The mean stress effect in fatigue life varies by material and loading conditions. Therefore, a classical low cycle fatigue (LCF) model based on mean stress correction shows limits in asymmetric loading cases in both accuracy and applicability. In this paper, the effect of strain ratio (R) on LCF life is analyzed and a strain ratio-based model is presented for asymmetric loading cases. Two correction factors are introduced to express correlations between strain ratio and fatigue strength coefficient and between strain ratio and fatigue ductility coefficient. Verifications are conducted through four materials under different strain ratios: high-pressure tubing steel (HPTS), 2124-T851 aluminum alloy, epoxy resin and AZ61A magnesium alloy. Compared with current widely used LCF models, the proposed model shows a better life prediction accuracy and higher potential in implementation in symmetric and asymmetric loading cases for different materials. It is also found that the strain ratio-based correction is able to consider the damage of ratcheting strain that the mean stress-based models cannot.

Bird strikes are a common, serious, and devastating event in aviation accidents, and multi-bird strikes are also frequently reported. A numerical multi-bird-strike simulation was performed to investigate the effect of flocking birds striking on engine blades. The smooth particle hydrodynamics (SPH) method was adopted in the hemispherical-ended bird substitute model, and the finite element method (FEM) with EOS state equation was adopted for the fan model as well. Impact analyses have been presented using different flocking birds and impact location distributions. A “0-2-1” supported rotor system dynamic model was established to study the effect of the multi-bird-strike impact forces on the rotor system. The results show that bird-strike severity is related to the impact location distribution, with blade-root impacts being the most dangerous. The small flocking bird strikes had little effect on the fan compared to the cases of medium flocking birds and the large single bird. The dynamic response of the fan to the small flocking birds was the same as without a bird strike, while the other cases changed the motion period and excited the rotor first-order vibration.

The cylinder liner bears alternating thermal load and mechanical load, and evaluating the cylinder liner deformation is a key issue in the design stage of an engine. In this work, the shape and position tolerance of the cylinder liner to various loads were studied based on the finite element method, the simplex algorithm and the least square method. Firstly, the heat transfer boundary conditions of the cylinder liner were obtained through combustion simulation. Combined with the mechanical load, the transient deformation of the cylinder liner under the thermo-mechanical load was obtained. Subsequently, the out-of-roundness and coaxiality were selected to evaluate the shape and position changes in the cylinder liner. Finally, the transient tolerance analysis of the cylinder liner under alternating thermo-mechanical load was carried out. The results show that the maximum out-of-roundness of the cylinder liner under thermal load, mechanical load and thermos-mechanical load was 15.12, 43.40 and 51.76 μm, respectively. The maximum coaxiality under thermal load, mechanical load and thermos-mechanical load were 6.17, 80.49 and 80.22 μm. The side thrust was more likely to cause uneven deformation of the cylinder liner section, the liner coaxiality was mainly affected by the cylinder burst pressure, and the liner shape tolerance was much more sensitive to the mechanical load than the mechanical load.

In this paper, a simulation method based on an orthogonal anisotropic material is proposed. A numerical example using a simple plate is presented to show the difference in the static performance between the orthogonal anisotropic and the isotropic models. Comparing with the tested modal data of a diesel engine oil cooler cover made by glass fiber reinforced polyamide 66 (PA66), the proposed simulation method was confirmed to be much closer to reality than the general isotropic model. After that, a comprehensive performance comparison between the plastic oil cooler covers with the orthogonal anisotropic and the isotropic fiber orientations was carried out including a static deformation and stress analysis under a pressure-temperature coupled load, a forced response analysis, and an acoustic analysis under real operating conditions. The results show that the stress, the deformation, the peak vibration velocity, and the overall sound power level of the orthogonal anisotropic model are different from that obtained with the isotropic model. More importantly, the proposed method can provide a much more detailed frequency content compared to the isotropic model.

WC-10Co-4Cr coating is highly valued for its corrosion resistance and wear resistance when applied using the high-velocity oxy-fuel (HVOF) spraying method. However, conventional grinding (CG) of this coating presents challenges, including substantial grinding forces and elevated surface temperatures. To address these concerns, our study proposed the utilization of ultrasonic vibration-assisted grinding (UVAG) as a means to enhance the machining properties of HVOF-sprayed WC-10Co-4Cr coatings. Comparative experiments were conducted to analyze the impacts of various factors on the grinding forces and surface roughness in UVAG and CG processes. Additionally, the topography of the ground surfaces was examined to gain insights into the material removal mechanism in UVAG. The experimental outcomes reveal significant reductions in tangential and normal grinding forces, amounting to 15.47% and 22.23%, respectively, in UVAG when compared with CG. Furthermore, UVAG led to a roughly 29.14% decrease in ground surface roughness compared with CG. Microscopic analysis of the ground surfaces using scanning electron microscopy (SEM) indicated that ductile removal was the predominant material removal mode in UVAG. Overall, UVAG was found to be effective in diminishing grinding forces, improving ground surface roughness, and enhancing surface integrity when contrasted with CG. These findings introduce a novel approach for processing WC-10Co-4Cr coatings.