WS0405 MGoetz

Oberseminar - ICP
Temperature Calculation for Tribological

Simulation
Michael Gtz
Robert Bosch GmbH
DS/ETI2
24. Januar 2005
DS/ETI2 Vortrag 24.01.05.tex 24.01.05
c Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing to third parties. 0
Overview
Where to calculate the heat: diesel injection pump
First focus: journal bearings
The Task
The Model as Black-Box,
In-/Output:
ABAQUS
,
h(t,x,y), p(t,x,y) T(x,y,(z))
ADAMS
Excite
piston/shaft
motion
long iteration (ms) new geometry

material properties
short iteration ( s)
Difculties
Problem: huge scales (10
6
)
spatial:
gap: m whole pump: range of cm
temporal:
Timestepping of the shaftrotation: -seconds
warming of the whole pump is a matter of seconds
Approach
Some assessments:
Heat diffuses 30m in diesel in the time of one rotation of the shaft.
It diffueses 0.4mm in steel. (4500 rpm assumed)
Using a stepping of 0.1
for rotation the heat diffuses only 8nm in the

steel in the meantime of one step
It takes some rotations to have the heat penetrate the whole pump
To register an effect of the warming to the geometry it takes a lot more
rotations
Model
Out of this:
To simulate the heat propagation in the uid, very short
calculationsteps are required (due to the very small clearance).
In this short time, the heat propagation in the body+shaft can be
neglected due to the huge dimensions compared to the range of the
heat.
The outside boundaries can be neglected in the gap-calculation!
Conclusion:
The problem can be devided into two subproblems:
the gap with stepping of s
the body with stepping of ms
Model
Overview of the properties of the gap- and the body-calculation:
Gap:
3-dimensional
Steps of s
has halfspace as boundaries instead of pump body/shaft
The body/shaft:
3-dimensional
Steps of ms
Dirichlet-BC on surface, to the gap:
the sum of the heat ux of the gap-calculation
Model
Gap in detail
inside
three-dimensional transient heat propagation:
c
p

T +c
p
_
u
T
x
+v
T
y
+w
T
z
_
. .
convection
+ T
. .
diffusion
=
_
p
t
+u
p
x
+v
p
y
_
T
. .
compression
+
_
x
u
z
+
y
v
z
_
. .
shear strain
(1)
Gap in detail
inside
Another effect of heat generation is the mixed lubrication. However this heat
is added directly to the halfspaces, since the reason for this heat is the
plastic deformation and adhesion of the metal. So the heat is created inside
the structure and is conducted into the body much faster than into the uid.
Gap in detail
BC
the gap is planar (since the input variables are calculated with the
Reynolds-equation they imply the same assumption)
x-direction: periodic BC
y-direction: Dirichlet BC
z-direction: halfspaces (Carslaw), convective BC;
the heatux into the halfspaces is summed
Gap in detail
BC
Gap in detail
BC
Boundary conditions at the body=halfspaces
T
n
= (T T
S0
(x, y)) =

q n = q, (2)
the temperature rise of the halfspaces is calculated with
dT =
ZZ
A
q(x
, y
, 0, t
)
4c
p
[a(t t
)]
3/2
exp[
(x x
)
2
+(y y
)
2
4a(t t
)
]dx
dy
dt
. (3)
The heat ux

q into the halfspace is saved to be used later as the BC for the
body.
Gap in detail
BC
boundary condition of the uid at the sides of the bearing:
T = T
F0
1/2
(4)
at
y = 0 and y = L
Body in detail
inside and BC at the uid
Heat conduction equation inside the body:
c
p

T = (T) (5)
Boundary conditions at the gap:
q =
q
t
S
=
T
n
S
(6)
with
q =
t
I+1
Z
t
I
qdt and

q =
1
T
p
T
p
Z
q
M
dt (7)
Body in detail
BC at the uid
The heat ux q
M
is the sum of heat ux produced by the heat generation of
the uid:
q
M
= q+ q
G
, wobei q
G
= p
S
|
V| (8)
Unknown
and approximations
How to handle grooves and bore
The side of the halfspace ist perfectly at, whereas the FEM-model of
the uid adopt the deformation calculated by the input-program.
Curvature of the gap:
neglect in energy equation
inuence on halfspace
Optimization/Simplication
Outlook
Scale height of gap to get nicer Finite Elements
Adaptive Stepping
Worst case: neglect the detailed calculation of the uid. Create a
analytic model of the gap. Fluid is only a heat source and heat
resistance.
Implementation
Tools
Already tried: FEMLAB
FEMLAB cannot handle the extreme spatial conditions
Halfspaces cannot be included in FEMLAB due to a missing/slow
interface
= Implementation with Diffpack - Libraries
Results and Status
Gap calculation implemented. Example:
Animation
Results and Status
Material: steel
_
c
p
= 1708500
J
m
3
K
; = 0.12
W
mK
_
H/B/T:2/2,5/7,8 cm
Boundary conditions:
front-side/back-side: periodic;
left/right: Dirichlet: 90
C-3.3
C;
up/down: Konvektion (Robin): 8
C-103
C
Results and Status
Verication:
Transient heat conduction for innite
plates and convective boundary con-
ditions:
t
=

2

T
x
2
,
oo
,
oo
x=0 L +L
t=t
1
t=0
d
T
i
T
x
Analytic solution:
T( x,
t) =
n=1
_
2sin
n
n
+sin
n
cos
n
_
cos(
n
x)e
2
n
t
with
n
beeing n-th solution of the transcent equation cot =

L
.
Results and Status
Comparison of analytic and numeric solution:
Temperature
20
30
40
50
60
70
80
90
0.01 0.005 0 0.005 0.01
t
e
m
p
e
r
a
t
u
r
e

[
C
]
zdirection [m]
simulation
analytic solution
Animation (ambient temperature: 90
C)
Results and Status
speed of uid
0
50
100
150
200
250
300
350
0 0.005 0.01 0.015 0.02
s
p
e
e
d

[
m
/
s
]
zdirection [m]
simulation
analytic solution
Results and Status
Now: realistic dimensions, i.e. slim gap:
Height shown 1000x inated.
Results and Status
20
30
40
50
60
70
80
90
1e05 5e06 0 5e06 1e05
t
e
m
p
e
r
a
t
u
r
e

[
C
]
zdirection [m]
simulation
analytic solution
Animation (ambient temperature: 90
C)
Results and Status
Speed of uid
0
1
2
3
4
5
6
7
0 5e06 1e05 1.5e05 2e05
s
p
e
e
d

[
m
/
s
]
zdirection [m]
simulation
analytic solution
Thank you for your attention!!
Anhang
Berechnungen
Wrmereichweite:
L =
t
c
p
(9)
Zeit fr eine Umdrehung
t =
1
4500rpm
60 13ms
Stahl: = 44.5, = 7850
kg
mJ
, c
p
= 470
J
kgK
L 0.4mm
Diesel: = 0.12
W
mK
, = 850
kg
mJ
, c
p
= 2010
J
kgK
L 30m
Anhang
Formeln
=
u
z
=
_
N
m
2
_
Kinematische Viskositt:
=

=
_
m
2
s
_
Hamrock S. 54
a =

c
p
=
_
p
t
/p
0
_
=
1
273.16
0
C
1
(10)
Anhang
Variablen
T : Temperatur [K]
: Wrmebergangskoefzient
_
W
m
2
K
_
: Wrmeleitkoefzient
_
W
mK
_
a : Temperaturleitzahl
_
m
2
s
_
: Dichte
_
kg
m
3
_
: (absolute) Viskositt
_
Ns
m
2
_
: (Festkrper-) Reibkoefzient [dimensionslos]
c
p
: spezische Wrmekapazitt
_
J
kgK
_
=
_
m
2
s
2
K
_
q : Wrmeuss
_
W
m
2
_
L : Lagerbreite [m]
p
S
: Druck der Festkrpertrageanteile
_
N
m
2
_
Anhang
Bemerkungen
Ist in 2 konstant oder Funktion vonv?
Die Carslaw-Funktion ist noch in Zylinderkoordinaten zu schreiben

WS0405 MGoetz

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WS0405 MGoetz

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Oberseminar - ICP

Temperature Calculation for Tribological

long iteration (ms) new geometry

for rotation the heat diffuses only 8nm in the

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