Abstract
A procedure to design the spiral springs finite life for dual-mass flywheels is presented. Due to design constraints, installation space, production processes, stiffness requirement, maximum torque, and maximum speed, these components are dimensioned for finite life. Two- and three-dimensional finite element model static structural analysis was performed to obtain the stress distribution, deformed shape, and to validate optimization design. The fatigue analysis was performed both experimentally and by means of a component life estimation model. An experimental duty cycle was applied. Finite element analysis and experimental analysis agree in pointing out the location and the value of maximum stresses and the shape of deformation. Vehicle tests highlight premature spiral springs’ failures, which do not agree with life estimation. The examination of the fracture showed that fretting and wear, along with fatigue phenomena, are the causes of premature failures. A dedicated component life estimation model is required, taking into account of wear and loading history.
Highlights
Automotive powertrains with piston engines generate a time-dependent torque, which mainly depends on engine speed and number of cylinders
The procedure integrates the results coming from static finite element analysis (FEA) simulations, load counting methods and life calculation methods, which take into account several critical failure causes
Spiral springs applied to dual-mass flywheel (DMF) allow good performance in terms of filtering function, but due to design constraints, as well as installation space, production processes, stiffness requirement, maximum torque, and maximum speed, they cannot be dimensioned for infinite life
Summary
Automotive powertrains with piston engines generate a time-dependent torque, which mainly depends on engine speed and number of cylinders. This variable torque introduces annoying vibrations, which affect the whole system. Such an issue is especially critical since the need to find a compromise between increasing engine efficiency, due to current CO2 reduction laws, and maintaining engine performance can introduce increased torsional vibrations in the drive train of future engines. Latest engine design aims at power increase and cross section reduction of crankshaft and gearbox shaft, with the consequent increase in crankshaft oscillations transmitted to the gearbox
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