1696 lines
46 KiB
HTML
1696 lines
46 KiB
HTML
<style>body{max-width:1250px;}body,table,td {font-size:14px; font-family: Arial, Helvetica, sans-serif;}</style><!DOCTYPE html PUBLIC "-//W3C//DTD HTML 4.01 Transitional//EN">
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<html>
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<head>
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<meta http-equiv="content-type" content="text/html; charset=utf-8">
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<!--font table contains 2 fonts total-->
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</head>
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<body><div id='divhlpmain'><sup>$</sup><sup>#</sup><sup>></sup><sup>K</sup><b><font size="4">BATS98 - Program Overview<br>
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</font></b><u><font size="2"><br>
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</font></u><center><sup>K</sup><img data="bm0.bmp" title="bm0.bmp"><br>
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</center>
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Bats is a collection of individual bolted joint calculatio<sup>K</sup>ns, that are normally applied to critical fasteners. Some of the sections are specific to a particular joint, such as an automotive split cap connecting rod, whilst others are more generic and may be applied to any bolt.<br>
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<br>
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The individual calculation modules are identified below:<br>
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<br>
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<u><img data="bm1.bmp" title="bm1.bmp"></u><br>
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1) <u>BATS</u> - Bolt Capability Analysis<br>
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<br>
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Select from the data base of BS3643 thread details the required bolt size and class of fit, identify the material properties to determine the maximum and minimum bolt clamp loads, the associated required lengths of thread engagements for both plastic and elastic tightening.<br>
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<br>
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<u><img data="bm2.bmp" title="bm2.bmp"></u><br>
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2) <u>JOINT</u> - Specific Bolt Specification<br>
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<br>
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Select from the data base of BS3643 thread details the required bolt size and class of fit, identify the material properties to determine the maximum and minimum bolt clamp loads, the associated required lengths of thread engagements, for the chosen tightening regime. Select from either yield tightened, torque + angle or torque tightened. The minimum torque capacity of a detailed 'friction' joint is also determined with the associated maximum contact stress.<br>
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<br>
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<u><img data="bm3.bmp" title="bm3.bmp"></u><br>
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3) <u>BEES</u> - Half Bearing Shell Interference<br>
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<br>
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Calculates the variation in the clearance and interference characteristics of a thin shell bearing in a split housing, (i.e. connecting rods and main bearings). The inclusion of component tolerances and thermal properties allows the total population to be analysed through the operating temperature range. This identifies the variation in bearing clearance, stresses in bearings, bearing 'crush' loads and bearing contact pressures. <br>
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<br>
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<u><img data="bm4.bmp" title="bm4.bmp"></u><br>
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4) <u>JOINT2</u> - Connecting Rod Bolt<br>
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<br>
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Identifies the suitability of a particular bolt and tightening specification to the applied loads for the detailed connecting rod application. The user defines basic engine geometry and masses together with the proposed operating speed. Real world joint effects are included via a joint lever ratio, bearing shell interference and relative stiffness calculations.<br>
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<br>
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<u><img data="bm5.bmp" title="bm5.bmp"></u><br>
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5) <u>JOINT3</u> - Main Bearing Bolt<br>
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<br>
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Identifies the suitability of a particular bolt and tightening specification to the applied loads for the detailed main bearing application. The user defines basic engine geometry and peak bearing loads. Real world joint effects are included via a joint lever ratio, bearing shell interference and relative stiffness calculations.<br>
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<br>
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<br>
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<u><img data="bm6.bmp" title="bm6.bmp"></u><br>
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6) <u>JOINT4</u> - Cylinder Head Bolt<br>
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<br>
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Identifies the suitability of a particular bolt and tightening specification to the applied loads for the detailed cylinder head application. The user defines basic engine geometry and peak gas loads. Real world joint effects are included via a gasket stiffness, gasket relaxation and relative stiffness calculations.<br>
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<br>
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<br>
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A number of the calculations share either common data or the results from one calculation form part of the input to another. The use of 'Import' functions allows these 'common' values to moved between the individual calculation data screens.<br>
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<br>
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Each calculation has its own window that contain three discrete sections. The first is the identification section that contains time, date and description strings. The second is the data entry section, which through either spread sheet type format or individual value entry and selection boxes the required data is entered. The third section displays the calculation results in a scrollable spread sheet, with design targets identified where relevant.<br>
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<br>
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<p><hr><p>
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<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><sup>K</sup><b><font size="4">Bats - Bolt Capability Analysis - Overview<br>
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</font></b><font size="2"><br>
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<b><br>
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</b></font><u><img data="bm1.bmp" title="bm1.bmp"></u><br>
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<b>Procedure<br>
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</b>A metric thread size is selected from the available options within BS3643, this together with its material grade are used to establish the clamp capability of a particular thread size. Alternatively different thread sizes/grades/tightening procedures are reviewed to identify the required thread size for a particular minimum pre-load.<br>
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<br>
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<b>Results<br>
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</b>The tensile stress area of the defined fastener. The maximum available clamp loads and associated range of clamp loads from either yield tightening or torque tightening the defined fastener. Estimates of torque a angle for yield tightening are identified as are the likely length of thread engagement that each load range will require.<br>
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<b><br>
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<br>
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<br>
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<p><hr><p>
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<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup></b><sup>K</sup><font size="4">Bats - Bolt Capability Analysis - Data Requirements<br>
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</font><font size="2"><br>
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<br>
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</font><u><img data="bm1.bmp" title="bm1.bmp"></u><br>
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<b>Identification:<br>
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<br>
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</b><table border="2">
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<tr><td><center>Project ID</td>
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</center>
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<td><center>Engine ID</td>
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</center>
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<td><center>Bolt ID</td>
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</center>
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<td><center>Date</td>
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</tr>
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</center>
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</center>
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<td></td>
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<td></td>
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<td></td>
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<td></td>
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</tr>
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<tr><td><b><br>
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<br>
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Program Objectives:<br>
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</b><br>
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1)
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To establish the available bolt preload alternatives for a given bolt.<br>
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or 2)
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Identify the required bolt size to achieve a target minimum clamp load.<br>
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<br>
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<br>
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<b>Drawing Numbers:<br>
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</b><font face="Times New Roman"><b><br>
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</b></font><font face="Arial"><center>Component</font></td>
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</center>
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<td><center>Number</td>
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</tr>
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</center>
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</center>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<br>
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<br>
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<tr><td><b>Data Requirements:<br>
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</b><font face="Times New Roman"><b><br>
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</b></font><font face="Arial"></font></td>
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</center>
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<td><center>Variable</td>
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</center>
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<td><center>Value</td>
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</tr>
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</center>
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<tr><td><i><center>a</i></td>
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</center>
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</center>
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<td>Bolt Diameter (mm)</td>
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<td></td>
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</tr>
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<tr><td><i><center>b</i></td>
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</center>
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</center>
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<td>Thread Pitch (mm)</td>
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<td></td>
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</tr>
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<tr><td><i><center>c</i></td>
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</center>
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</center>
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<td>External Thread Class</td>
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<td></td>
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</tr>
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<tr><td><i><center>d</i></td>
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</center>
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</center>
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<td>Internal Thread Class</td>
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<td></td>
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</tr>
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<tr><td><i><center>e</i></td>
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</center>
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</center>
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<td>Bolt Material Grade<br>
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<i><b>1</b></i> Select from grades (ie 10.9)<br>
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<i><b>2</b></i> User Defined</td>
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<td></td>
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</tr>
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<tr><td><i><center>f</i></td>
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</center>
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</center>
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<td> for <i><b>2</b></i> Bolt UTS (N/mm2)</td>
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<td></td>
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</tr>
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<tr><td><i><center>g</i></td>
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</center>
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</center>
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<td> for <i><b>2</b></i> Bolt Yield (N/mm2)</td>
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<td></td>
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</tr>
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<tr><td><i><center>h</i></td>
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</center>
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</center>
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<td>External Thread UTS range (N/mm2)</td>
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<td></td>
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</tr>
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<tr><td><i><center>i</i></td>
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</center>
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</center>
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<td>Shank Type<br>
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<i><b>1</b></i> Plain<br>
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<i><b>2</b></i><b> </b> or Waisted</td>
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<td></td>
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</tr>
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<tr><td><sup>K</sup><i><center>j</i></td>
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</center>
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</center>
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<td> for <i><b>2</b></i>, Waisted Shank Dia (mm)</td>
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<td></td>
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</tr>
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<tr><td><i><center>k</i></td>
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</center>
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</center>
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<td>Internal Thread UTS (N/mm2)</td>
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<td></td>
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</tr>
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<tr><td><i><center>l</i></td>
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</center>
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</center>
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<td>Free Bolt Length (mm)</td>
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<td></td>
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</tr>
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<tr><td><i><center>m</i></td>
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</center>
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</center>
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<td>Thread Coefficient of Friction</td>
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<td></td>
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</tr>
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<tr><td><font face="Times New Roman"><b><br>
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<br>
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<font face="Arial">Notes:<br>
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<br>
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</font></b></font>1) Typical external thread UTS range, (item <i>h</i>), is 200 N/mm2, i.e the difference from one grade to the next.<br>
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<br>
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2) Free bolt length, (item <i>l),</i> is the length of the fastener under tension, i.e. first engaged thread to bolt underhead.<b><br>
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</b><br>
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<p><hr><p>
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<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><b><font size="4">Joint - Specific Bolt Specification - Overview<br>
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||
</font></b><font size="2"><br>
|
||
<b><br>
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||
</b></font><u><img data="bm2.bmp" title="bm2.bmp"></u><br>
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||
<b>Procedure<br>
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||
</b>A metric thread size is selected from the available options within BS3643, this together with its material grade are used to establish the clamp capability of a particular thread size at a defined tightening condition.<br>
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||
<br>
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||
<br>
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||
<b>Results<br>
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</b>The tensile stress area of the defined fastener. The maximum available clamp loads and associated range of clamp loads from the specified tightening procedure. Estimates of a service torque and angle are identified for yield tightening as are the likely length of required thread engagement.<br>
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<b><br>
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<br>
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<br>
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<p><hr><p>
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</b></td>
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</tr>
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</table>
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<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><font size="4">Joint - Specific Bolt Specification - Data Requirements<br>
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</font><font size="2"><br>
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<br>
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</font><u><img data="bm2.bmp" title="bm2.bmp"></u><br>
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<b>Identification:<br>
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<br>
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</b><table border="2">
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<tr><td><center>Project ID</td>
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</center>
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<td><center>Engine ID</td>
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</center>
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<td><center>Joint ID</td>
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</center>
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<td><center>Date</td>
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</tr>
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</center>
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</center>
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<td></td>
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<td></td>
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<td></td>
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<td></td>
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</tr>
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<tr><td><b><br>
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<br>
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Program Objectives:<br>
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</b><br>
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1)
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To establish the bolt preload variation.<br>
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2)
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To set the length of required thread engagement.<br>
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Actual engagement (mm)</td>
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<td></td>
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</tr>
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<br>
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<br>
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<tr><td><b>Drawing Numbers:<br>
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</b><font face="Times New Roman"><b><br>
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</b></font><font face="Arial"><center>Component</font></td>
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</center>
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<td><center>Number</td>
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</tr>
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</center>
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</center>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<td></td>
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<td></td>
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</tr>
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<br>
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<br>
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<tr><td><b>Data Requirements:<br>
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</b><font face="Times New Roman"><b><br>
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</b></font><font face="Arial"></font></td>
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</center>
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<td><center>Variable</td>
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</center>
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<td><center>Value</td>
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</tr>
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</center>
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<tr><td><i><center>a</i></td>
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</center>
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</center>
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<td>Bolt Diameter (mm)</td>
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<td></td>
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</tr>
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<tr><td><i><center>b</i></td>
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</center>
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</center>
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<td>Thread Pitch (mm)</td>
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<td></td>
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</tr>
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<tr><td><i><center>c</i></td>
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</center>
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</center>
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<td>External Thread Class</td>
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<td></td>
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</tr>
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<tr><td><i><center>d</i></td>
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</center>
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</center>
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<td>Internal Thread Class</td>
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<td></td>
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</tr>
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<tr><td><i><center>e</i></td>
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</center>
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</center>
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<td>Bolt Material Grade<br>
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<i><b>1</b></i> Select from grades (ie 10.9)<br>
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<i><b>2</b></i> User Defined</td>
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<td></td>
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</tr>
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<tr><td><i><center>f</i></td>
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</center>
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</center>
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<td> for <i><b>2</b></i> Bolt UTS (N/mm2)</td>
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<td></td>
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</tr>
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<tr><td><i><center>g</i></td>
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</center>
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</center>
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<td> for <i><b>2</b></i> Bolt Yield (N/mm2)</td>
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<td></td>
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</tr>
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<tr><td><i><center>h</i></td>
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</center>
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</center>
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<td>External Thread UTS range (N/mm2)</td>
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<td></td>
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</tr>
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<tr><td><i><center>i</i></td>
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</center>
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</center>
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<td>Shank Type<br>
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<i><b>1</b></i> Plain<br>
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<i><b>2</b></i><b> </b> or Waisted</td>
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||
<td></td>
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||
</tr>
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<tr><td><i><center>j</i></td>
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||
</center>
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||
</center>
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<td> for <i><b>2</b></i>, Waisted Shank Dia (mm)</td>
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||
<td></td>
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</tr>
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<tr><td><i><center>k</i></td>
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</center>
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||
</center>
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||
<td>Internal Thread UTS (N/mm2)</td>
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<td></td>
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||
</tr>
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||
<tr><td><i><center>l</i></td>
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</center>
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||
</center>
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||
<td>Free Bolt Length (mm)</td>
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||
<td></td>
|
||
</tr>
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||
<tr><td><i><center>m</i></td>
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||
</center>
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||
</center>
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<td>Thread Coefficient of Friction</td>
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||
<td></td>
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||
</tr>
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||
<tr><td><i><center>n</i></td>
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||
</center>
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||
</center>
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<td>Tightening Technique<br>
|
||
<i><b>1</b></i> Yield Tightened<br>
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<i><b>2</b></i> or Maximum Torque <br>
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<i><b>3</b></i> or Specify Torque<br>
|
||
<i><b>4</b></i> or Specify Torque and Angle</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>o</i></td>
|
||
</center>
|
||
</center>
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||
<td> for <i><b>3</b></i><i> </i>and <i>4</i>, Tightening Torgue (N/m)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>p</i></td>
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||
</center>
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||
</center>
|
||
<td> for <i><b>4</b></i>, Angle (deg)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>q</i></td>
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||
</center>
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||
</center>
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||
<td>No of Bolts</td>
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||
<td></td>
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||
</tr>
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||
<tr><td><i><center>r</i></td>
|
||
</center>
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||
</center>
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||
<td>Contact Area OD (mm)</td>
|
||
<td></td>
|
||
</tr>
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||
<tr><td><i><center>s</i></td>
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||
</center>
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||
</center>
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||
<td>Contact Area ID (mm)</td>
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||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>t</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Joint Friction Coeff</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<br>
|
||
<font face="Arial">Notes:<br>
|
||
<br>
|
||
</font></b></font>1) Items <i>q</i> to <i>t</i> are only relevant for friction drive joints, i.e. flywheel palm.<br>
|
||
<br>
|
||
2) Typical external thread UTS range, (item <i>h</i>), is 200 N/mm2, i.e the difference from one grade to the next.<br>
|
||
<br>
|
||
3) Free bolt length, (item <i>l),</i> is the length of the fastener under tension, i.e. first engaged thread to bolt underhead.<font face="Times New Roman"><b><br>
|
||
</b></font><br>
|
||
<p><hr><p>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><b><font size="4">Bees - Half Bearing Shell Interference - Overview<br>
|
||
</font></b><font size="2"><br>
|
||
<b><br>
|
||
</b></font><u><img data="bm3.bmp" title="bm3.bmp"></u><br>
|
||
<b>Procedure<br>
|
||
</b>A connecting rod bolt is required to provide sufficient clamp load under all assembly and operating conditions to maintain contact between the connecting rod and the cap. In addition the alternating load <font face="Arial">felt</font><font face="Times New Roman"><font face="Arial"> by the bolt must not lead to fatigue failure of the bolt. Bolt under head stresses at the maximum clamp load must be less than the compressive yield strength of the connecting rod cap, and the minimum length of thread engagement must be greater than that required to carry the maximum bolt load.<br>
|
||
</font></font>Bolt loads and stresses are based on the joint diagram, derived from the relative stiffness of bolt, shell, and rod. The bolt <font face="Times New Roman"><font face="Arial">felt</font></font><font face="Times New Roman"><font face="Arial"> load can then be determined for any given applied load.<br>
|
||
Due to the eccentric nature of the joint, applied loads are factored by an assumed lever ratio, this lever ratio being derived from the joint moment arms<br>
|
||
The joint diagram can also be used to determine the theoretical separation point, by including the leverage ratio of the eccentrically applied load, and comparing to the minimum clamp load, which is based on the condition of minimum bolt load and the maximum bearing overstand.<br>
|
||
</font></font>Thick shell theory and the bearing and housing dimensions are used to derive the maximum bearing shell overstand, stiffness, and crush load under assembly conditions.<br>
|
||
<br>
|
||
<b>Results<br>
|
||
</b>The variation of the bearing clearance throughout the defined tolerance and temperature ranges. The maximum bearing overstand, and hence crush load are identified. Contact pressures between the shell and the housing are compared to design targets for adequate protection against fretting. The stresses in the bearing shells should be compared to the yield strength of the bearing backing material.<br>
|
||
<b><br>
|
||
<br>
|
||
<br>
|
||
<p><hr><p>
|
||
</b></td>
|
||
</tr>
|
||
</table>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><sup>K</sup><font size="4">Bees - Half Bearing Shell Interference - Data Requirements<br>
|
||
</font><font size="2"><br>
|
||
<br>
|
||
</font><u><img data="bm3.bmp" title="bm3.bmp"></u><br>
|
||
<b>Identification:<br>
|
||
<br>
|
||
</b><table border="2">
|
||
<tr><td><center>Project ID</td>
|
||
</center>
|
||
<td><center>Engine ID</td>
|
||
</center>
|
||
<td><center>Bearing ID</td>
|
||
</center>
|
||
<td><center>Date</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><b><br>
|
||
<br>
|
||
Program Objectives:<br>
|
||
</b><br>
|
||
1)
|
||
To predict the bearing shell stiffness.<br>
|
||
2)
|
||
To calculate the maximum bearing shell crush load.<br>
|
||
3)
|
||
To calculate the operating clearance range.<br>
|
||
<br>
|
||
<br>
|
||
<b>Drawing Numbers:<br>
|
||
</b><font face="Times New Roman"><b><br>
|
||
</b></font><font face="Arial"><center>Component</font></td>
|
||
</center>
|
||
<td><center>Number</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<br>
|
||
<br>
|
||
<tr><td><b>Data Requirements:<br>
|
||
</b><font face="Times New Roman"><b><br>
|
||
</b></font><font face="Arial"></font></td>
|
||
</center>
|
||
<td><center>Variable</td>
|
||
</center>
|
||
<td><center>Value</td>
|
||
</tr>
|
||
</center>
|
||
<tr><td><i><center>a</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Housing Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>b</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Housing Tolerance (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>c</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Journal Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>d</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Journal Tolerance (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>e</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Max Wall Thickness (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>f</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Wall Thickness Tolerance (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>g</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Steel Thickness (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>h</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bearing Material Type<br>
|
||
<i><b>2</b></i> Bronze<br>
|
||
<i><b>3</b></i> Aluminium</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>I</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bearing Length (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>j</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Checking Load (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>k</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Checking Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>l</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Minimum Checking Overstand (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>m</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Checking Overstand (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>n</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Outer Diameter Multiplier </td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>o</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Young<font face="Times New Roman"><font face="Arial">s Modulus - Bearing (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>p</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Young<font face="Times New Roman"><font face="Arial">s Modulus - Housing (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>q</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Poisson<font face="Times New Roman"><font face="Arial">s Ratio - Bearing</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>r</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Poisson<font face="Times New Roman"><font face="Arial">s Ratio - Housing</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>s</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Housing Linear Coeff of Expansion (oC)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>t</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bearing Linear Coeff of Expansion (oC)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>u</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Journal Linear Coeff of Expansion (oC)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>v</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Minimum Operating Temperature (C)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>x</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Operating Temperature (C)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<br>
|
||
<font face="Arial">Notes:<br>
|
||
<br>
|
||
</font></b></font>1) Typical ranges for tolerances are as follows,<br>
|
||
|
||
|
||
Housing Tolerance (item <i>b</i>)
|
||
|
||
0.012 - 0.019 mm<br>
|
||
|
||
|
||
Journal Tolerance (item <i>d</i>)
|
||
|
||
|
||
0.012 - 0.016 mm<br>
|
||
|
||
|
||
Wall Thickness Tolerance (item <i>f</i>)
|
||
0.006 - 0.008 mm<br>
|
||
<br>
|
||
2) The Outer Multiplier, (item <i>n</i>), is the ratio, relative to the maximum housing diameter, that is used to calculate the effective outer diameter of the housing.<br>
|
||
<br>
|
||
3) The wall thickness, (item <i>e</i>), is the overall bearing shell thickness value, whilst the maximum steel thickness, (item g), is the thickness of the backing shell only.<br>
|
||
<br>
|
||
4) Typical values for the linear coefficient of thermal expansion, (items s,t and<i> u) </i>are,<br>
|
||
|
||
|
||
Steel
|
||
|
||
|
||
12.0 x10-6/oC<br>
|
||
|
||
|
||
Cast Iron
|
||
|
||
11.0 x10-6/oC<br>
|
||
|
||
|
||
Aluminium
|
||
|
||
22.0 x10-6/oC<font face="Times New Roman"><b><br>
|
||
</b></font><br>
|
||
<p><hr><p>
|
||
</td>
|
||
</tr>
|
||
</table>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><sup>K</sup><b><font size="4">Joint 2 - Connecting Rod Bolt - Overview<br>
|
||
</font></b><font size="2"><br>
|
||
<b><br>
|
||
</b></font><u><img data="bm4.bmp" title="bm4.bmp"></u><br>
|
||
<b>Procedure<br>
|
||
</b>A connecting rod bolt is required to provide sufficient clamp load under all assembly and operating conditions to maintain contact between the connecting rod and the cap. In addition the alternating load <font face="Arial">felt</font><font face="Times New Roman"><font face="Arial"> by the bolt must not lead to fatigue failure of the bolt. Bolt under head stresses at the maximum clamp load must be less than the compressive yield strength of the connecting rod cap, and the minimum length of thread engagement must be greater than that required to carry the maximum bolt load.<br>
|
||
</font></font>Bolt loads and stresses are based on the joint diagram, derived from the relative stiffness of bolt, shell, and rod. The bolt <font face="Times New Roman"><font face="Arial">felt</font></font><font face="Times New Roman"><font face="Arial"> load can then be determined for any given applied load.<br>
|
||
Due to the eccentric nature of the joint, applied loads are factored by an assumed lever ratio, this lever ratio being derived from the joint moment arms<br>
|
||
The joint diagram can also be used to determine the theoretical separation point, by including the leverage ratio of the eccentrically applied load, and comparing to the minimum clamp load, which is based on the condition of minimum bolt load and the maximum bearing overstand.<br>
|
||
</font></font>Thick shell theory and the bearing and housing dimensions are used to derive the maximum bearing shell overstand, stiffness, and crush load under assembly conditions.<br>
|
||
<br>
|
||
<b>Results<br>
|
||
</b>The suitability of the connecting rod bolt joint in terms of assembly, thread engagement, under head stress and clamp load for the proposed load cases, or the required fastener specification.<br>
|
||
<b><br>
|
||
<br>
|
||
<p><hr><p>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup></b><font size="4">Joint 2 - Connecting Rod Bolt - Data Requirements<br>
|
||
</font><font size="2"><br>
|
||
<br>
|
||
</font><u><img data="bm4.bmp" title="bm4.bmp"></u><br>
|
||
<b>Identification:<br>
|
||
<br>
|
||
</b><table border="2">
|
||
<tr><td><center>Project ID</td>
|
||
</center>
|
||
<td><center>Engine ID</td>
|
||
</center>
|
||
<td><center>Date</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><b><br>
|
||
<br>
|
||
Program Objectives:<br>
|
||
</b><br>
|
||
1)
|
||
To confirm clamping reserve factor acceptable. (>1.2)<br>
|
||
2)
|
||
To establish bolt fatigue reserve factor. (>1.2)<br>
|
||
3)
|
||
To establish underhead contact reserve factor. (>1.0)<br>
|
||
<br>
|
||
<br>
|
||
<b>Drawing Numbers:<br>
|
||
</b><font face="Times New Roman"><b><br>
|
||
</b></font><font face="Arial"><center>Component</font></td>
|
||
</center>
|
||
<td><center>Number</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<br>
|
||
<br>
|
||
<tr><td><b>Data Requirements:<br>
|
||
</b><font face="Times New Roman"><b><br>
|
||
</b></font><font face="Arial"></font></td>
|
||
</center>
|
||
<td><center>Variable</td>
|
||
</center>
|
||
<td><center>Value</td>
|
||
</tr>
|
||
</center>
|
||
<tr><td><i><center>a</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Piston Assembly Mass (kg)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>b</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Small End Mass (kg)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>c</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Big End Mass (kg)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>d</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Big End Cap Mass (kg)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>e</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Engine Speed (rpm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>f</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Rod Centre Length (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>g</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Crankshaft Stroke (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>h</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Shell Stiffness (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>I</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Nominal Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>j</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Tensile Stress Area (mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>k</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Thread Core Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>l</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Thread Pitch (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>m</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Head Thickness (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>n</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>o</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Free Thread Length (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>p</i></td>
|
||
</center>
|
||
</center>
|
||
<td>No of Bolt Sections</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><br>
|
||
</font>
|
||
|
||
<font face="Arial">For Each Bolt Section<br>
|
||
</font></td>
|
||
<td><center>Diameter (mm)</td>
|
||
</center>
|
||
<td><center>Length (mm)</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<tr><td>1</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>2</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>3</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>4</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>5</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<br>
|
||
</b></font><font face="Arial"></font></td>
|
||
</center>
|
||
<td><center>Variable</td>
|
||
</center>
|
||
<td><center>Value</td>
|
||
</tr>
|
||
</center>
|
||
<tr><td><i><center>q</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>r</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Head Face Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>s</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>t</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Comp Yield Strength (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>u</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Minimum Bolt Preload (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>v</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Bolt Preload (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>w</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Shell Crush Load (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>x</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Joint Lever Ratio</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>y</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Endurance Limit (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<font face="Arial">Notes:<br>
|
||
<br>
|
||
</font></b></font>1) Items <i>j,k,</i> <i>u</i> and <i>v</i> can be obtained from program <font face="Times New Roman"><font face="Arial">Joint</font></font><font face="Times New Roman"><font face="Arial"> output.<br>
|
||
<br>
|
||
2) Typical bolt endurance limit, (item y), is 75 N/mm2, this assumes a rolled thread and high strength grade base material.<br>
|
||
<br>
|
||
3) Free thread length, (item <i>o),</i></font></font> is the length of the threaded portion under tension, i.e. first engaged thread to start of plain shank portion.<br>
|
||
<br>
|
||
4) Foot diameter, (item <i>q</i>), is the equivalent diameter of the assumed effective column of material within the joint.<br>
|
||
<br>
|
||
5) Items .<i>h </i>and <i>w</i> can be obtained from program <font face="Times New Roman"><font face="Arial">Bees</font></font><font face="Times New Roman"><font face="Arial"> output.</font></font><font face="Times New Roman"><b><br>
|
||
</b></font><br>
|
||
6) Typical values for joint lever ratio vary between 1.4 and 1.6.<br>
|
||
<br>
|
||
<br>
|
||
<p><hr><p>
|
||
</td>
|
||
</tr>
|
||
</table>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><b><font size="4">Joint 3 - Main Bearing Bolt - Overview<br>
|
||
</font></b><font size="2"><br>
|
||
</font><b><br>
|
||
</b><u><img data="bm5.bmp" title="bm5.bmp"></u><br>
|
||
<b>Procedure<br>
|
||
</b>The correct clamping of the main bearing is essential to provide consistent bearing support under the applied loads. These loads are derived from the bearing analysis program.<br>
|
||
Normally due to the eccentric nature of the joint, applied loads are factored by an assumed lever ratio, this lever ratio being derived from the joint moment arms.<br>
|
||
The working load in the bolt is determined by considering the relative stiffness of the bearing cap, bolt, and bearing shell.<br>
|
||
Thick shell theory and the bearing and housing dimensions are used to derive the maximum bearing shell overstand, stiffness and crush load under assembly conditions.<br>
|
||
Given the strengths of the mating components and bolt the required length of thread engagement is calculated, and under head contact stresses compared to the component compressive strength.<br>
|
||
<br>
|
||
<b>Results<br>
|
||
</b>The suitability of the main bearing bolt joint in terms of assembly, thread engagement, under head stress and clamp load for the proposed load cases, or the required fastener specification.<br>
|
||
<b><br>
|
||
<br>
|
||
<p><hr><p>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup></b><font size="4">Joint 3 - Main Bearing Bolt - Data Requirements<br>
|
||
</font><font size="2"><br>
|
||
<br>
|
||
</font><u><img data="bm5.bmp" title="bm5.bmp"></u><br>
|
||
<b>Identification:<br>
|
||
<br>
|
||
</b><table border="2">
|
||
<tr><td><center>Project ID</td>
|
||
</center>
|
||
<td><center>Engine ID</td>
|
||
</center>
|
||
<td><center>Date</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><b><br>
|
||
<br>
|
||
Program Objectives:<br>
|
||
</b><br>
|
||
1)
|
||
To confirm vertical clamping reserve factor acceptable. (>1.2)<br>
|
||
2)
|
||
To confirm horizontal clamping reserve factor acceptable. (>1.2)<br>
|
||
3)
|
||
To establish bolt fatigue reserve factor. (>1.2)<br>
|
||
4)
|
||
To establish underhead contact reserve factor. (>1.0)<br>
|
||
<br>
|
||
<br>
|
||
<b>Drawing Numbers:<br>
|
||
</b><b><br>
|
||
</b><font face="Arial"><center>Component</font></td>
|
||
</center>
|
||
<td><center>Number</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<br>
|
||
<br>
|
||
<tr><td><b>Data Requirements:<br>
|
||
</b><font face="Times New Roman"><b><br>
|
||
</b></font><font face="Arial"></font></td>
|
||
</center>
|
||
<td><center>Variable</td>
|
||
</center>
|
||
<td><center>Value</td>
|
||
</tr>
|
||
</center>
|
||
<tr><td><i><center>a</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Horizontal Bearing Load (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>b</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Vertical Bearing Load (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>c</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Coefficient of Friction</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>d</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Shell Stiffness (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>e</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Nominal Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>f</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Tensile Stress Area (mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>g</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Thread Core Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>h</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Thread Pitch (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>i</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Head Thickness (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>j</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>k</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Free Thread Length (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>l</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Washer Length (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>m</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Washer Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>n</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Washer Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>o</i></td>
|
||
</center>
|
||
</center>
|
||
<td>No of Bolt Sections</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><br>
|
||
</font>
|
||
|
||
<font face="Arial">For Each Bolt Section<br>
|
||
</font></td>
|
||
<td><center>Diameter (mm)</td>
|
||
</center>
|
||
<td><center>Length (mm)</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<tr><td>1</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>2</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>3</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>4</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>5</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<br>
|
||
</b></font><font face="Arial"></font></td>
|
||
</center>
|
||
<td><center>Variable</td>
|
||
</center>
|
||
<td><center>Value</td>
|
||
</tr>
|
||
</center>
|
||
<tr><td><i><center>p</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>q</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Head Face Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>r</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>s</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Comp Yield Strength (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>t</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Minimum Bolt Preload (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>u</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Bolt Preload (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>v</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Shell Crush Load (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>w</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Joint Lever Ratio</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>x</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Endurance Limit (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<font face="Arial">Notes:<br>
|
||
<br>
|
||
</font></b></font>1) Items <i>f,g,</i> <i>t</i> and <i>u</i> can be obtained from program <font face="Times New Roman"><font face="Arial">Joint</font></font><font face="Times New Roman"><font face="Arial"> output.<br>
|
||
<br>
|
||
2) Typical bolt endurance limit, (item x), is 75 N/mm2, this assumes a rolled thread and high strength grade base material.<br>
|
||
<br>
|
||
3) Free thread length, (item <i>k),</i></font></font> is the length of the threaded portion under tension, i.e. first engaged thread to start of plain shank portion.<br>
|
||
<br>
|
||
4) Foot diameter, (item <i>p</i>), is the equivalent diameter of the assumed effective column of material within the joint.<br>
|
||
<br>
|
||
5) Items .<i>d </i>and <i>v</i> can be obtained from program <font face="Times New Roman"><font face="Arial">Bees</font></font><font face="Times New Roman"><font face="Arial"> output.</font></font><font face="Times New Roman"><b><br>
|
||
</b></font><br>
|
||
6) Typical values for joint lever ratio vary between 1.0 for a ladder frame or four bolt fix, to 1.7 for a conventional two bolt separate cap.<br>
|
||
<br>
|
||
7) With a four bolt fix bearing cap the vertical bearing load, (item a), the shell stiffness (item <i>d</i>), and the maximum shell crush load, (item <i>v</i>) should all be halved for the correct calculation of reserve factors.<b><br>
|
||
</b><br>
|
||
<b><br>
|
||
</b><br>
|
||
<p><hr><p>
|
||
</td>
|
||
</tr>
|
||
</table>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><sup>K</sup><b><font size="4">Joint 4 - Cylinder Head Bolt - Overview<br>
|
||
</font></b><font size="2"><br>
|
||
</font><br>
|
||
<u><img data="bm6.bmp" title="bm6.bmp"></u><br>
|
||
<b>Procedure<i><br>
|
||
</i></b>Cylinder head clamp loads are required to maintain adequate gasket security under all starting and running conditions.<br>
|
||
Clamping loads are considered for a single bore acting in isolation with shared bolts containing the cylinder of interest. Clamp loads must cover the scatter in bolt material properties, friction, gasket relaxation, and applied gas loads. Working loads in the bolts are controlled by the relative stiffness of joint, bolt and gasket.<br>
|
||
<br>
|
||
<b>Results<br>
|
||
</b>The suitability of the cylinder head bolt joint in terms of assembly, thread engagement, under head stress and clamp load for the proposed load cases, or the required fastener specification.<br>
|
||
<p><hr><p>
|
||
<sup>+</sup><sup>$</sup><sup>#</sup><sup>></sup><sup>K</sup><b><font size="4">Joint 4 - Cylinder Head Bolt - Data Requirements<br>
|
||
</font></b><font size="2"><br>
|
||
<br>
|
||
</font><u><img data="bm6.bmp" title="bm6.bmp"></u><br>
|
||
<b>Identification:<br>
|
||
<br>
|
||
</b><table border="2">
|
||
<tr><td><center>Project ID</td>
|
||
</center>
|
||
<td><center>Engine ID</td>
|
||
</center>
|
||
<td><center>Date</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><b><br>
|
||
<br>
|
||
Program Objectives:<br>
|
||
</b><br>
|
||
1)
|
||
To confirm clamping reserve factor acceptable. (>3.0)<br>
|
||
2)
|
||
To establish bolt fatigue reserve factor. (>1.2)<br>
|
||
3)
|
||
To establish underhead contact reserve factor. (>1.0)<br>
|
||
<br>
|
||
<br>
|
||
<b>Drawing Numbers:<br>
|
||
</b><b><br>
|
||
</b><font face="Arial"><center>Component</font></td>
|
||
</center>
|
||
<td><center>Number</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<br>
|
||
<br>
|
||
<tr><td><b>Data Requirements:<br>
|
||
</b><font face="Times New Roman"><b><br>
|
||
</b></font><font face="Arial"></font></td>
|
||
</center>
|
||
<td><center>Variable</td>
|
||
</center>
|
||
<td><center>Value</td>
|
||
</tr>
|
||
</center>
|
||
<tr><td><i><center>a</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Cylinder Bore (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>b</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Peak Cylinder Pressure (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>c</i></td>
|
||
</center>
|
||
</center>
|
||
<td>No of Bolts in Group</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>d</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Gasket Stiffness (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>e</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Gasket Relaxation (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>f</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Nominal Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>g</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Tensile Stress Area (mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>h</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Thread Core Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>i</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Thread Pitch (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>j</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Head Thickness (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>k</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>l</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Free Thread Length (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>m</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Washer Length (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>n</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Washer Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>o</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Washer Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>p</i></td>
|
||
</center>
|
||
</center>
|
||
<td>No of Bolt Sections</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman">
|
||
|
||
<font face="Arial">For Each Bolt Section<br>
|
||
</font></font></td>
|
||
<td><center>Diameter (mm)</td>
|
||
</center>
|
||
<td><center>Length (mm)</td>
|
||
</tr>
|
||
</center>
|
||
</center>
|
||
<tr><td>1</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>2</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>3</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>4</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td>5</td>
|
||
<td></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<br>
|
||
</b></font><font face="Arial"></font></td>
|
||
</center>
|
||
<td><center>Variable</td>
|
||
</center>
|
||
<td><center>Value</td>
|
||
</tr>
|
||
</center>
|
||
<tr><td><i><center>q</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>r</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Head Face Diameter (mm)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>s</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Young<font face="Times New Roman"><font face="Arial">s Modulus (N/mm2)</font></font></td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>t</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Foot Comp Yield Strength (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>u</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Minimum Bolt Preload (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>v</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Maximum Bolt Preload (N)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><i><center>w</i></td>
|
||
</center>
|
||
</center>
|
||
<td>Bolt Endurance Limit (N/mm2)</td>
|
||
<td></td>
|
||
</tr>
|
||
<tr><td><font face="Times New Roman"><b><br>
|
||
<font face="Arial">Notes:<br>
|
||
<br>
|
||
</font></b></font>1) Items <i>g,h,</i> <i>u</i> and <i>v</i> can be obtained from program <font face="Times New Roman"><font face="Arial">Joint</font></font><font face="Times New Roman"><font face="Arial"> output.<br>
|
||
<br>
|
||
2) Typical bolt endurance limit, (item w), is 75 N/mm2, this assumes a rolled thread and high strength grade base material.<br>
|
||
<br>
|
||
3) Free thread length, (item <i>l),</i></font></font> is the length of the threaded portion under tension, i.e. first engaged thread to start of plain shank portion.<br>
|
||
<br>
|
||
4) Foot diameter, (item <i>q</i>), is the equivalent diameter of the assumed effective column of material within the joint.<br>
|
||
<br>
|
||
5) Typical values for gasket stiffness, (item <i>d</i>), vary between 200000 N/mm2 and 600000 N/mm2 depending on construction. (i.e. three layer metal gasket would be towards the top end of this range, whilst a <font face="Times New Roman"><font face="Arial">conventional</font></font><font face="Times New Roman"><font face="Arial"> fibre gasket would be towards the low end).<br>
|
||
<br>
|
||
6) Typical values for gasket relaxation, (item <i>e</i></font></font>), vary between 0.09 mm and 0.15 mm again depending on construction. (i.e. three layer metal gasket would be towards the low end of this range, whilst a <font face="Times New Roman"><font face="Arial">conventional</font></font><font face="Times New Roman"><font face="Arial"> fibre gasket would be towards the top end).<br>
|
||
</font></font><br>
|
||
<p><hr><p>
|
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</td>
|
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</tr>
|
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