In order to characterize mechanical components used in high responsibility applications, the knowledge of chemical composition and results from regular experiments such as traction, impact and hardness tests is important, but not sufficient. They cannot supply the necessary information that permit anticipating, in a reliable way, the components behavior in actual working conditions. As an example, there are engines cylinder head submitted to mechanical and thermal tensions that are relatively high during the in service use, and very high in same very demanding condition. During long run times and any failure in the cooling and/or lubrication the temperature may reach 300ºC. This temperature variation causes thermal shocks which may generate cracks and/or a wide ranging of plastic deformation in regions close to the pistons. Even not considering the thermal shock effects caused by failure, even so, a short number of start-up and shutdown cycles of engine, are considered the main cause of small cracks. This indicates that the generation of cracks in cylinder head may be considered as low cycle thermomechanical fatigue problem. Another problem is the microstructure heterogeneity in the component due to the casting process, leading to different physical and mechanical properties in the same piece. Besides the presence of porosity generated by gas bubbles and voids of solidification, which may be as great as short crack, reducing the nucleation life and changing the problems focus for the fatigue crack growth. The purpose of this study was to determine the isothermal and thermomechanical fatigue property through low cycle fatigue, as well as the fatigue crack growth, relaxation, microestrutural characterization and modeling of mechanical behavior by finite element for the aluminum alloy employed in the manufacture of engine cylinder head by the national automotive industry. Isothermal fatigue experiments were carried out at temperature of 120ºC and 280ºC and the thermomechanical performed in phase between the temperatures of 120ºC and 280ºC. The relaxation experiments were performed at some temperatures with trapezoidal wave loading, whereas the experiments of fatigue crack growth carried out at temperatures of 120ºC, 200ºC and 280ºC for sine and trapezoidal wave loading in displacement and load control. The microstructure analysis was also made in the specimens after the fatigue test by optical microscopy and scanning electron microscopy SEM. The results of these experiments showed that the casting defects and materials inhomogeneities, coupled long run times in high temperatures and loads, are a critical factor in the component performance. These results help us to establish accurate models for life prediction of the engine cylinder head. / Para caracterizar componentes usados em aplicações de alta responsabilidade não basta apenas conhecer a composição química e os resultados de ensaios de tração, impacto e dureza, pois estes podem não fornecer os subsídios necessários que permitam prever, de maneira confiável, o comportamento dos componentes nas condições reais de trabalho. Exemplo disto são os cabeçotes de motor automotivos, submetidos a tensões térmicas e mecânicas relativamente altas durante seu uso normal e altíssimo em condições extremas. Durante longos tempos de funcionamento e eventuais falhas na refrigeração e ou lubrificação a temperatura pode chegar a valores próximos de 300ºC. Esta variação de temperaturas provoca choques térmicos que podem gerar trincas e/ou uma grande quantidade de deformação plástica em regiões próximas aos pistões. Desconsiderando a presença de choques térmicos provocados por falhas, ainda assim, uma pequena quantidade de ciclos de acionamento e parada do motor, é considerada como os principais causadores de pequenas trincas. Isso indica que o surgimento de trincas em cabeçotes de motor deve ser considerado um problema de fadiga termomecânica de baixo ciclo. Outro problema é a heterogeneidade microestrutural no componente devido ao processo de fundição, levando a propriedades mecânicas e físicas diferentes em uma mesma peça. Além da presença de porosidade gerada por bolhas de gás e vazios de solidificação, que podem adquirir tamanho tal que se aproximem de pequenas trincas, diminuindo a vida para a nucleação e assim mudando o foco do problema para o de propagação de trinca por fadiga. A proposta deste trabalho foi a de determinar as propriedades de fadiga isotérmica e termomecânica através de ensaios de fadiga de baixo ciclo, bem como as propriedades de propagação de trinca por fadiga, relaxação, caracterização microestrutural e modelagem do comportamento mecânico por elementos finitos para a liga de alumínio utilizada na fabricação de cabeçotes de motores automotivos pela indústria nacional. Os ensaios de fadiga isotérmica foram realizados nas temperaturas de 120ºC e 280ºC e os ensaios termomecânicos foram realizados em fase entre as temperaturas de 120ºC e 280ºC. Os ensaios de relaxação foram realizados em várias temperaturas com carregamento de onda trapezoidal, enquanto que os ensaios de propagação de trinca por fadiga foram realizados nas temperaturas de 120ºC, 200ºC e 280ºC para carregamentos de onda senoidal e trapezoidal em controle de carga e de deslocamento. Foi feita também análise microestrutural nos corpos de prova, após os ensaios de fadiga, por microscopia óptica e por microscopia eletrônica de varredura MEV. Os resultados destes ensaios mostraram que os defeitos de fundição e a falta de homogeneidade no material, aliados a longos tempos de exposição a carregamentos e em altas temperaturas, constituem um fator crítico no desempenho do componente. Estes resultados ajudarão a estabelecer modelos precisos de previsão de vida para os cabeçotes de motor.

The studied material is an A356 Al alloy, used to produce engine cylinder heads for the automotive industry by die casting process. The material displays a quite coarse dendritic microstructure in a eutectic matrix, with a mean grains size of 25 microns, intemetallic precipitates and porosities. The tensile properties are strongly affected by testing temperature, with a quite sensitive drop of the Young's modulus, the Yield stress as the temperature was raised. The isothermal fatigue life dropped of markedly (approximately 10 times) when the testing temperature is raised from 120 to 280 °C, under strain control. From the themomechanical in-phase cyclic tests, with temperature varying from (120 to 280 oC), it was possible to observe that life is quite similar to the isothermal fatigue test at 280 oC. In this case, the more sensitive damage caused the in-phase mechanical and thermal cycle take place at the highest temperature. Relaxation tests indicated two distinct behaviors, with the temperature of 240°C being a threshold. At lower temperatures, the material hardens cyclically whereas it softens cyclically at higher temperatures. From the fatigue crack growth results, it was observed that temperature and wave shape has a strong influence on the crack growth rate as well as on the stress intensity threshold. Considering sinusoidal wave shape (10 Hz), as the temperature increased the DKth decreased and the crack propagation rate increased. However, the rate as da/dN change with temperature is quite similar, as an indicative that the micromechanism of crack growth has not changed due to the high frequency used, and it was due only to loss of mechanical strength. An elastic-visco-plastic non-isothermal constitutive law was identified for the material. For the cast material studied in this work, the mechanical behavior parameters are statistically distributed. However, it was shown that the model was able to reproduce, with a reasonable approximation, the stress - strain relationship at different temperatures, for the isothermal and anisothermal cases.

In order to characterize mechanical components used in high responsibility applications, the knowledge of chemical composition and results from regular experiments such as traction, impact and hardness tests is important, but not sufficient. They cannot supply the necessary information that permit anticipating, in a reliable way, the components behavior in actual working conditions. As an example, there are engines cylinder head submitted to mechanical and thermal tensions that are relatively high during the in service use, and very high in same very demanding condition. During long run times and any failure in the cooling and/or lubrication the temperature may reach 300ºC. This temperature variation causes thermal shocks which may generate cracks and/or a wide ranging of plastic deformation in regions close to the pistons. Even not considering the thermal shock effects caused by failure, even so, a short number of start-up and shutdown cycles of engine, are considered the main cause of small cracks. This indicates that the generation of cracks in cylinder head may be considered as low cycle thermomechanical fatigue problem. Another problem is the microstructure heterogeneity in the component due to the casting process, leading to different physical and mechanical properties in the same piece. Besides the presence of porosity generated by gas bubbles and voids of solidification, which may be as great as short crack, reducing the nucleation life and changing the problems focus for the fatigue crack growth. The purpose of this study was to determine the isothermal and thermomechanical fatigue property through low cycle fatigue, as well as the fatigue crack growth, relaxation, microestrutural characterization and modeling of mechanical behavior by finite element for the aluminum alloy employed in the manufacture of engine cylinder head by the national automotive industry. Isothermal fatigue experiments were carried out at temperature of 120ºC and 280ºC and the thermomechanical performed in phase between the temperatures of 120ºC and 280ºC. The relaxation experiments were performed at some temperatures with trapezoidal wave loading, whereas the experiments of fatigue crack growth carried out at temperatures of 120ºC, 200ºC and 280ºC for sine and trapezoidal wave loading in displacement and load control. The microstructure analysis was also made in the specimens after the fatigue test by optical microscopy and scanning electron microscopy SEM. The results of these experiments showed that the casting defects and materials inhomogeneities, coupled long run times in high temperatures and loads, are a critical factor in the component performance. These results help us to establish accurate models for life prediction of the engine cylinder head. / Para caracterizar componentes usados em aplicações de alta responsabilidade não basta apenas conhecer a composição química e os resultados de ensaios de tração, impacto e dureza, pois estes podem não fornecer os subsídios necessários que permitam prever, de maneira confiável, o comportamento dos componentes nas condições reais de trabalho. Exemplo disto são os cabeçotes de motor automotivos, submetidos a tensões térmicas e mecânicas relativamente altas durante seu uso normal e altíssimo em condições extremas. Durante longos tempos de funcionamento e eventuais falhas na refrigeração e ou lubrificação a temperatura pode chegar a valores próximos de 300ºC. Esta variação de temperaturas provoca choques térmicos que podem gerar trincas e/ou uma grande quantidade de deformação plástica em regiões próximas aos pistões. Desconsiderando a presença de choques térmicos provocados por falhas, ainda assim, uma pequena quantidade de ciclos de acionamento e parada do motor, é considerada como os principais causadores de pequenas trincas. Isso indica que o surgimento de trincas em cabeçotes de motor deve ser considerado um problema de fadiga termomecânica de baixo ciclo. Outro problema é a heterogeneidade microestrutural no componente devido ao processo de fundição, levando a propriedades mecânicas e físicas diferentes em uma mesma peça. Além da presença de porosidade gerada por bolhas de gás e vazios de solidificação, que podem adquirir tamanho tal que se aproximem de pequenas trincas, diminuindo a vida para a nucleação e assim mudando o foco do problema para o de propagação de trinca por fadiga. A proposta deste trabalho foi a de determinar as propriedades de fadiga isotérmica e termomecânica através de ensaios de fadiga de baixo ciclo, bem como as propriedades de propagação de trinca por fadiga, relaxação, caracterização microestrutural e modelagem do comportamento mecânico por elementos finitos para a liga de alumínio utilizada na fabricação de cabeçotes de motores automotivos pela indústria nacional. Os ensaios de fadiga isotérmica foram realizados nas temperaturas de 120ºC e 280ºC e os ensaios termomecânicos foram realizados em fase entre as temperaturas de 120ºC e 280ºC. Os ensaios de relaxação foram realizados em várias temperaturas com carregamento de onda trapezoidal, enquanto que os ensaios de propagação de trinca por fadiga foram realizados nas temperaturas de 120ºC, 200ºC e 280ºC para carregamentos de onda senoidal e trapezoidal em controle de carga e de deslocamento. Foi feita também análise microestrutural nos corpos de prova, após os ensaios de fadiga, por microscopia óptica e por microscopia eletrônica de varredura MEV. Os resultados destes ensaios mostraram que os defeitos de fundição e a falta de homogeneidade no material, aliados a longos tempos de exposição a carregamentos e em altas temperaturas, constituem um fator crítico no desempenho do componente. Estes resultados ajudarão a estabelecer modelos precisos de previsão de vida para os cabeçotes de motor.

The subject of this diploma thesis is the theoretical basis of the screw connection theory and the subsequent application to the specific screw connection problem. Mentioned connection is part of the turbo charged combustion engine, specifically directly between the cylinder head and the turbocharger. The diploma thesis is divided into several parts. The first part dealing with selected chapters of the screw connections and the combustion engines theory, whose knowledge is important for further chapters of this diploma thesis. The next part shows method of creating the geometric and computational model, on which were performed the appropriate sensory analyses with respect to determine the cause of the nut and bolt loose in the given connection. On the basis of the gained knowledge and their evaluation has been created a separate calculation methodology in the last part of this thesis, which describing parameters that have an impact on this undesirable phenomenon, and which should be included in analyses for similar issues. The diploma thesis was realized in cooperation with ŠKODA Auto a.s., tř. Václav Klementa 869, Mladá Boleslav, and AUDI AG, Union-Straße 1, Ingolstadt.

The work deals with the analysis of various possibilities of increasing the efficiency of a small internal combustion engine potentially usable for use in the field of autonomous devices of smaller dimensions. It contains an outline of the problems of modern smaller autonomous means and an analysis of available drives designed for them, especially an analysis of propulsion by internal combustion engines. In his next part of the work he provides information about the created mathematical model of the demonstration internal combustion engine in the GT-Power program and an analysis of places where and in what ways its efficiency can be increased. The design of two such components together with the evaluation of the achieved results offers the conclusion of this work.

Diploma thesis deals with the dynamic analysis of OHV pushrod valve train drive of the old-new conception of 6-cylinder tractor engine with 24 valves made by Zetor Tractors, a.s.. There is a requirement to create an analytical model and design valve springs for the engine. The work also points to the current analytical methods of appropriate simulation software used in automotive industry.

This dissertation thesis deals with interactions on the interface core - melt by casting of cylinder heads from Al alloys in semi-permanent moulds and solves a specific problem with sticky sand after decoring of a diesel cylinder head casting. It describes in detail the process of core production using the Cold-Box method and process of casting using the progressive technology Rotacast. It theoretically analyses the reaction on the interface core-melt and presents a classification of surface defects by Al castings produced by gravity casting into semi-permanent moulds. It also states the results of technological tests of binders, core mixtures and cores (Cogas analysis). By solution of a problem with sticky sand in intake and exhaust ports of diesel cylinder head casting is used methodology for problem solving DMAIC. All experimental tests are solved in laboratory and production conditions of an international company dealing with casting of cylinder heads from Al alloys in semi-permanent moulds.

Controlling the temperature of the exhaust valves is paramount for proper functioning of engines and for the long lifespan of valve train components. The majority of the heat outflow from the valve takes place along the valve-seat-cylinder head-coolant thermal path which is significantly influenced by the thermal contact resistance (TCR) present at the valve/seat and seat/head interfaces. A test rig facility and experimental procedure were successfully developed to assess the effect of the valve/seat and seat/head interfaces on heat outflow from the valve, in particular the effects of the valve/seat interface geometry, seat insert assembly method, i.e. press or shrink fit, and seat insert metallic coating on the operating temperature of the valve. The results of tests have shown that the degree of the valve-seat geometric conformity is more significant than the thermal conductivity of the insert: for low conforming assemblies, the mean valve head temperature recorded during tests on copper-infiltrated insert seats was higher than that recorded during tests on noninfiltrated seats of higher conformance. The effect of the insert-cylinder head assembly method, i.e. shrink-fitted versus press-fitted inserts, has proved negligible: results have shown insignificant valve head temperature variations, for both tin-coated and uncoated inserts. On the other hand, coating the seat inserts with a layer of tin (20-22¿m) reduced the mean valve head temperature by approximately 15°C as measured during tests on uncoated seats. The analysis of the valve/seat and seat/head interfaces has indicated that the surface asperities of the softer metal in contact would undergo plastic deformation. Suitable thermal contact conductance (TCC) models, available in the public domain, were used to evaluate the conductance for the valve/seat and seat/cylinder head interfaces. Finally, a FE thermal model of the test rig has been developed with a view to assess the quality of the calculated TCC values for the valve/seat and seat/head interfaces. The results of the thermal analysis have shown that predicted temperatures at chosen control points agree with those measured during tests on thermometric seats with an acceptable level of accuracy, proving the effectiveness of the used TCC models.

Für den Zylinderkopf ist das Schwerkraftgießen ein etabliertes Gießverfahren. Jedoch gehen die Gießereien in der Ausführung des Schwerkraftgusses unterschiedlich vor. Durch die mannigfaltigen Anschnittsysteme und die sich dadurch ergebenden Vor- bzw. Nachteile bei der Herstellung entstehen Unterschiede bei Qualität und Kosten. Ziel dieser Arbeit ist es, Standards und Vereinheitlichungen während der Produktentstehung eines Zylinderkopfes zu etablieren, um eine gleichbleibende Qualität der Zylinderköpfe in den Gießereien zu gewährleisten. Dazu sind vielfältige Ansatzpunkte zu verfolgen. Eine Möglichkeit ist die geometrische Beurteilung des Zylinderkopfs, wie z.B. Wandstärken, Speisungswege und die Außengeometrien. Die nach Lastenheftvorgaben zu erfüllenden Eigenschaften spielen gleichermaßen eine Rolle und haben Einfluss auf die Wahl des Gießverfahrens. Mit Hilfe von speziellen Entscheidungsmethoden ist eine Vorauswahl für ein Gießverfahren möglich. Des Weiteren werden mittels experimentellen Untersuchungen die Entscheidungen gestützt. Die Gießsimulation ist als zusätzliches Auslegungswerkzeug einzusetzen. Hierbei sind Gussfehler im Bauteil zu lokalisieren und zu vermeiden. Unzureichende Speisungswege oder zu geringe Wandstärken durch komplizierte Kerngeometrien sind zu ermitteln. Des Weiteren sind Vorhersagen zu Dendritenarmabständen und Materialausnutzung (Speiserdimensionierung) möglich, die direkt mit der Wahl des Gießverfahrens zusammenhängen. Die Verzahnung von Geometrie- und Metallurgiefaktoren führt idealerweise zur Definition von Standardisierungsaspekten zur Auswahl der Gießtechnologie bei der Zylinderkopfentwicklung. Durch eine parallele Produkt- und Prozessentwicklung ist eine Verkürzung des Produktentstehungsprozesses erreichbar.

Le matériau étudié est un alliage Al A356, utilisés pour produire des têtes de cylindres pour l'industrie automobile par fonderie. Le matériau présente une microstructure dendritique assez grossière dans une matrice eutectique, avec une taille moyenne de grains de 25 microns, des précipités intermetalliques et des porosités. Les propriétés de traction sont fortement affectées par la température d'essai, avec une baisse assez sensible du module de Young, de la limite d'élasticité lorsque la température augmente. La durée de vie de fatigue isotherme chute de façon marquée (approximativement d'un facteur 10) lorsque la température d'essai est portée de 120 à 280 °C, en déformation imposée. Du essais thermomecaniques cycliques en phase, avec une température variant de 120 à 280 °C, on montré que la durée de vie en anisotherme est assez similaire à celle obtenue en conditions isothermes à 280 oC. Dans ce cas, les dommages causés par le chargement thermomécanique cyclique se produisent à la température la plus élevée du cycle. Les essais de relaxation ont montré l'existence de deux comportements distincts. À basse température, le matériau présente de l'écrouissage cyclique tandis qu'il s'adoucit cycliquement à des températures plus élevées. A partir des résultats de croissance des fissures de fatigue, on a observé que la température et la forme du cycle de fatigue a une forte influence sur la vitesse de fissuration par fatigue ainsi que sur le facteur d'intensité des contraintes seuil. Une loi de comportement élastique visco-plastique non-isotherme a été identifiée pour le matériau. Les paramètres de comportement mécanique sont statistiquement distribués du fait de la fabrication du matériau par fonderie. Toutefois, il a été démontré que le modèle était capable de se reproduire, avec une approximation raisonnable, les essais contrainte-déformation à des températures différentes, pour le cas isotherme et anisotherme. / The studied material is an A356 Al alloy, used to produce engine cylinder heads for the automotive industry by die casting process. The material displays a quite coarse dendritic microstructure in a eutectic matrix, with a mean grains size of 25 microns, intemetallic precipitates and porosities. The tensile properties are strongly affected by testing temperature, with a quite sensitive drop of the Young's modulus, the Yield stress as the temperature was raised. The isothermal fatigue life dropped of markedly (approximately 10 times) when the testing temperature is raised from 120 to 280 °C, under strain control. From the themomechanical in-phase cyclic tests, with temperature varying from (120 to 280 oC), it was possible to observe that life is quite similar to the isothermal fatigue test at 280 oC. In this case, the more sensitive damage caused the in-phase mechanical and thermal cycle take place at the highest temperature. Relaxation tests indicated two distinct behaviors, with the temperature of 240°C being a threshold. At lower temperatures, the material hardens cyclically whereas it softens cyclically at higher temperatures. From the fatigue crack growth results, it was observed that temperature and wave shape has a strong influence on the crack growth rate as well as on the stress intensity threshold. Considering sinusoidal wave shape (10 Hz), as the temperature increased the DKth decreased and the crack propagation rate increased. However, the rate as da/dN change with temperature is quite similar, as an indicative that the micromechanism of crack growth has not changed due to the high frequency used, and it was due only to loss of mechanical strength. An elastic-visco-plastic non-isothermal constitutive law was identified for the material. For the cast material studied in this work, the mechanical behavior parameters are statistically distributed. However, it was shown that the model was able to reproduce, with a reasonable approximation, the stress – strain relationship at different temperatures, for the isothermal and anisothermal cases. / Para caracterizar componentes usados em aplicações de alta responsabilidade não basta apenas conhecer a composição química e os resultados de ensaios de tração, impacto e dureza, pois estes podem não fornecer os subsídios necessários que permitam prever, de maneira confiável, o comportamento dos componentes nas condições reais de trabalho. Exemplo disto são os cabeçotes de motor automotivos, submetidos a tensões térmicas e mecânicasrelativamente altas durante seu uso normal e altíssimo em condições extremas. Durante longos tempos de funcionamento e eventuais falhas na refrigeração e ou lubrificação a temperatura pode chegar a valores próximos de 300ºC. Esta variação de temperaturas provoca choques térmicos que podem gerar trincas e/ou uma grande quantidade de deformação plástica em regiões próximas aos pistões. Desconsiderando a presença de choques térmicos provocadospor falhas, ainda assim, uma pequena quantidade de ciclos de acionamento e parada do motor, é considerada como os principais causadores de pequenas trincas. Isso indica que o surgimento de trincas em cabeçotes de motor deve ser considerado um problema de fadiga termomecânica de baixo ciclo. Outro problema é a heterogeneidade microestrutural no componente devido ao processo de fundição, levando a propriedades mecânicas e físicas diferentes em uma mesma peça. Além da presença de porosidade gerada por bolhas de gás e vazios de solidificação, que podem adquirir tamanho tal que se aproximem de pequenas trincas, diminuindo a vida para a nucleação e assim mudando o foco do problema para o de propagação de trinca por fadiga. A proposta deste trabalho foi a de determinar as propriedades de fadiga isotérmica e termomecânica através de ensaios de fadiga de baixo ciclo, bem como as propriedades de propagação de trinca por fadiga, relaxação, caracterização microestrutural e modelagem do comportamento mecânico por elementos finitos para a liga de alumínio utilizada na fabricação de cabeçotes de motores automotivos pela indústria nacional. Todos os ensaios e análises computacionais foram realizados nos laboratórios da Universidade de São Paulo (EESC-USP) e da École Normale Supérieure de Cachan (ENS-LMT). Os ensaios de fadiga isotérmica foram realizados nas temperaturas de 120ºC e 280ºC e os ensaios termomecânicos foram realizados em fase entre as temperaturas de 120ºC e 280ºC. Os ensaios de relaxação foram realizados em várias temperaturas com carregamento de onda trapezoidal, enquanto que os ensaios de propagação de trinca por fadiga foram realizados nas temperaturas de 120ºC, 200ºC e 280ºC para arregamentos de onda senoidal e trapezoidal em controle de carga e de deslocamento. Foi feita também análise microestrutural nos corpos de prova, após os ensaios de fadiga, por microscopia óptica e por microscopia eletrônica de varredura MEV.Os resultados destes ensaios mostraram que os defeitos de fundição e a falta de homogeneidade no material, aliados a longos tempos de exposição a carregamentos e em altas temperaturas, constituem um fator crítico no desempenho do componente. Estes resultados ajudarão a estabelecer modelos precisos de previsão de vida para os cabeçotes de motor.