Papers by Keyword: Cylinder Head

Abstract: The present experimental study proposes an alternative for diagnostic methods and quality control in cylinder head defectology. The composition of the material is characterized by spectrometry, obtaining an approximation of aluminum 2117. For the detection of defectologies, non-destructive tests (NDT) are carried out, applicable to cylinder heads such as: visual inspection (VT) under conditions of standard EN 13018, penetrating inks (PT) visible according to ASTM E 165-02 and others not yet included in the vehicle fleet.; infrared thermography (IRT) with equipment specifications under ISO 18434 - 1, ultrasound (UT) based on standard EN 583 for the use of the equipment and Eddy currents (ECT) conforming standard ISO 15548, the analysis is carried out on the flat surface of the cylinder head, combustion chamber, valve seats and intake - exhaust ports, the different defects found are: cracks, fissures, discontinuities and pitting, showing longitudinal dimensions from 0,8 [mm]. To determine the reliability of results, an analogy is made of the tests mentioned in the same defect, the method with the greatest scope is Eddy currents as it has more inspection coverage with respect to the remaining tests; the simulation of computer-aided engineering CAE of the defect is performed, applying an AC magnetic analysis to identify the flux density, current density and visualize how the Eddy currents act in the cylinder head. After this research, artificial intelligence will be used as a complementary diagnosis, to predict defectologies not perceived by the human eye and to obtain a better analysis of defectologies in cylinder heads.

Abstract: Next generation IC engines are designed to achieve high efficiency and high specific power. As a single most design drivingfactor, combustion pressure is increased more than before. This has major impact on the design aspects of cylinder head. Its featuresbecome more delicate to accommodate various elements. Thermal aspects composing of heat generation (by combustion); heat transfer(combustion, cooling water, intake and exhaust gas) makes the design more challenging. Methods to enhance the heat transfer andcontrolling body temperature are discussed by various authors. In this paper a high specific power engine cylinder head is analysedusing coupled field analysis. To enhance heat transfer, inner flame deck surface is configured as a curved surface instead of flat presentin the conventional cylinder heads. Effect of reduction in the cross sectional area due to curvature is analysed against flat surface. It isfound that this new approach reduces the flame deck temperature considerably without compromising the structural strength factors.CFD, steady state thermal and structural analysis has been carried out for four different cases to conclude the extend of effectivenessdue to curvature.

Abstract: This paper documents the initially made and generally applicable systematisation and classification for optimised design of automotive cylinder heads by using hybrid compound material solutions. Proceeding from this background, different technical variants for design and manufacture of cylinder heads are presented. The intention is to combine different materials, so that locally different stresses in modern cylinder heads may be taken up through the specific use of appropriate materials. On the basis of fundamental investigations into the bonding behaviour of different materials, appropriate opportunities for an effective reduction resp. overcoming of the interfering oxide layer are derived. With this in view new design approaches are presented. As the basis for assessment and evaluation of their performance potential different FEM and CFD calculations for temperature field analysis, strength prognosis and fatigue strength are shown. Finally special casting tests regarding the practical feasibility of the appropriate conceptions in production are presented.

Abstract: The main rejections in the machining sections are exhaust valve port leak, injector bore blow hole, induction passage punchered, inlet valve port leak, top face unwash, valve guide hole blow hole, top face leak, joint face unwash, induction face unwash, rear face unwash, valve port unwash, water mixing with oil., water passage blocked, emf leak, injector bore leak, inlet valve port blocked, water way leak, oil way leak and defective jig location pad. This paper describes the method by which the rejections while maching the cylinder head, is minimized.

Abstract: The thermal state of the cylinder head has a huge influence on its fatigue and damage situation; therefore it is essential to accurately simulate the thermal state of the cylinder head during engine operation. In this paper, a method research of the cylinder head thermal state simulation test has been done. A thermal state simulation test bench has been launched, using induction heating and water-cooling to regulate the temperature. A series of cylinder head surface temperature field simulation tests has been accomplished. Compared to the actual engine test results, the temperature simulation results have an average error of less than 5% and a maximum error of 8.5% in these temperature test points. It turns out that the test bench can simulate the actual cylinder head temperature distribution accurately and will has significant effects on the research of the cylinder head thermal stress distribution and thermal fatigue situation.

Abstract: The analysis of structure and performance of internal combustion engine is presented in this paper from the following two aspects: the thermal load of I. C. Engine and the thermal efficiency of diesel engines. Firstly, the thermal load of key parts of I. C. Engine as well as the evaluation parameters of which are introduced briefly. Furthermore, based on the factors influencing the heat transfer process of internal combustion engine, the current research situation of internal combustion engine work process and heat balance for combustion chamber components, and the whole engine using numerical simulation method is described, while the coupled study of internal combustion engine components is developing trends of internal combustion engine heat balance study in the future.

Abstract: Remanufacturing process among industries is relatively new in Malaysia. In USA, Europe, Japan, China and India, remanufacturing is already viewed as a huge business opportunity that significantly stimulates growth in Gross Domestic Product (GDP) and employment. The aim of this paper is to expose all possible causes of failures using the Ishikawa diagram and identify the most significant failures using Failure Mode and Effect Analysis (FMEA) with two Risk Priority Number (RPNs). The cleaning process is both time-consuming as well as the most costly of the entire remanufacturing processes. The case study is performed in an automotive contract remanufacturing environment in Malaysia, specifically the remanufacturing of cylinder heads. This work outcome explores the current situation pertaining to the cleaning process in a real world situation, and attempts to promote among researchers green ideas that will bring Malaysias remanufacturing on par with that of other developed countries.

Abstract: The model of a gasoline engines cylinder head with 4 cylinders was reconstructed by CAD through slicing method and using Imageware and UG. The reverse design methods used for complex interior structure surface were explored based on slicing method through remodeling the cylinder head. The technologies of reverse design such as the measure method of points cloud, points cloud data treatment, and curve modeling were studied. The methods can be referenced for reverse designing the similar parts.

Abstract: The paper analyzed the temperature field, the thermal stress field and the stress field under mechanical loads of a diesel engine cylinder head with finite element analysis software ANASYS, then took above temperature field results and mechanical loads as boundary conditions to impose on the established model of cylinder head using the thermal mechanism indirect coupled method, researched the stress field and distortion of cylinder head under effect of multiplicative loads. The result indicates that the point of the highest temperature and the maximum thermal stress locates on the middle nose of fire deck; under thermal mechanism coupled effect, the points of maximum stress locate on the interface of bolt head and screw of cylinder head and on the middle nose of fire deck; the maximum pull stress the cylinder head undertook is less than that the material can survive; the distortion of the cylinder head is very small, thus has little influence on the fabrication of other accessories, and the global distortion of cylinder head performs symmetry.

Abstract: A synthesized simulation process was used to predicting temperature and high cycle fatigue (HCF) of cylinder head in this paper. Firstly, the temperature prediction model was built and calibrated by the test data, which ensured the rationality. The simulation result shows that the material thermal conductivity is very low and the position of the drilling holes near the deck is very high, and the thermal load was reduced effectively through improving the material conductivity and optimizing the structure design. Finally a fatigue life evaluation has been performed which shows the HCF safety factor is higher than the original design due to the temperature reduction.