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DNVGL-CG-0037 Calculation of Crankshafts for Reciprocating

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DNVGL-CG-0037 Calculation of Crankshafts for Reciprocating CLASS GUIDELINE DNVGL-CG-0037 Edition November 2015 Calculation of crankshafts for reciprocating internal combustion engines The electronic pdf version of this document, available free of charge from http://www.dnvgl.com, is the officially binding version. DNV GL AS FOREWORD DNV GL class guidelines contain methods, technical requirements, principles and acceptance criteria related to classed objects as referred to from the rules. © DNV GL AS November 2015 Any comments may be sent by e-mail to [email protected] If any person suffers loss or damage which is proved to have been caused by any negligent act or omission of DNV GL, then DNV GL shall pay compensation to such person for his proved direct loss or damage. However, the compensation shall not exceed an amount equal to ten times the fee charged for the service in question, provided that the maximum compensation shall never exceed USD 2 million. In this provision "DNV GL" shall mean DNV GL AS, its direct and indirect owners as well as all its affiliates, subsidiaries, directors, officers, employees, agents and any other acting on behalf of DNV GL. CHANGES – CURRENT This is a new document. Editorial corrections In addition to the above stated main changes, editorial corrections may have been made. Changes - current Class guideline — DNVGL-CG-0037. Edition November 2015 Page 3 Calculation of crankshafts for reciprocating internal combustion engines DNV GL AS CONTENTS Changes – current...................................................................................................... 3 Contents Section 1 General....................................................................................................... 6 1 Scope...................................................................................................... 6 2 Field of application................................................................................. 6 3 Principles of calculation..........................................................................6 4 Drawings and particulars to be submitted.............................................. 7 Section 2 Calculation of stresses..............................................................................11 1 Explanations and Basic principles.........................................................11 2 Calculation of stresses due to bending moments and radial forces.......11 3 Calculation of alternating torsional stresses......................................... 17 Section 3 Evaluation of stress concentration factors................................................ 22 1 General................................................................................................. 22 2 Crankpin fillet....................................................................................... 24 3 Journal fillet (not applicable to semi-built crankshaft)......................... 25 4 Outlet of crankpin oil bore................................................................... 26 5 Outlet of journal oil bore......................................................................26 6 Inclined oil bores..................................................................................26 Section 4 Additional bending stresses......................................................................28 1 General................................................................................................. 28 Section 5 Calculation of fatigue strength................................................................. 29 1 General................................................................................................. 29 2 Empirical formulae for non-surface treated fillets.................................29 3 Surface treated fillets and/or oil holes.................................................32 Section 6 Acceptability criteria.................................................................................33 1 General................................................................................................. 33 2 The crankpin fillet criterion.................................................................. 33 3 The journal fillet criterion.....................................................................33 4 The oil hole criterion............................................................................ 34 Section 7 Calculation of shrink-fits of semi-built crankshaft.................................... 35 1 General................................................................................................. 35 2 Maximum permissible hole in the journal pin....................................... 36 Class guideline — DNVGL-CG-0037. Edition November 2015 Page 4 Calculation of crankshafts for reciprocating internal combustion engines DNV GL AS 3 Necessary minimum oversize of shrink-fit............................................ 36 4 Maximum permissible oversize of shrink-fit......................................... 37 Appendix A Definition of stress concentration factors in crankshaft fillets............... 38 Appendix B Stress concentration factors and stress distribution at the edge of oil Contents drillings.................................................................................................................39 Appendix C Alternative method for calculation of stress concentration factors in the web fillet radii of crankshafts by utilising finite element method................... 40 1 General................................................................................................. 40 2 Model requirements.............................................................................. 40 3 Load cases............................................................................................ 41 Appendix D Guidance for evaluation of fatigue tests................................................47 1 Introduction..........................................................................................47 2 Evaluation of test results......................................................................47 3 Small specimen testing....................................................................... 53 4 Full size testing.................................................................................... 54 5 Use of existing results for similar crankshafts......................................56 Appendix E Surface tested fillets and oil bore outlets.............................................. 58 1 Introduction..........................................................................................58 2 Definition of surface treatment............................................................ 58 3 Calculation principles............................................................................58 4 Induction hardening............................................................................. 63 5 Nitriding................................................................................................65 6 Cold forming......................................................................................... 67 Appendix F Stress concentration factors in the oilbore outlets of crankshafts by utilizing finite element method.............................................................................70 1 General................................................................................................. 70 2 Model requirements.............................................................................. 70 3 Load cases............................................................................................ 71 Class guideline — DNVGL-CG-0037. Edition November 2015 Page 5 Calculation of crankshafts for reciprocating internal combustion engines DNV GL AS SECTION 1 GENERAL 1 Scope This class guideline contains methods for calculation of safety against fatigue failure in pin and journal fillets and in oil bores, as well as safety against slippage for semi-built crankshafts. Note that also axial bores in crankpins can be critical. Section 1 In principle, any relevant calculation method may be applied for this purpose. E.g. the fatigue criteria assume that maximum resp. minimum bending stresses occur simultaneously with the maximum resp. minimum torsional stresses. (This assumption yields results which are more or less to the safe side.) If properly documented an evaluation of the fatigue capacity by using multi-axial fatigue methods may replace the criteria applied in this class guideline. A crankshaft will be approved when the calculation method as presented in this class guideline and/or the IACS UR M53 method is fulfilled. Crankshafts that cannot satisfy these rules may be subject to special consideration when detailed calculations and/or measurements are made to demonstrate equivalence to these rules. 2 Field of application These methods apply to engines for both main propulsion and auxiliary purpose, being designed for continuous operation at the specified (nominal) rating. If frequent use of overload (in excess of nominal) rating is foreseen, i.e. accumulating several millions of stress cycles, this overload should form the basis for the calculation. Further, the methods apply to solid forged or semi-built crankshafts of forged or cast steel, and with one crank throw between main bearings. Designs with more than one crank throw between main bearings, fillets between offset crankpins, fully built crankshafts, or welded crankshafts will be specially considered on basis of equivalence with the “normal” requirements. This method is also valid: — for
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