PSI - Issue 42

Denny Knabner et al. / Procedia Structural Integrity 42 (2022) 561–569 Author name / Structural Integrity Procedia 00 (2019) 000 – 000

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5. Validation of the new approach on the connecting rod setup Since the calculation approach is based on local parameters, these must first be determined by means of FE simulation. For this purpose, the 3D-model shown in Figure 6 was created using the ABAQUS software. This model has already been described in detail in [31] and also [33]. The material properties were set according to Table 1. The force was set to a mean value , = 43.01 N and an amplitude , = 40.50 N according to the fatigue limit determined in Section 3.1. The normal contact behaviour of contacts K1 and K2 was set to "hard" and the contact stiffness value was set to 10 7 . The tangential behaviour was set to “ penalty friction ” and the elastic slip was set to 0.1 µm . The coefficient of friction (CoF) was adjusted iteratively by comparing the simulated slip amplitude with the experimentally determined slip amplitude (see Section 3.1). It was found that a CoF of µ = 0.15 (for both contacts) leads to the corresponding slip amplitude.

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Bolt Bushing Connecting rod

K1

K2

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K2 K1

Symmetry plane

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K2

K1

Symmetry plane

F Z,a

F Z,a

Figure 6: FE-Model of the connecting – rod setup

Figure 7 shows the results of the simulation for the contact surface of the connecting-rod (connecting rod ─ bushing contact). The plots in Figure 7 are the unrolled contact area. The angular positions follow the angles in Figure 6 left. The axial position is the width of the connecting rod.

Mean contact pressure

Slip amplitude

Böhme equivalent stress

Degree of utilization

Degree of utilization (−)

Angular position (°)

Angular position (°)

Angular position (°)

Angular position (°)

(µm)

, (MPa)

Experimental failure location

(MPa)

Maximum

Axial position (mm)

Axial position (mm)

Axial position (mm)

Axial position (mm)

Figure 7: Simulation results and calculated degree of utilization