TORQUE DESIGN, ANALYSIS AND CHARACTERIZATION OF CRITICAL FASTENERS IN DIESEL ENGINES

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5 Fig.5. Elongation of bolt at 13.5 kg-m torque Similarly, preload generated in torque-angle controlled tightening is calculated and used as bolt pretension to define boundary condition in the analysis. Figures 6, 7 and 8 shows elongation of connecting rod bolts when torque-angle controlled tightening technique is used. Fig.8.Elongation of bolt at (3 kg-m+60+30degree) angular torque Similarly, for cylinder head bolts when tightening is done by torque-angle control tightening technique, generated preload values are calculated and used as bolts pretension for deformation analysis. This is shown in fig. 9, 10& 11. Fig.6. Elongation of bolt at 3 kg-m snug torque Fig.9. Elongation of bolt at 3kg-m degree angular torque Fig.7. Elongation of bolt at (3 kg-m+ 60 degree) angular torque Fig.10. Elongation of bolt at (3kg-m+ 90 degree) angular torque 27

7 Fig.14.Fatigue factors for connecting rod bolts. Fig.18. Torque-Angle control for cylinder head bolts. Fig.15. Fatigue factors of cylinder head bolts Fig.19. Direct torque control for cylinder head bolts. Fig.16. Torque-Angle control technique. CONCLUSION Fig.20. Load vs. Deformation comparison. Results reveal that for critical fasteners Torque-Angle controlled tightening technique gives better results than the direct torque control tightening technique. The Correlation is developed between angle and elongation for connecting rod bolts and cylinder head bolts for any size, length, grade and type of the bolts. REFERENCES Fig.17. Direct torque control technique. [1] Metal fatigue analysis handbook: Chapter no. 12 Design and Analysis of Metric Bolted Joints, VDI Guideline and 29

8 Finite Element Analysis by Yung-Li Lee, Chrysler Group LLC & Hsin-Chung Ho, Chrysler Group LLC. pp.490. [2] Shigley s Mechanical Engineering Design, Eighth Edition Budynas Nisbett, pp [3] VDI 2230 Part I standards, February 2003, An German standard book for bolt design. [4] Introduction to the Design and Behavior of Bolted Joints by, John H. Bickford, Founding Editor L. L. Faulkner Columbus Division, Battelle Memorial Institute and Department of Mechanical Engineering, The Ohio State University Columbus, Ohio, pp.167 to168. [5] Shigley s Mechanical Engineering Design, Eighth Edition Budynas Nisbett, pp pp.413 [6] Norbar USM-3 ultrasonic bolt meter operation and reference manual VER Norbrar USA INC. 30

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