Chapter 28: Model Airplane Analysis

28 Model Airplane
Engine Analysis


Summary 462

Introduction 463

Required Solution 463

FEM Solution 463

Input File 469
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CHAPTER 28

Summary
Title Chapter 28: Model Airplane Engine Analysis
Contact features Deformable-deformable contact - glue contact
Gasket material
Bolt modeling with MPCs
Geometry

66

Units: mm
33

82

Eq. Stress At Pressure

Material properties Linear elastic material (Steel) for the engine block, plug, and bolts:
E = 2.1  10 5 MPa ,  = 0.3

Linear elastic material (aluminium) for the cylinder head:

E = 7.0  10 4 MPa ,  = 0.3

Isotropic in-plane behavior or the gasket body:

E = 120MPa , G = 60MPs

Isotropic in-plane behavior of the gasket body:

E = 100MPa , G = 50MPa

Out-of-plane pressure-over closure curves are used for the gasket body and
gasket ring using loading and unloading curves.
Analysis type Quasi-static analysis
Boundary conditions Some nodes on the outer boundaries on the engine block are constrained in
all directions
Applied loads Step 1: Enforces displacement of 0.25 mm on the bolts using MPC.
Step 2: Pressure load of 16 MPa
Element type 4-node tetrahedron elements
8-node CHEXA to model the gasket
Contact properties Glue contact
Extended tangential contact tolerance at sharp corners
FE results Displacement of the engine model
Contact pressure and forces on the gasket
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Model Airplane Engine Analysis

Introduction
The model airplane engine analysis consists of a cylinder head, a engine block, a gasket, bolts, and a
plug. The gasket is assembled between the head and the block. The problems demonstrates how the
solution sequence 400 of MD Nastran can be used for a typical analysis for engine involving the
nonlinear pressure-over closure relationship of the gasket material and bolt pre-tension load. Glued
contact is used to establish contact between the different parts of this engine model.

Required Solution
The nonlinear analysis involving large displacement and gasket nonlinearity is carried for the model
airplane engine to find the forces in the bolts and contact forces in the gasket.

FEM Solution
MD Nastran’s nonlinear solution sequence SOL 400 is used to analyze the engine model under the bolt
and pressure loads in two steps. The details of finite element models, contact simulations, material, load,
boundary conditions, and solution procedure are discussed in the following sections.

Finite Element Model

The finite element model used for the 3-D solid approach is shown in Figure 28-1. The model consists
of 88293 CTETRA element and 468 CHEXA elements. MD Nastran’s 4-node tetrahedral elements are
used for block using the following PSOLID and PSLDN1 options. Head, bolts, and plug are also models
with 4-node tetrahedral elements.
PSOLID 1 1 0
PSLDN1 1 1

Figure 28-1 Finite Element Model for Model Airplane Engine

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Using the following PSOLID and PSLDN1 options, the gasket body is modeled using MS Nastran’s
8-node hexahedral gasket elements. Here, the gasket material is referred to by the material ID 3. The
gasket ring is also modeled in a similar way using the different material ID 5.
PSOLID 5 3 0
PSLDN1 5 3 1
C8 SLCOMP L

Contact Model
For the contact definition, various parts of the model airplane engine are defined as deformable contact
bodies. the following BCBODY and BSURF entries show the contact body definition for the gasket. The
contact bodies for other parts of the model as also defined in a similar way. Figure 28-2 presents the
details of different contact bodies defined for the model airplane engine.
BCBODY 1 3D DEFORM 1 0
BSURF 1 70172 70173 70174 70175 70176 70177 70178
...

Zoomed view of contact parts

without head and block

Figure 28-2 Details of the Different Contact Bodies

The following BCTABLE entries identify how the contact bodies can touch each other. The BCTABLE
with ID 1 is used to define contact conditions at the first step of the analysis. This option is flagged in the
case control section through the optional BCONTACT = 1 option. Similar BCTABLE option with ID 2 is
used to define the contact conditions for second step in the analysis, and it is flagged using the option
BCONTACT = 2 in the case control section. Glued contact is used for all the six contact pairs defined in
the BCTABLE option. Delayed sliding is enabled for the contact pairs involving gasket by choosing the
value 2 for the field ICOORD.
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Model Airplane Engine Analysis

BCTABLE 1 6
SLAVE 1 0. 0. 0. 0. 1 0.
1 2 0
MASTERS 4
SLAVE 1 0. 0. 0. 0. 1 0.
1 2 0
MASTERS 7
SLAVE 2 0. 0. 0. 0. 1 0.
1 0 0
MASTERS 4
SLAVE 2 0. 0. 0. 0. 1 0.
1 0 0
MASTERS 7
SLAVE 3 0. 0. 0. 0. 1 0.
1 0 0
MASTERS 4
SLAVE 4 0. 0. 0. 0. 1 0.
1 0 0

Material
The linear isotropic elastic properties of the steel and aluminium materials are defined using the
following MAT entries. Steel properties are used for block, bolts and plug and aluminium properties are
used for cylinder head.
MAT1 1 210000. .3 7.86-6 1.-5
MAT1 2 70000. .3 2.7-6 2.4-5

The in-plane membrane properties of gasket body (ID 4) and gasket ring (ID 6) materials are defined
using the following MAT1 entries. The nonlinear pressure-over closure relation for the gasket body (ID
3) and gasket ring (ID 5) are defined using the following MATG entries.
MAT1 4 120. 60. 1.-6 5.-5
MAT1 6 100. 50. 2.-6 1.-4
MATG 3 4 0 1 2
52. 72.
35. .05
MATG 5 6 0 3 4
42. 64.
35. 0.

Figure 28-3 shows the pressure-over closure properties for the gasket materials. The following
TABLES1 entries (referred in the MATG entries) are used to define these nonlinear gasket properties.
$ Displacement Dependent Table : body_loading
TABLES1 1
0. 0. .027 2.08 .054 8.32 .081 18.72
.108 33.28 .135 52. .175 56. ENDT
$ Displacement Dependent Table : body_unloading
TABLES1 2
.1 0. .1225 5.04 .1375 14. .1525 27.44
.16 35.84 .1675 45.36 .175 56. ENDT
$ Displacement Dependent Table : ring_loading
TABLES1 3
0. 0. .026 1.68 .052 6.72 .078 15.12
.104 26.88 .13 42. .18 48. ENDT
$ Displacement Dependent Table : ring_unloading
TABLES1 4
.12 0. .138 4.32 .15 12. .162 23.52
.168 30.72 .174 38.88 .18 48. ENDT
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Gasket Pressure (MPa)

60
Body
Loading Curve Body
50 Unloading Curve Body Ring
Loading Curve Ring
40
Unloading Curve Ring

30

20

10

0
0.00 0.05 0.10 0.15 0.20
Gasket Closure (mm)
Figure 28-3 Pressure-over Closure Relations for Gasket Materials

Loading and Boundary Conditions

The analysis for the model airplane engine is carried out in two steps. In the first step, a pre-tension load
is applied on bolts. In the second step, a pressure load is applied in the part of head and gasket. Some
nodes on the outer boundaries on the block are constrained in all directions. Figure 28-4 shows these
boundary conditions applied in both Steps 1 and 2.

Figure 28-4 Constraints used in Steps 1 and 2

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Model Airplane Engine Analysis

The following data in case control section of the input file defines the load and boundary conditions at
the two different steps of the analysis. The bulk data entries SPCD, SPC1, and PLOAD4 are used to
define the boundary condition and loads in these steps. Bolt pretension loading is simulated using MPCs.
This technique is discussed in Chapter 23: Bolted Plates. The SPCD data is used for applying the
imposed displacement of 0.25 mm in the vertical direction in Steps 1 and 2 at the controlled nodes for
bolts. The lateral displacements at these four control nodes are constrained.
STEP 1
NLPARM = 1
BCONTACT = 1
MPC=100
SPC = 2
LOAD = 1
STEP 2
NLPARM = 2
BCONTACT = 2
MPC=100
SPC = 2
LOAD = 3
...
SPCD 1 37676 2 .25
SPCD 1 37714 2 .25
SPCD 1 37752 2 .25
SPCD 1 37790 2 .25
...
SPC1 11 13 37676
SPC1 13 2 37676
...
SPC1 20 123 987
SPC1 20 123 2453 THRU 2465
...
PLOAD4 2 55616 16. 15870 15071
...

Solution Procedure
The nonlinear procedure for the Step 1 is defined through the following NLPARM entry with ID 1. Here,
10 indicates the total number of increments; FNT represents Full Newton-Raphson Technique; 50 is the
maximum number of allowed recycles for every increment. PV indicates that convergence will be
checked on residuals (P). NO indicates that intermediate output will not be produced after every
increment. The 0.01 defined in the second line of NLPARM indicates the convergence tolerances of 0.1
for the residual checking. The fields MAXQN, MAXLS, and MAXBIS are set to zero to disable the Quasi
Newton, line search, and bisection techniques in the iterative process. Similar NLPARM option with ID
2 is used for Step 2.
NLPARM 1 10 FNT 1 50 P NO
0.01 0 0
0

Results
The variation of the bolt force at grid point 37676 as a function of the bolt shortening is shown in
Figure 28-5. This clearly shows a nonlinear response. The normal contact forces in gasket are shown in
Figure 28-6.
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Bolt Force (N)

5000

4000

3000

2000

1000
% of Load
0
0 20 40 60 80 100
Figure 28-5 Bolt Force as a Function of Bolt Shortening

Figure 28-6 Normal Contact Forces in Gasket

The displacement contours of the engine model in y-direction at Steps 1 and 2 are shown in Figure 28-7
and Figure 28-8.
The pressure-closure output for the gasket element 70582 is presented here from the f06 output file at
the end of Step 2. It is observed that the pressure for this gasket element exceeded the yield pressure of
52 MPa and this result in a plastic closure of 0.12 mm.
ELEMENT ID PLY ID INT. PT. ID PRESSURE CLOSURE PLASTIC CLOSURE
70582 1 1 7.637606E+01 1.986685E-01 1.200000E-01
2 8.096667E+01 2.016887E-01 1.200000E-01
3 7.600546E+01 1.984247E-01 1.200000E-01
4 8.045052E+01 2.013491E-01 1.200000E-01
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Model Airplane Engine Analysis

Figure 28-7 Displacement Contours in y-direction at Step 1

Figure 28-8 Displacement Contours in y-direction at Step 2

Input File
File Description
nug_28m.dat MD Nastran SOL 400 input for model airplane engine
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