International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

International Journal of Research and Innovation in

Thermal Engineering (IJRITE)
THERMAL INVESTIGATION (PRESSURE DISTRIBUTION) ON BOX TYPE CYLINDER
HEAD OF A 4 STROKE SINGLE CYLINDER WATER COOLED DIESEL ENGINE MATERIAL BY USING ANSYS15.0
Ch.Naga Mahalakshmi1, Medapati Sreenivasa Reddy2,Vallem Srinivasa Rao3.
1 Research Scholar, Department of Thermal Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India.
2 Associate Professor, Department of Mechanical Engineering, , Aditya Engineering College, Surampalem, Andhra Pradesh, India.
3 Associate Professor, Department of Mechanical Engineering, , Aditya Engineering College, Surampalem, Andhra Pradesh, India.

Abstract
In this project, we chose Optimization method as Optimization by Material. Present most used material for cylinder head
is Cast Iron. We are replacing with different aluminum alloys as their densities are less than that of Cast Iron. Thereby
the weight of the cylinder head reduces when aluminum alloys are used. In this project we are going to vary the materials LM6, LM24, LM25 different types of aluminum alloys. By varying above materials we are going to find out maximum
optimal convection rate. We are going to conduct thermal analysis as a FEA. By using thermal analysis result we are
going to conduct optimization analysis.
The parametric model is done in CATIA and analysis is done in ANSYS
*Corresponding Author:

WORKING OF BOX TYPE CYLINDER HEAD

Ch.Naga Mahalakshmi
Research Scholar, Department of Thermal Engineering,
Aditya Engineering College, Surampalem, Andhra Pradesh, India.
Email: ijripublishers@gmail.com

In the spark ignition engine an Air/Fuel mixture is formed

outside the combustion chamber. This mixture is generated in a Carburetor or by means of Fuel Injection, but in
either case the final Air/Fuel mixture is fed into the Cylinder, through the Intake, past the Inlet Valve. The mixture is then Compressed and subsequently Ignited by the
Spark Plug. The combustion of ignitable Air/Fuel mixture
is initiated (Ignited) by an Electric Spark and burnt inside
a working Cylinder.

Year of publication: 2016

Review Type: peer reviewed
Volume: III, Issue : I
Citation: Ch.Naga Mahalakshmi, "Thermal Investigation (Pressure Distribution) on Box Type Cylinder Head of A 4 Stroke Single Cylinder Water Cooled Diesel Engine Material By Using Ansys15.0" International Journal of Research and Innovation on
Science, Engineering and Technology (IJRISET) (2016) 67-71

INTRODUCTION TO IC ENGINES
The internal combustion engine is an engine in which
the combustion of a fuel (normally a fossil fuel) occurs
with an oxidizer (usually air) in a combustion chamber.
In an internal combustion engine, the expansion of the
high-temperature and high -pressure gases produced by
combustion apply direct force to some component of the
engine. This force is applied typically to pistons, turbine
blades, or a nozzle. This force moves the component over
a distance, transforming chemical energy into useful mechanical energy. The first internal combustion engine was
created by tienne Lenoir.

The combustion Heat given off increases the pressure of

the pre-compressed gasses. This after-combustion pressure is typically 400 to 700 PSI, which is much higher
than the pre-combustion pressure of 95 to 155 PSI
This high pressure produces mechanical work by forcing the Piston down and via Pin and Con Rod causes the
Crankshaft to turn.
After each Power Stroke the burnt gases are expelled by
the Piston's upward motion and discharged into the atmosphere past the Outlet Valve through Exhaust tract.
APPLICATIONS
Internal combustion engines are most commonly used for
mobile propulsion in vehicles and portable machinery. In
mobile equipment, internal combustion is advantageous
since it can provide high power-to-weight ratios together
with excellent fuel energy density. Generally using fossil fuel (mainly petroleum), these engines have appeared
in transport in almost all vehicles (automobiles, trucks,
motorcycles, boats, and in a wide variety of aircraft and
locomotives).
Where very high power-to-weight ratios are required, internal combustion engines appear in the form of gas turbines. These applications include jet aircraft, helicopters,
large ships and electric generators.

BOX TYPE CYLINDER HEAD

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

INTRODUCTION TO CYLINDER HEAD

Heat Flux: q = k (Tb- T) w/m

In an internal combustion engine, the cylinder head (often

informally abbreviated to just head) sits above the cylinders on top of the cylinder block. It consists of a platform containing part of the combustion chamber (usually,
though not always), and the location of the poppet valves
and spark plugs. In a flathead engine, the mechanical
parts of the valve train are all contained within the block,
and the head is essentially a flat plate of metal bolted to
the top of the cylinder bank with a head gasket in between; this simplicity leads to ease of manufacture and
repair, and accounts for the flathead engine's early success in production automobiles and continued success in
small engines, such as lawnmowers. This design, however, requires the incoming air to flow through a convoluted
path, which limits the ability of the engine to perform at
higher revolutions per minute (rpm), leading to the adoption of the overhead valve (OHV) head design, and the
subsequent overhead camshaft (OHC) design.
DETAILS
Internally, the cylinder head has passages called ports or
tracts for the fuel/air mixture to travel to the inlet valves
from the intake manifold, for exhaust gasses to travel
from the exhaust valves to the exhaust manifold. In a water-cooled engine, the cylinder head also contains integral
ducts and passages for the engines' coolant - usually a
mixture of water and antifreeze - to facilitate the transfer
of excess heat away from the head, and therefore the engine in general.
THEORETICAL CALCULATIONS OF CYLINDER HEAD
LM: 25
Bore x stroke = 87.5 x 110 mm
Clearance Volume = 661 cc = 0.000661m3
Swept Volume = "/(4 )" * d2 * L = 0.000661452 m

Total Volume of the Cylinder = Clearance volume + Swept

Volume = 0.001271452 m3
Density = 2680 Kg / m3

Material

K ( Thermal
Conductivity)
in (w/m-k)

Bulk
Temperature
(K)

Cylinder
Head
Temperature
(K)

q heat flux
(w/m)

LM 6

142.55

320

288.5

4490.33

LM 24

96.23

320

288.5

3031.25

LM 26

150.24

320

288.5

4732.56

CI

71.8

320

288.5

2261.7

Heat Transfer:
Q= (q * Area of cylinder)

Material

q(w/m)

Area of Cylinder
( m2)

Q
( watts)

LM 6

4490.33

0.006013204

27.00124

LM 24

3031.25

0.006013204

18.22749

LM 26

4732.56

0.006013204

28.45785

CI

2261.7

0.006013204

13.60006

Heat Transfer Co-efficient:

h = Q / (A * (Tb T))
Material

Q( watts)

Area of Cylinder
( m2)

h (w/m2-k)

LM 6

27.00124

0.006013204

142.55

LM 24

18.22749

0.006013204

96.23

LM 26

28.45785

0.006013204

150.24

CI

13.60006

0.00601324

71.8

STRUCTURAL ANALYSIS OF CYLINDER HEAD USING

CAST IRON

Mass of Cylinder Head = 3.40749136 KGs

Temperature = 288.555K
PV= m R T
P= m R T / V
P =2.21902.66 bar
CAST IRON:
Bore x stroke = 87.5 x 110 mm
Clearance Volume = 661 cc = 0.000661m3
Swept Volume = "/(4 )" * d2 * L = 0.000661452 m3
Total Volume of the Cylinder = Clearance volume + Swept
Volume = 0.001271452 m3

The above image is showing mesh model of object, meshing is

used to deconstruct complex problem in to number of small
problems using finite element method

Density = 7300 Kg / m3
Mass of Cylinder Head = 9.2815996 KGs
Temperature = 288.555K
PV= m R T
P= m R T / V
P =6.04436.35 bar

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

The above image is showing total deformation value

The above image is showing equivalent stress value

The above image shows total heat flux

The above image shows thermal error

STRUCTURAL ANALYSIS OF CYLINDER HEAD USING

ALUMINIUM CASTING ALLOY LM6

The above image is showing equivalent strain value

THERMAL ANALYSIS OF CYLINDER HEAD USING

CAST IRON

The above image shows temperature

The above image is showing equivalent stress value

THERMAL ANALYSIS OF CYLINDER HEAD USING ALUMINIUM CASTING ALLOY LM6

The above image shows temperature

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

RESULTS

In the next step a 3D parametric models of box type cylinder head was prepared and converted into IGES file to
conduct Analysis work in ANSYS.
Coupled field (structural & thermal combinations) analysis was conducted on parts us in Cast iron, Lm-6, LM-24
& LM-25 to evaluate the results. As per the obtained results LM-6 is showing good characteristics and also LM-6
is low weight material and low cost.
This theses work concludes that LM-6 will be the best
alternative for cylinder head instead of cast iron & LM-25
to reduce weight and to improve thermal transportations
values.
References
1 Engine Cylinder Head Thermal and Structural Stress
Analysis by Ing. Radek Tichnek, Ing. Miroslav paniel,
CSc. Czech Technical University in Prague
2 CYLINDER HEAD FEM ANALYSIS AND ITS IMPROVEMENT by Shixiong Li , Jinlong Mao1 , Shumao Wangn
College of Engineering, China Agricultural University,
Beijing, China,
3 A Study on Structural Stress Analysis of an Engine Cylinder Head by Dr. M. Lakshman Rao from Prakasam Engineering College , Kandukur
4 Static Stress Analysis of IC Engine Cylinder Head by
Sreeraj Nair K., Kiran Robert and Shamnadh M. Dept.
of Mechanical Engineering, T.K.M College of Engineering,
Kollam, Kerala, India.
5 Design and analysis of gasket sealing of cylinder head
under engine operation conditions by Chang-Chun Leea,
Kuo-Ning Chianga,,Wen-King Chenb, Rong-Shieh
Chenb from Department of Power Mechanical Engineering, National Tsing Hua University, Hsin Chu, Taiwan
300, ROC
6 paniel, M. - Macek, J. - Divi, M. - Tichnek, R.: Diesel
Engine Head Steady State Analysis, MECCA - Journal of
Middle European Construction and Design of Cars. 2003,
vol. 2, no. 3, s. 34-41. ISSN 1214-0821.

CONCLUSION
This theses work details with thermal investigation
(pressure distribution) on box type cylinder head of a 4
stroke single cylinder water cooled diesel engine material
by using ansys15.0 to provide best suitable material and
to improve thermal and structural efficiency and also to
reduce cost of the product.
At the beginning of theses literature survey and data collection was done to know about previous researches, approach and analysis work.
Theoretical calculations are done to provide values of
pressure, temperature, thermal co-efficiency, weight
etc. for cast iron, LM-6, LM-24 & LM-25.

7 McAssey, E.V. - Kandlikar, S.G.: Convective heat transfer of binary mixtures under flow boiling conditions, Villanova University, Villanova, PA USA
8 Hork, F. - Macek, J.: Use of Predicted Fields in Main
Parts of Supercharged Diesel Engine. Proceedings of XIX.
Conference of International Centre of Mass and Heat
Transfer. Pergamon Press, New York, 1987.
9 Macek, J. - Vvra, J. - Tichnek, R. - Divi, M.: Vpoet
obhu motoru 6c28 a stanoven okrajovch podmnek pro
pevnostn a deforman vpoet dna hlavy vlce. VUT v
Praze, Fakulta strojn, VCJB, 2001.
10 Macek, J. - Vtek, O. - Vvra, J.: Kogeneran jednotka
s plynovm motorem o vkonu vetm ne 3 MW-II. VUT
v Praze, Fakulta strojn, 2000.

Cast iron and LM-25 was the existing materials of box

type cylinder heads, here Lm-24 & Lm-6 is introduced to
reduce weight and to evaluate thermal stabilities.

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)

Author

Ch.Naga Mahalakshmi,
Research Scholar,Department of Thermal Engineering,
Aditya Engineering College, Surampalem,
Andhra Pradesh, India.

Medapati Sreenivasa Reddy,

Associate Professor, Department of Mechanical Engineering, Aditya Engineering College, Surampalem,
Andhra Pradesh, India.

Vallem Srinivasa Rao,

Associate Professor, Department of Mechanical Engineering, Aditya Engineering College, Surampalem,
Andhra Pradesh, India.

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