Dynamic Finite Element Model Based on Timoshenko Beam Theory for Simulating High-Speed Nonlinear Helical Springs

Area of Science:

• Mechanical Engineering
• Computational Mechanics

Background:

• Classical linear springs have limitations in high-speed dynamic scenarios.
• Existing finite element (FE) models for springs, particularly those using solid elements, are computationally intensive.
• Nonlinear helical springs demonstrate enhanced performance in diminishing dynamic responses.

Purpose of the Study:

• To develop an efficient FE spring model for high-speed dynamic simulations of nonlinear springs.
• To validate the proposed model using a beehive valve spring sample.
• To compare the computational resources and accuracy against traditional solid element FE models.

Main Methods:

• Development of a novel FE spring model based on Timoshenko beam theory.
• Simulation of a beehive valve spring under high-speed dynamic conditions (5600 and 8000 RPM).
• Comparison of simulation results with an FE model using solid elements and experimental engine head test data.

Main Results:

• The proposed FE model accurately predicts dynamic spring forces and coil clash phenomena.
• Rapid coil impact was observed to generate significant spike forces.
• The beam element-based FE model offers sufficient accuracy with substantially reduced computational resources compared to solid element models.

Conclusions:

• The Timoshenko beam theory-based FE model is a computationally efficient and accurate tool for simulating nonlinear springs.
• This approach is suitable for high-speed dynamic analysis, outperforming traditional solid element models.
• The findings are crucial for optimizing spring performance in demanding applications like automotive engines.