There were fatigue cracking problems at the intake ports of a prototype heavy-duty six-cylinder head. Several proposals of design change were evaluated by finite element and reliability analysis. Constant amplitude loading and monotonic temperature-dependent properties of the head material are assumed. An equivalent stress-strain parameter (ESSP) is proposed to consider multiaxial stress/strain effect on fatigue cracking. A significant reliability improvement was predicted with cost savings and verified by limited engine tests.
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