysis and Improvement on a Single Cylinder Head of Spark Ignition Engine, International Journal of Engineering and Science, 4 (2014), 20-26, doi:07.4721/044020026
[4] T. Takahashi, K. Sasaki, Low cycle fatigue of aluminum alloy cylinder head in consideration if changing metrology microstructure, Procedia Engineering, 2 (2010), 767-776, doi: https://doi.org/10.1016/j.proeng.2010.03.083
[5] https://www.faa.gov/regulations_policies/airworthiness_directives/search/?q=2008&makeModel=&type=Current&filter=&sort=effectiveDate&direction=asc, 15.12.2021.
[6] https://www.ntsb.gov/_layouts/ntsb.recsearch/Recommendation.aspx?Rec=A-12-007, accessed on 15.12.2021.
[7] M. Chafi, A. Boulenouar, A numerical modelling of mixed mode crack initiation and growth in functionally graded materials, Materials Research, 22 (2019), 1-10, doi: http://dx.doi.org/10.1590/1980-5373-mr-2018-0701
[8] G. Jovicic, M. Zivkovic, N. Jovicic, D. Milovanovic, Improvement of algorithm for numerical crack modelling, Archives of Civil and Mechanical Engineering, 10 (2010), 19-35, doi: https://doi.org/10.1016/S1644-9665(12)60134-4
[9] T. Fujimoto, T. Nishioka, Experimental and numerical study for crack propagation in Aluminum alloy A2024-T351, Materials Science and Engineering, 10 (2010), 1-10, doi: 10.1088/1757-899X/10/1/012055
[10] A.F. Golestaneh, A. Ali, M. Bayat, Analytical and numerical investigation of fatigue crack growth in Aluminum alloy, Key Engineering Materials, 462-463 (2011), 1050-1055, doi: 10.4028/www.scientific.net/KEM.462-463.1050
[11] M. Zych, Thermal cracking of the cylindrical tank under construction. II: Early age cracking, Journal of Performance of Constructed Facilities, 29 (2014), 1-10, doi: https://doi.org/10.1061/(ASCE)CF.1943-5509.0000577
[12] T. Seiichiro, S. Moe, F. Riccardo, Prediction of fatigue crack initiation life of Aluminium alloy joints using cyclic elasto-plasticity FEM analysis, MATEC Web of Conferences, 165 (2018), 1-6, doi: https://doi.org/10.1051/matecconf/201816514012
[13] S. Sajith, K.S.R.K. Murthy, P.S. Robi, Experimental and numerical investigation of mixed mode fatigue crack growth models in Aluminum 6061-T6, International Journal of Fatigue, 130 (2020), 1-15, doi: https://doi.org/10.1016/j.ijfatigue.2019.105285
[14] N. Vučetić, G. Jovičić, B. Krstić, M. Živković, V. Milovanović, J. Kačmarčik, R. Antunović, Further investigation of the repetitive failure in an aircraft engine cylinder head - Mechanical properties of Aluminum alloy 242.0, MECHANIKA, 26 (2020) 4, 285-292 , doi: https://doi.org/10.5755/j01.mech.26.4.24556
[15] N. Vučetić, G. Jovičić, B. Krstić, M. Živković, V. Milovanović, J. Kačmarčik, R. Antunović, Research of an aircraft engine cylinder assembly integrity assessment - Thermomechanical FEM analysis, Engineering Failure Analysis, 111C (2020), doi: https://doi.org/10.1016/j.engfailanal.2020.104453
[16] Z. Xian-Kui, A.J. James, Review of fracture toughness (G, K, J, CTOD, CTOA) testing and standardization, Engineering Fracture Mechanics, 85 (2012), 1-46, doi: https://doi.org/10.1016/j.engfracmech.2012.02.001
[17] N. Vučetić, Development of methodology for integrity assessment of air-cooled aircraft piston engine exposed to high-cyclic mechanical and thermal load, PhD Thesis, Kragujevac 2020.
[18] ASTM: E399-12, Standard Test Method for Linear-Elastic Plane-Strain Fracture Toughness KIC of Metallic Materials, Baltimore 2013.
[19] I. Al Emran, J. Saifulnizan, K. KamarulAzhar, M.N. Mohd Khir, I. Mohd Norihan, C. Moch. Agus, An overview of fracture Mechanics with Ansys, International Journal of Integrated Engineering: Mechanical Engineering, 10 (2018) 5, 59-67, doi: 10.30880/ijie.2018.10.05.010
[20] M. Chafi, A. Boulenouar, A numerical modelling of mixed mode crack initiation and growth in functionally graded materials, Materials Research, 22 (2019) 3, 1-10, doi: https://doi.org/10.1590/1980-5373-MR-2018-0701
[21] N. Gupta, P. Pachauri, An experimental and computational investigation of crack growth initiation in compact tension (CT) specimen, International Journal of Scientific and Research Publications, 2 (2012), 1-7
[22] T. Fujimoto, T. Nishioka, Experimental and numerical study for crack propagation in Aluminum alloy A2024-T351, Materials Science and Engineering, 10 (2010), 1-10, doi: 10.1088/1757-899X/10/1/012055
[23] M. Zych, Thermal cracking of the cylindrical tank under construction. II: Early age cracking, Journal of Performance of Constructed Facilities, 29 (2014), 1-10, doi: https://doi.org/10.1061/(ASCE)CF.1943-5509.0000577
[24] S. Jiang, J. Xu, Calculation and analysis of J-integral using Ansys, Applied Mechanics and Materials, 602-605 (2014), 536-538, doi: https://doi.org/10.4028/www.scientific.net/AMM.602-605.536
[25] M. Heidarvand, N. Soltani, F. Hajializadeh, Experimental and numerical determination of critical stress intensity factor of Aluminum curved thin sheets under tensile stress, Journal of Mechanical Science and Technology, 31 (2017), 2185-2195, doi: 10.1007/s12206-017-0414-8
[2] M. Azadi, A. Mafi, M. Roozban, F. Moghaddam, Failure Analysis of a Cracked Gasoline Engine Cylinder Head, Journal of Failure Analysis and Prevention, 12 (2012) 3, 286-294, doi: https://doi.org/10.1007/s11668-012-9560-6
[3] P.M. Tripathi, S. Prakash, R. Singh, K.S. Dwivedi, The Finite Element Analysis and Improvement on a Single Cylinder Head of Spark Ignition Engine, International Journal of Engineering and Science, 4 (2014), 20-26, doi:07.4721/044020026
[4] T. Takahashi, K. Sasaki, Low cycle fatigue of aluminum alloy cylinder head in consideration if changing metrology microstructure, Procedia Engineering, 2 (2010), 767-776, doi: https://doi.org/10.1016/j.proeng.2010.03.083
[5] https://www.faa.gov/regulations_policies/airworthiness_directives/search/?q=2008&makeModel=&type=Current&filter=&sort=effectiveDate&direction=asc, 15.12.2021.
[6] https://www.ntsb.gov/_layouts/ntsb.recsearch/Recommendation.aspx?Rec=A-12-007, accessed on 15.12.2021.
[7] M. Chafi, A. Boulenouar, A numerical modelling of mixed mode crack initiation and growth in functionally graded materials, Materials Research, 22 (2019), 1-10, doi: http://dx.doi.org/10.1590/1980-5373-mr-2018-0701
[8] G. Jovicic, M. Zivkovic, N. Jovicic, D. Milovanovic, Improvement of algorithm for numerical crack modelling, Archives of Civil and Mechanical Engineering, 10 (2010), 19-35, doi: https://doi.org/10.1016/S1644-9665(12)60134-4
[9] T. Fujimoto, T. Nishioka, Experimental and numerical study for crack propagation in Aluminum alloy A2024-T351, Materials Science and Engineering, 10 (2010), 1-10, doi: 10.1088/1757-899X/10/1/012055
[10] A.F. Golestaneh, A. Ali, M. Bayat, Analytical and numerical investigation of fatigue crack growth in Aluminum alloy, Key Engineering Materials, 462-463 (2011), 1050-1055, doi: 10.4028/www.scientific.net/KEM.462-463.1050
[11] M. Zych, Thermal cracking of the cylindrical tank under construction. II: Early age cracking, Journal of Performance of Constructed Facilities, 29 (2014), 1-10, doi: https://doi.org/10.1061/(ASCE)CF.1943-5509.0000577
[12] T. Seiichiro, S. Moe, F. Riccardo, Prediction of fatigue crack initiation life of Aluminium alloy joints using cyclic elasto-plasticity FEM analysis, MATEC Web of Conferences, 165 (2018), 1-6, doi: https://doi.org/10.1051/matecconf/201816514012
[13] S. Sajith, K.S.R.K. Murthy, P.S. Robi, Experimental and numerical investigation of mixed mode fatigue crack growth models in Aluminum 6061-T6, International Journal of Fatigue, 130 (2020), 1-15, doi: https://doi.org/10.1016/j.ijfatigue.2019.105285
[14] N. Vučetić, G. Jovičić, B. Krstić, M. Živković, V. Milovanović, J. Kačmarčik, R. Antunović, Further investigation of the repetitive failure in an aircraft engine cylinder head - Mechanical properties of Aluminum alloy 242.0, MECHANIKA, 26 (2020) 4, 285-292 , doi: https://doi.org/10.5755/j01.mech.26.4.24556
[15] N. Vučetić, G. Jovičić, B. Krstić, M. Živković, V. Milovanović, J. Kačmarčik, R. Antunović, Research of an aircraft engine cylinder assembly integrity assessment - Thermomechanical FEM analysis, Engineering Failure Analysis, 111C (2020), doi: https://doi.org/10.1016/j.engfailanal.2020.104453
[16] Z. Xian-Kui, A.J. James, Review of fracture toughness (G, K, J, CTOD, CTOA) testing and standardization, Engineering Fracture Mechanics, 85 (2012), 1-46, doi: https://doi.org/10.1016/j.engfracmech.2012.02.001
[17] N. Vučetić, Development of methodology for integrity assessment of air-cooled aircraft piston engine exposed to high-cyclic mechanical and thermal load, PhD Thesis, Kragujevac 2020.
[18] ASTM: E399-12, Standard Test Method for Linear-Elastic Plane-Strain Fracture Toughness KIC of Metallic Materials, Baltimore 2013.
[19] I. Al Emran, J. Saifulnizan, K. KamarulAzhar, M.N. Mohd Khir, I. Mohd Norihan, C. Moch. Agus, An overview of fracture Mechanics with Ansys, International Journal of Integrated Engineering: Mechanical Engineering, 10 (2018) 5, 59-67, doi: 10.30880/ijie.2018.10.05.010
[20] M. Chafi, A. Boulenouar, A numerical modelling of mixed mode crack initiation and growth in functionally graded materials, Materials Research, 22 (2019) 3, 1-10, doi: https://doi.org/10.1590/1980-5373-MR-2018-0701
[21] N. Gupta, P. Pachauri, An experimental and computational investigation of crack growth initiation in compact tension (CT) specimen, International Journal of Scientific and Research Publications, 2 (2012), 1-7
[22] T. Fujimoto, T. Nishioka, Experimental and numerical study for crack propagation in Aluminum alloy A2024-T351, Materials Science and Engineering, 10 (2010), 1-10, doi: 10.1088/1757-899X/10/1/012055
[23] M. Zych, Thermal cracking of the cylindrical tank under construction. II: Early age cracking, Journal of Performance of Constructed Facilities, 29 (2014), 1-10, doi: https://doi.org/10.1061/(ASCE)CF.1943-5509.0000577
[24] S. Jiang, J. Xu, Calculation and analysis of J-integral using Ansys, Applied Mechanics and Materials, 602-605 (2014), 536-538, doi: https://doi.org/10.4028/www.scientific.net/AMM.602-605.536
[25] M. Heidarvand, N. Soltani, F. Hajializadeh, Experimental and numerical determination of critical stress intensity factor of Aluminum curved thin sheets under tensile stress, Journal of Mechanical Science and Technology, 31 (2017), 2185-2195, doi: 10.1007/s12206-017-0414-8
Published
2022-08-17
How to Cite
1.
Vučetić N, Jovičić G, Antunović R, Sovilj-NikićS, Košarac A, Jeremić D. INTEGRITY ASSESSMENT OF AN AIRCRAFT CYLINDER ASSEMBLY WITH A CRACK. MatTech [Internet]. 2022Aug.17 [cited 2025Jun.15];56(4):389–396. Available from: https://mater-tehnol.si/index.php/MatTech/article/view/430
Section
Articles
