Machining Quality Analysis of an Engine Cylinder Head Using Finite Element Methods
Structural analysis is routinely used to design parts but less frequently used to design manufacturing processes. Structural analysis should be used in process design for many parts because loads experienced during manufacture exceed service loads. Application of these analyses has been limited due...
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| Veröffentlicht in: | Journal of manufacturing processes 2003, Vol.5 (2), p.170-184 |
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| creator | Xie, Jeffrey Q. Agapiou, John S. Stephenson, David A. Hilber, Patrick |
| description | Structural analysis is routinely used to design parts but less frequently used to design manufacturing processes. Structural analysis should be used in process design for many parts because loads experienced during manufacture exceed service loads. Application of these analyses has been limited due to lack of validation results for realistically complex parts against extensive sets of data.
This paper describes structural analysis results for the manufacture of an aluminum engine cylinder head. Three specific error sources are modeled using finite element analysis (FEA): (1) cylinder head deckface distortion due to clamping forces, (2) deckface (or part) distortion due to a pressing in of seats and guides, and (3) seat and guide distortion due to clamping forces. A compliant fixture and contact-based boundary conditions are used for the clamping analysis using ABAQUS/Standard for the FEA modeling. The valve seat and guide insertion is modeled as a shrink-fit operation using the contact-pair approach, which greatly simplifies the numerical problem with satisfactory precision. The roundness and concentricity are computed for a variety of press-fit interference conditions covering the range of variation expected within the tolerance bands of the powder metal inserts and the pre-bored holes. Computed results from all studies agree well with direct CMM measurements and laboratory validation data. |
| doi_str_mv | 10.1016/S1526-6125(03)70052-8 |
| format | Article |
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This paper describes structural analysis results for the manufacture of an aluminum engine cylinder head. Three specific error sources are modeled using finite element analysis (FEA): (1) cylinder head deckface distortion due to clamping forces, (2) deckface (or part) distortion due to a pressing in of seats and guides, and (3) seat and guide distortion due to clamping forces. A compliant fixture and contact-based boundary conditions are used for the clamping analysis using ABAQUS/Standard for the FEA modeling. The valve seat and guide insertion is modeled as a shrink-fit operation using the contact-pair approach, which greatly simplifies the numerical problem with satisfactory precision. The roundness and concentricity are computed for a variety of press-fit interference conditions covering the range of variation expected within the tolerance bands of the powder metal inserts and the pre-bored holes. Computed results from all studies agree well with direct CMM measurements and laboratory validation data.</description><identifier>ISSN: 1526-6125</identifier><identifier>EISSN: 2212-4616</identifier><identifier>DOI: 10.1016/S1526-6125(03)70052-8</identifier><language>eng</language><publisher>Oxford: Elsevier Ltd</publisher><subject>Accuracy ; Aluminum ; Aluminum Engine ; Applied sciences ; Boundary conditions ; Deformation ; Distortion ; Engine Cylinder Head ; Engines ; Exact sciences and technology ; FEA (Finite Element Analysis) ; Finite element analysis ; Fixtures ; Laboratories ; Machinery ; Machining Quality ; Manufacturing ; Mathematical models ; Mechanical engineering. Machine design ; Process Design ; Process planning ; Production management ; Quality control ; Simulation ; Structural Analysis ; Studies</subject><ispartof>Journal of manufacturing processes, 2003, Vol.5 (2), p.170-184</ispartof><rights>2003 Society of Manufacturing Engineers</rights><rights>2004 INIST-CNRS</rights><rights>Copyright Society of Manufacturing Engineers 2003</rights><lds50>peer_reviewed</lds50><woscitedreferencessubscribed>false</woscitedreferencessubscribed><citedby>FETCH-LOGICAL-c279t-76efaec05a1ef656efc68e00f75bf7509d505e4e65acc58f284779384c2476ca3</citedby><cites>FETCH-LOGICAL-c279t-76efaec05a1ef656efc68e00f75bf7509d505e4e65acc58f284779384c2476ca3</cites></display><links><openurl>$$Topenurl_article</openurl><openurlfulltext>$$Topenurlfull_article</openurlfulltext><thumbnail>$$Tsyndetics_thumb_exl</thumbnail><linktohtml>$$Uhttps://www.sciencedirect.com/science/article/pii/S1526612503700528$$EHTML$$P50$$Gelsevier$$H</linktohtml><link.rule.ids>314,776,780,3537,4010,27900,27901,27902,65306</link.rule.ids><backlink>$$Uhttp://pascal-francis.inist.fr/vibad/index.php?action=getRecordDetail&idt=15459563$$DView record in Pascal Francis$$Hfree_for_read</backlink></links><search><creatorcontrib>Xie, Jeffrey Q.</creatorcontrib><creatorcontrib>Agapiou, John S.</creatorcontrib><creatorcontrib>Stephenson, David A.</creatorcontrib><creatorcontrib>Hilber, Patrick</creatorcontrib><title>Machining Quality Analysis of an Engine Cylinder Head Using Finite Element Methods</title><title>Journal of manufacturing processes</title><description>Structural analysis is routinely used to design parts but less frequently used to design manufacturing processes. Structural analysis should be used in process design for many parts because loads experienced during manufacture exceed service loads. Application of these analyses has been limited due to lack of validation results for realistically complex parts against extensive sets of data.
This paper describes structural analysis results for the manufacture of an aluminum engine cylinder head. Three specific error sources are modeled using finite element analysis (FEA): (1) cylinder head deckface distortion due to clamping forces, (2) deckface (or part) distortion due to a pressing in of seats and guides, and (3) seat and guide distortion due to clamping forces. A compliant fixture and contact-based boundary conditions are used for the clamping analysis using ABAQUS/Standard for the FEA modeling. The valve seat and guide insertion is modeled as a shrink-fit operation using the contact-pair approach, which greatly simplifies the numerical problem with satisfactory precision. The roundness and concentricity are computed for a variety of press-fit interference conditions covering the range of variation expected within the tolerance bands of the powder metal inserts and the pre-bored holes. Computed results from all studies agree well with direct CMM measurements and laboratory validation data.</description><subject>Accuracy</subject><subject>Aluminum</subject><subject>Aluminum Engine</subject><subject>Applied sciences</subject><subject>Boundary conditions</subject><subject>Deformation</subject><subject>Distortion</subject><subject>Engine Cylinder Head</subject><subject>Engines</subject><subject>Exact sciences and technology</subject><subject>FEA (Finite Element Analysis)</subject><subject>Finite element analysis</subject><subject>Fixtures</subject><subject>Laboratories</subject><subject>Machinery</subject><subject>Machining Quality</subject><subject>Manufacturing</subject><subject>Mathematical models</subject><subject>Mechanical engineering. Machine design</subject><subject>Process Design</subject><subject>Process planning</subject><subject>Production management</subject><subject>Quality control</subject><subject>Simulation</subject><subject>Structural Analysis</subject><subject>Studies</subject><issn>1526-6125</issn><issn>2212-4616</issn><fulltext>true</fulltext><rsrctype>article</rsrctype><creationdate>2003</creationdate><recordtype>article</recordtype><sourceid>BENPR</sourceid><recordid>eNqFkFtLAzEQhYMoWKs_QQiCoA-rSTbJ7j6JlNYKLeKlzyFmJ23KNluTrbD_3u0FffRhGAa-c2bmIHRJyR0lVN6_U8FkIikTNyS9zQgRLMmPUI8xyhIuqTxGvV_kFJ3FuCSEMk5oD71NtVk47_wcv2505ZoWP3pdtdFFXFusPR76ufOAB23lfAkBj0GXeBa3ilEnbAAPK1iBb_AUmkVdxnN0YnUV4eLQ-2g2Gn4Mxsnk5el58DhJDMuKJskkWA2GCE3BStFNRuZAiM3EZ1ekKAURwEEKbYzILct5lhVpzg3jmTQ67aOrve861F8biI1a1pvQHR8VLQTjqcxYB4k9ZEIdYwCr1sGtdGgVJWqbntqlp7bRKJKqXXoq73TXB3Mdja5s0N64-CcWXBRCph33sOeg-_TbQVDROPAGShfANKqs3T-bfgD9QIK9</recordid><startdate>2003</startdate><enddate>2003</enddate><creator>Xie, Jeffrey Q.</creator><creator>Agapiou, John S.</creator><creator>Stephenson, David A.</creator><creator>Hilber, Patrick</creator><general>Elsevier Ltd</general><general>Elsevier</general><general>Society of Mechanical Engineers</general><general>SME</general><scope>IQODW</scope><scope>AAYXX</scope><scope>CITATION</scope><scope>3V.</scope><scope>7WY</scope><scope>7WZ</scope><scope>7XB</scope><scope>87Z</scope><scope>883</scope><scope>88I</scope><scope>8AO</scope><scope>8FE</scope><scope>8FG</scope><scope>8FK</scope><scope>8FL</scope><scope>ABJCF</scope><scope>ABUWG</scope><scope>AFKRA</scope><scope>AZQEC</scope><scope>BENPR</scope><scope>BEZIV</scope><scope>BGLVJ</scope><scope>CCPQU</scope><scope>DWQXO</scope><scope>FRNLG</scope><scope>F~G</scope><scope>GNUQQ</scope><scope>HCIFZ</scope><scope>K60</scope><scope>K6~</scope><scope>L.-</scope><scope>L6V</scope><scope>M0C</scope><scope>M0F</scope><scope>M2P</scope><scope>M7S</scope><scope>PQBIZ</scope><scope>PQBZA</scope><scope>PQEST</scope><scope>PQQKQ</scope><scope>PQUKI</scope><scope>PRINS</scope><scope>PTHSS</scope><scope>PYYUZ</scope><scope>Q9U</scope><scope>S0X</scope></search><sort><creationdate>2003</creationdate><title>Machining Quality Analysis of an Engine Cylinder Head Using Finite Element Methods</title><author>Xie, Jeffrey Q. ; Agapiou, John S. ; Stephenson, David A. ; Hilber, Patrick</author></sort><facets><frbrtype>5</frbrtype><frbrgroupid>cdi_FETCH-LOGICAL-c279t-76efaec05a1ef656efc68e00f75bf7509d505e4e65acc58f284779384c2476ca3</frbrgroupid><rsrctype>articles</rsrctype><prefilter>articles</prefilter><language>eng</language><creationdate>2003</creationdate><topic>Accuracy</topic><topic>Aluminum</topic><topic>Aluminum Engine</topic><topic>Applied sciences</topic><topic>Boundary conditions</topic><topic>Deformation</topic><topic>Distortion</topic><topic>Engine Cylinder Head</topic><topic>Engines</topic><topic>Exact sciences and technology</topic><topic>FEA (Finite Element Analysis)</topic><topic>Finite element analysis</topic><topic>Fixtures</topic><topic>Laboratories</topic><topic>Machinery</topic><topic>Machining Quality</topic><topic>Manufacturing</topic><topic>Mathematical models</topic><topic>Mechanical engineering. Machine design</topic><topic>Process Design</topic><topic>Process planning</topic><topic>Production management</topic><topic>Quality control</topic><topic>Simulation</topic><topic>Structural Analysis</topic><topic>Studies</topic><toplevel>peer_reviewed</toplevel><toplevel>online_resources</toplevel><creatorcontrib>Xie, Jeffrey Q.</creatorcontrib><creatorcontrib>Agapiou, John S.</creatorcontrib><creatorcontrib>Stephenson, David A.</creatorcontrib><creatorcontrib>Hilber, Patrick</creatorcontrib><collection>Pascal-Francis</collection><collection>CrossRef</collection><collection>ProQuest Central (Corporate)</collection><collection>ABI/INFORM Collection</collection><collection>ABI/INFORM Global (PDF only)</collection><collection>ProQuest Central (purchase pre-March 2016)</collection><collection>ABI/INFORM Global (Alumni Edition)</collection><collection>ABI/INFORM Trade & Industry (Alumni Edition)</collection><collection>Science Database (Alumni Edition)</collection><collection>ProQuest Pharma Collection</collection><collection>ProQuest SciTech Collection</collection><collection>ProQuest Technology Collection</collection><collection>ProQuest Central (Alumni) (purchase pre-March 2016)</collection><collection>ABI/INFORM Collection (Alumni Edition)</collection><collection>Materials Science & Engineering Collection</collection><collection>ProQuest Central (Alumni Edition)</collection><collection>ProQuest Central UK/Ireland</collection><collection>ProQuest Central Essentials</collection><collection>ProQuest Central</collection><collection>Business Premium Collection</collection><collection>Technology Collection</collection><collection>ProQuest One Community College</collection><collection>ProQuest Central Korea</collection><collection>Business Premium Collection (Alumni)</collection><collection>ABI/INFORM Global (Corporate)</collection><collection>ProQuest Central Student</collection><collection>SciTech Premium Collection</collection><collection>ProQuest Business Collection (Alumni Edition)</collection><collection>ProQuest Business Collection</collection><collection>ABI/INFORM Professional Advanced</collection><collection>ProQuest Engineering Collection</collection><collection>ABI/INFORM Global</collection><collection>ABI/INFORM Trade & Industry</collection><collection>Science Database</collection><collection>Engineering Database</collection><collection>One Business (ProQuest)</collection><collection>ProQuest One Business (Alumni)</collection><collection>ProQuest One Academic Eastern Edition (DO NOT USE)</collection><collection>ProQuest One Academic</collection><collection>ProQuest One Academic UKI Edition</collection><collection>ProQuest Central China</collection><collection>Engineering Collection</collection><collection>ABI/INFORM Collection China</collection><collection>ProQuest Central Basic</collection><collection>SIRS Editorial</collection><jtitle>Journal of manufacturing processes</jtitle></facets><delivery><delcategory>Remote Search Resource</delcategory><fulltext>fulltext</fulltext></delivery><addata><au>Xie, Jeffrey Q.</au><au>Agapiou, John S.</au><au>Stephenson, David A.</au><au>Hilber, Patrick</au><format>journal</format><genre>article</genre><ristype>JOUR</ristype><atitle>Machining Quality Analysis of an Engine Cylinder Head Using Finite Element Methods</atitle><jtitle>Journal of manufacturing processes</jtitle><date>2003</date><risdate>2003</risdate><volume>5</volume><issue>2</issue><spage>170</spage><epage>184</epage><pages>170-184</pages><issn>1526-6125</issn><eissn>2212-4616</eissn><abstract>Structural analysis is routinely used to design parts but less frequently used to design manufacturing processes. Structural analysis should be used in process design for many parts because loads experienced during manufacture exceed service loads. Application of these analyses has been limited due to lack of validation results for realistically complex parts against extensive sets of data.
This paper describes structural analysis results for the manufacture of an aluminum engine cylinder head. Three specific error sources are modeled using finite element analysis (FEA): (1) cylinder head deckface distortion due to clamping forces, (2) deckface (or part) distortion due to a pressing in of seats and guides, and (3) seat and guide distortion due to clamping forces. A compliant fixture and contact-based boundary conditions are used for the clamping analysis using ABAQUS/Standard for the FEA modeling. The valve seat and guide insertion is modeled as a shrink-fit operation using the contact-pair approach, which greatly simplifies the numerical problem with satisfactory precision. The roundness and concentricity are computed for a variety of press-fit interference conditions covering the range of variation expected within the tolerance bands of the powder metal inserts and the pre-bored holes. Computed results from all studies agree well with direct CMM measurements and laboratory validation data.</abstract><cop>Oxford</cop><cop>Dearborn, MI</cop><pub>Elsevier Ltd</pub><doi>10.1016/S1526-6125(03)70052-8</doi><tpages>15</tpages></addata></record> |
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| subjects | Accuracy Aluminum Aluminum Engine Applied sciences Boundary conditions Deformation Distortion Engine Cylinder Head Engines Exact sciences and technology FEA (Finite Element Analysis) Finite element analysis Fixtures Laboratories Machinery Machining Quality Manufacturing Mathematical models Mechanical engineering. Machine design Process Design Process planning Production management Quality control Simulation Structural Analysis Studies |
| title | Machining Quality Analysis of an Engine Cylinder Head Using Finite Element Methods |
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