FINITE ELEMENT ANALYSIS OF INSTALLATION FAILURES IN ENGINE CYLINDER-LINERS

There exist concerns regarding the failures that occur during the installation of thin cylinder-liners of engines at the authorized and unauthorized service centers. Analyzing the probable causes from the points of view of the design, manufacturing, and authorized and unauthorized installation procedures define the problem. The problem involves the simulation of the process of press-fitting the liner into the cylinder bore. A choice of finite element analysis using commercially available software ANSYS helped the analysis of the probable causes of failure. Estimation of the probable loads experienced by the cylinder-liners during the procedures that exist in the installation-process paved the way to the definition of loads that prevail in the problem of relevance. Prediction of the nature of contacts that prevail in the current problem and the impact of the application of the loads enabled the definition of constraints for the simulation procedures. Reference material properties chosen in the conservative sense modeled the problem realistically. The evolution of the recommendations for the manufacturing and installation of thin cylinder-liners concluded the study.