Stress Concentration Analysis of the Injection Pump Shaft
Paweł Bałon 1, 2  
,   Andrzej Świątoniowski 1  
,   Edward Rejman 3  
,   Bartłomiej Kiełbasa 2  
,   Robert Smusz 3  
,   Janusz Szostak 1  
,   Łukasz Kowalski 1  
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AGH University of Science and Technology, Al. Mickiewicza 30-B2, 30-059 Kraków, Poland
ZPU Mirosław Pogoda, ul. Wojska Polskiego 3, 39-300 Mielec, Poland
Rzeszów University of Technology, Al. Powstańców Warszawy 12, 35-959 Rzeszów, Poland
Paweł Bałon   

AGH University of Science and Technology, Al. Mickiewicza 30-B2, 30-059 Kraków, Poland
Publication date: 2020-06-01
Adv. Sci. Technol. Res. J. 2020; 14(2):155–162
The paper presents the methodology for designing the injection shaft drive for diesel engines with 2,3,4,6 and 8 cylinders as well as power from 2.5 to 52 kW per cylinder using the FEM method and experimental research. The pump is the original solution of the authors. The shaft is a basic part of the pump with a complex structure. In order to assess the state of stress in the shaft, the FEM analytical method was used and experimental tests were carried out, subjecting the shaft to torsional moment resulting from the transmitted power. Experimental studies confirmed the results of numerical calculations and the correctness of the adopted solution. The destructive tests were carried out to assess the maximum load capacity of the shaft, loading it with an increasing torque until visible plastic deformations occurred. This condition appeared at twice the moment (Ms = 602 Nm) in relation to the maximum predicted moment in operation (extreme operating conditions of the pump shaft). The theoretical studies confirmed very significant stress concentration (αk coefficient at the level of 2.63 or even 4.7), which may be the cause of fatigue cracks. It also determines the strength of the shaft and its torsional stiffness, which influences the proper functioning of the pump and ensures adequate fuel injection phases.