Fatigue Life Assessment of Diesel Engine Pump Part

The intention of this thesis is first, to determine material constants of ductile cast irons (EN-GJS-400-15,EN-GJS-500-7, EN-GJS-600-3) for estimating fatigue damage. These constants are obtained from experimental results. These results are stress versus strain tests, strain versus crack initiation life tests,and consequently, Smith, Watson and Topper damage parameter, PSWT can be calculated. Using data fitting, the constants can be estimated, thus Uniform Material Law for ductile cast irons is fulfilled. Endurance limit stress is obtained based on research report termed Synthetic Wöhler Lines(SWL).It is found out that the endurance limit stress is a function of yield limit stress. Endurance life cycle is set as three millions for the three materials. Secondly, fatigue life assessment is done for diesel engine pump part made of the three ductile cast irons. Finite element calculation is done to get elastic stress concentration factor, Kt, and plastic notch factor Kp. Neuber ´s rule is used to determine local stress at notch subjected to constant amplitude load test and variable amplitude loading. The constant amplitude loading is conducted at a stress ratio of R=0 on the pump part. The test results show that fatigue life assessment based on the material constants is accurate. On the basis of the accuracy of constant amplitude test results, it is possible to determine for fatigue life for variable amplitude loading which is the real loading on the pump part. The variable amplitude loading is normally standardized for computational efficiency. This standardized loading is termed as CORAL (COmmon RAil Loading) sequence. CORAL is used to calculate fatigue life of pump part and is inputted to a Fatigue Life Evaluation computer program. This program uses rain flow cycle counting method. It can be concluded that the material constants for ductile cast irons fit well which is proved by experimental tests by constant amplitude loading on pump part. Then life prediction can be done for the typical pump loading, standardized variable amplitude loading known as CORA