1 s2.0 S1026309811000101 Main
1 s2.0 S1026309811000101 Main
1 s2.0 S1026309811000101 Main
KEYWORDS Abstract The results of a thermo-mechanical analysis of a natural gas, internal combustion engine
Heat transfer; cylinder head are presented in this paper. The results are pertinent to the evaluation of overheating
Thermo mechanical; damage in critical areas. The three-dimensional geometries of the cylinder head and the water jacket were
Cylinder head; modeled by means of a computer-aided engineering tool. Commercial finite element and computational
Engine cooling; fluid dynamics codes were used to compute details of mechanical stress in the head and flow details in
CFD; the cylinder and cooling jacket, respectively. A six-cylinder, four-stroke diesel engine and a spark-ignition
FEA. natural gas engine were modeled over a range of speeds at full load. Computed results, such as maximum
allowable cylinder pressure, output power, BMEP and BSFC, were validated by experimented data in the
diesel engine model. The results were in good agreement with experimental data. The results show high
stresses at the valve bridge. Cylinder head temperatures and comparison of output power with high stress
measurements, often exceeding the elastic limit, were found at the valve bridge.
© 2011 Sharif University of Technology. Production and hosting by Elsevier B.V.
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Nomenclature
A area (m2 )
d average diameter of inlet and outlet ports (m)
g acceleration of gravity (m/s2 )
Gr Grashoff number
h convective heat transfer coefficient (W/m2 K)
k thermal conductivity coefficient (W/mK)
ṁ mass flow rate (kg/s)
Nu Nusselt number
P gas pressure (Pa)
P0 intake cylinder pressure (Pa)
Pe exhaust gas pressure (Pa)
P4 exhaust gas pressure at the starting point of the
exhaust valve opening
Pr Prandtl number
Ra Rayleigh number
Re Reynolds number
T temperature (K) Figure 1: Experimental set-up.
Diesel engine
and at 1100 engine speed for a diesel engine at full load, is A high speed turbocharger boosted the air introduced into
shown in Figure 3. the cylinders. Due to the boosting process, ambient air pressure
and temperature, according to Tables 3 and 4, were raised
3. Combustion simulation to 630 mbars (relative pressure) and 364 K, respectively, at
1000 rpm. By increasing engine speed to 1200 and 1800 rpm,
The combustion of natural gas in the considered engine was the inlet air pressure rose to 850 and 1400 bars and the inlet
simulated by the chemical reaction computation, CHEMKIN, air temperature reached 381 and 426 K, respectively. Direct
M. Fadaei et al. / Scientia Iranica, Transactions B: Mechanical Engineering 18 (2011) 66–74 69
Figure 4: Comparison of output torque and output power diesel engine with
technical data.
Details of efforts include: model definition, meshing, model The cylinder head geometry (Figure 7) and its associ-
analysis, validation of the Finite Element Analysis (FEA) model, ated thermal and structural constraint conditions are three-
70 M. Fadaei et al. / Scientia Iranica, Transactions B: Mechanical Engineering 18 (2011) 66–74
near the firedeck, which has given the valve bridge a smaller
cross-section than any other location in the cylinder head. The
valve bridge area is a region of concern and is finely meshed
to determine stress gradients accurately as recommended [4].
Figure 7: Multi-field computations procedure for (a) thermal-structural, (b) So to achieve more accurate results in the combustion and
CFD-thermal, and (c) loops sequence. valve bridge area, normal mesh, which is shown in Figure 10a,
has been converted to precise mesh, which is shown in
dimensionally modeled using SOLIDWORKS 2008. The mesh Figure 10b. The completed three-dimensional model contains
and analysis for the cylinder head are constructed by ANSYS. For 47234 elements and 48234 nodes (for solid), and 62234
thermo hydraulic analysis, a model of the water jacket for the elements and 51245 nodes (for CFD). Element aspect ratios are
cylinder is constructed, as well as the cylinder head (Figures 8 approximately 1.9 in the combustion and valve bridge area,
and 9). Flow characteristics of the water jacket, critical or main- which is shown in Figure 10b. Away from the combustion and
taining uniform firedeck cooling, were analyzed using CFD and valve area, element aspect ratios are less than 4.5. However,
the model of the water jacket. A brick-element mesh was con- this is not considered to be a significant problem, because the
structed and analyzed for the CFD work by using ANSYS 10. stress gradients at these locations are very low. In the non-
For an accurate result, mesh generation plays an important sensitive regions, such as the top of the cylinder head, a coarse
role. The small and sensitive areas are meshed with high mesh is applied in order to reduce the number of elements
resolution. The shape at the valve opening tapers outward and CPU time. Then the water jacket model of the cylinder
M. Fadaei et al. / Scientia Iranica, Transactions B: Mechanical Engineering 18 (2011) 66–74 71
Te = T4 (Pe /P4 )k /k .
−1
(7)
To apply outside boundary conditions, the Raleigh equation A comparison of diesel engine thermal analysis results
is used in the form of a free convection surface. For the and natural gas engine results is shown in Figure 11. The
72 M. Fadaei et al. / Scientia Iranica, Transactions B: Mechanical Engineering 18 (2011) 66–74
Figure 12: Comparison of average thermal results of natural gas and diesel
engines corresponding to selected path in Figure 10a.
Figure 15: Comparison of Von Mises stress results of natural gas and diesel
engines corresponding to selected path in Figure 10a.
Figure 16: Von Mises stress on the firedeck combustion surface is more than
yield stress in some areas.
Figure 14: Von Mises stress contours on the firedeck combustion surface of
(a) diesel engine, and (b) natural gas engine (MPa).
at the valve bridge, resulting from a constrained thermal
head. Based on computations results, the Von Mises stress for a expansion of the cylinder head, are generally compressive
natural gas engine in 6 nodes at the combustion area, shown in in those areas. For this natural gas engine, it is concluded
Figure 15, is 1.149 times more than the diesel engine stress at that about 91%–94% of total stress is due to thermal loading,
each point. The graph shapes for two engines are the same and and the remainder is due to pressure loading and mechanical
because of the temperature difference, the value of Von Mises at constraints. The temperature gradient at the surface of
each point is different. The temperature difference is the reason the combustion chamber is not uniform. According to the
for the Von Mises difference in the two engines. computation results, the Von Mises stress value exceeds
Another important result from the analysis is that the the elastic limit for cylinder head material in a natural gas
predicted Von Mises stresses exceed the elastic limit for a engine.
typical cylinder head material. The black regions in Figure 16 2. The use of cast iron GG-30 in the production process instead
depict regions of stress in a natural gas engine, which are high of the existing material of a natural gas engine, cast iron
and out of range (yield strength range). This high stress would GG25, leads to prevention of quick destructive fractures in
lead quickly to a destructive fracture in the cylinder head [25]. the cylinder head and makes the assurance factor increase.
3. Decrease of maximum compressive stress and high temper-
9. Conclusion ature in some critical areas, such as the valve bridge or valve
seat, the water-cooling system or water jackets in the cylin-
An investigation of stress and heat transfer by extensive der head, should be improved. The effect of coolant velocity
solid work, FEM/CFD and thermal analysis selected cylinder on the heat transfer coefficient is significant, so changing the
heads (converted engine) is conducted in the present work to water pump in order to increase the rate of coolant in the en-
determine their critical areas and weak points for development gine is recommended.
and design. Based on the reported results, the following
conclusions may be drawn: References
1. Maximum compressive stress is located at valve seats and
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optimization of IC engine’’, International Journal of Oil & Gas Science and Technology. He has worked in the Training Department of Iran Khodro Diesel as
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pressure simulation for a hermetic compressor, in: 2006 Int. Conf. on Mechanical Engineering. He is Managing Director Advisor of TKC Co., Member
Compressor Engineering, C071, Purdue, Indiana, USA, 2006, pp. 61–65. of the Board of Setare Iran Co., and Member of the Board of Tavoni Maskan Iran
[15] Catania, A.E., Misul, D., Mittica, A. and Spessa, E. ‘‘A refined two-zone heat Khodro. He has also been Deputy Managing Director in Engineering of TKC Co.,
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Verlag, Heidelberg, Berlin, (2006). His research interests are: Fluid Mechanics, Aerospace, Automotive, Powertrain
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