Cylinder Head Report

ICE
mini project 2017

CYLINDER HEAD DESIGN & SIMULATION
Submitted by
Group (2)
Under supervision
Prof. Dr. Saad Abdelhamid
Dr. Mohamed Anwar
Eng. Sherif Ahdy
December 2, 2017

1
Table of Contents
PART 1 (DESIGN)
INTRODUCTION 3
DESIGN OF INTAKE VALVE 4
DESIGN OF EXHAUST VALVE 7
DESIGN OF VALVE SPRING 10
DESIGN OF INTAKE PORTS 12
DESIGN OF EXHAUST PORTS 14
DESIGN OF PUSH ROD 16
DESIGN OF ROCKER ARM 17
DESIGN OF CYLINDER HEAD GASKET 21
CONCLUSION 24
PART 2 (STRESS ANALYSIS)
SIMULATION OF INTAKE VALVE 27
SIMULATION OF EXHAUST VALVE 32
SIMULATION OF INTAKE PUSH ROD 37
SIMULATION OF EXHAUST PUSH ROD 42
SIMULATION OF CYLINDER HEAD 47
SIMULATION OF INTAKE ROCKER ARM 52
PART 3 (THERMAL ANALYSIS)
SIMULATION OF INTAKE VALVE 57
SIMULATION OF EXHAUST VALVE 60
SIMULATION OF CYLINDER HEAD 63
PART 4 (PRODUCTION METHOD)
PRODUCTION OF INTAKE & EXHAUST VALVE 66
PRODUCTION OF INTAKE & EXHAUST PUSH ROD 69
PRODUCTION OF INTAKE & EXHAUST ROCKER ARM 71
PRODUCTION OF CYLINDER HEAD 76
REFRENCES 82
2
Part 1
Introduction
Cylinder Head design is a part of complicated configuration whose construction and principal
dimensions are dependent on the size of inlet and exhaust valves, fuel injectors positioning and
mounting, port layout and swirl and shape of combustion chambers. The cylinder head of a
gasoline engine has to perform many functions. It has to bring charge air and fuel mixture to
the cylinder and exhaust gas from the cylinder, with minimum pumping loss and required swirl
and other properties of charge motion. This paper describes about the Robust, Reliable and an
integrated approach used in design and development of a cylinder head for a high power density
engine, which can be adopted for automotive application. Design of Head is carried out within
several design, assembly and manufacturing constraints such as to maintain a specific cylinder
center distance, four valve layout, internal EGR passage, CGI material, incorporation of
various accessories, viz. manifolds, thermostat housing, cam carrier, glow plugs integrated with
pressure transducer, etc. Major focuses have been given on cylinder head layout, bolt Pattern,
port layoutting, water jacket core optimization for flow and strength while going for the design.
Components of Cylinder Head

Intake Valve
Exhaust Valve
Intake port
Exhaust port
Push rod
Rocker Arm
Head Gasket
Valve Spring
Cylinder Head Assembly
3
ENGINE SPECEFICATIONS:
Bore = 88.9 mm
Stroke = 100.076 mm
Power = 130.48 kwatt
Torque = 230.48 N. m
N = 4500 RBM
Z = 4 cylinder
8 = 2488 cc
: = 9.7
DESIGN OF INTAKE VALVE:

A poppet valve is a valve typically used to control the timing and quantity of gas or vapor flow
into an engine.
It consists of a hole, usually round or oval, and a tapered plug, usually a disk shape on the end
of a shaft also called a valve stem. The portion of the hole where the plug meets with it is
referred to as the 'seat' or 'valve seat'. The shaft guides the plug portion by sliding through a
valve guide.
Intake valves of most engines are poppet valves that are spring loaded closed and pushed open
at the proper time by the cam shaft. they have the advantage of being cheap, good seating, easy
lubrication and good heat transfer to the cylinder head.
Design Parameters:
A. Valve seat
B. Head Diameter
C. Stem Diameter
D. Valve head thickness
E. spring
F. Mean port diameter
4
Material Properties of valve:
Material properties Symbol Value
Density 7627 kg/m<
Youngs Modulus E 210 GPa
Ultimate Tensile Strength S>?@ 776 MPa
Yield Strength SA 314 MPa
composition Mn=0.4% , C=0.45%, Si=3.3%, S=8.6%
1- Valve head diameter

CD
A = C B B
EF
G
= dJ B
H
UL = 2LN
HPQQ S
= 2100.07610N< = 15.011
RQ T
15.011
AV = 1.3(88.910N< )B = 4.49610NH
343
G
AV = dJ B
H
dJ B = 5.72410NH
dJ =.0239
dJ =24 mm
2- Port diameter
Z
dY = B
[
HPQQ
dY = 88.9
<H<RQ
= 41.57 mm
dY]F^_`a = 20.8 mm
5
3- Valve lift
Q.BP bc
h=
deT
Q.BP BQ.g
h= = 7.35 mm
deT HP
4- Port area
Y
a = dY B
H
Y
a = 20.8B = 819.398 mmB
H
5- Thickness of valve disk

ijkl
t= K dY
m
BQ YQn
t = 0.4220.8 = 1.63 mm
Po.PYQp
6- Diameter of valve head opening
d< = dY B + dVr@stu Js?Ju B
d< = 20.8B + 24B = 28.9 mm
7- Width of seating
b =0.5 ( dJ dY )
=0.5 (24 20.8 ) = 1.6 mm
8- Diameter of valve stem

bc
de = +4
g
BQ.g
de = + 4 = 6.6 mm
g
6
Ne Symbol Design Parameter Dimension (mm)
1 dY Port Diameter 20.8
2 h Valve Lift 7.35
3 t Thickness of Valve 1.63
4 b Width 1.6
5 dJ Valve Diameter 24
6 de Valve steam 6.6
DESIGN OF EXHAUST VALVE:

Exhaust valve is termed as essential component of an IC engine as it provides path to expel out
the exhaust gases generated after combustion of the fuel in the combustion chamber. If there is
improper design of exhaust valve, then it indirectly affects its reliability. exhaust valve fails
before performing its intended function and thus the following stroke will begin to mix with
exhaust fumes rather than clean air. This may be inadequate for proper combustion and it leads
to poor running conditions. Exhaust valve fail at higher rate than intake valve. Because intake
valves are virtually cooled by fresh air, however exhaust valves are subjected to a very high
temperature burnt gases. Because of that it can be exposed to very high thermal stresses more
than intake valves and hence there are more chances of failure of exhaust valves rather than
intake valves. The detailed literature is available relevant to the proposed study.
Design problems:
In exhaust valve there is sudden change in cross section due to presence of valve stem as a
small shaft and valve head as a small disc, which is a functional requirement of exhaust valve.
Such a discontinuity in cross of exhaust valve generates maximum stress s concentration at the
junction where there is abrupt change in cross section. It is impossible to eliminate presence of
stress concentration totally but its reduction is possible to some extent. Change in cross
sectional area should be gradual to the possible extent, hence fillet is provided at the junction.
Thus stress concentration level can be reduced by selecting suitable fillet radius. Thus problem
statement is to design the valve with modeling & structural analysis by selecting suitable fillet
radius s for which stresses are less and recommending the best alternative material by finite
element analysis, so that valve can withstand to given operating conditions and to verify it
experimentally on UTM.
7
Design Parameters:
A. Valve seat
B. Head Diameter
C. Stem Diameter
D. Valve head thickness
E. spring
F. Mean port diameter
1- Port diameter
wx
dY = B
yz
YP
dY = 88.9
g<.<<
= 37.76
dY]F^_`a = 18.88 mm
2- Valve lift
Q.BP bc
h=
deT
Q.BP Yg.gg
h= = 6.675 mm
deT HP
3- Port area
Y
a = dY B
H
Y
a = 18.88B = 373.25 mmB
H
4- Thickness of valve disk

ijkl
t= K dY
m
BQ YQn
t = 0.4218.88 = 1.47 mm
Po.PYQp
8
5- Diameter of valve head
dB = dY + 2( (90 ))
dB = 18.88 + 2(1.47 (90 45))
dB = 20.88 mm
6- Diameter of valve head opening
d< = dY B + dVr@stu Js?Ju B
d< = 18.88B + 20.88B = 28 mm
7- Width of seating
b =0.5 ( dJ dY )
=0.5 (20.88 18.88) = 1 mm
8- Diameter of valve stem

bc
de = +4
g
Yg.gg
de = + 4 = 6.35 mm
g
Symbol Design Parameter Dimension ()
1 Y Port Diameter 18.88
2 h Valve Lift 6.675
3 t Thickness of Valve 1.47
4 b Width 1
5 y Valve Head Diameter 20.88
6 Valve Stem Diameter 6.35
9
DESIGN OF SPRING:
Take the material of spring Stainless Steel 316
= 580 MPa
G = 68947.57 MPa
PgQ
= = = 290 MPa
.. B
Design Parameters:
A. Wire diameter
B. Mean diameter
C. Free length
D. No. of turns
E. Pitch
1- Wire Diameter
g
=
G 8
where
F: Force acting on spring
D: mean Diameter
HB
K: constant K= , where C: spring Index , C=
HN< 8
Take C=10
d: Wire Diameter
Force acting on spring calculation:

= : x [ - [ x g
= 0.02 MPa
[ = 24 mm
[ = 40 gm

= 0.02 x x 24B - 0.04 x 9.8
H
= 11 N
10
g g YY YQ 8 Y.YHHg
= = = 290
G 8 G 8
= 1.05 mm
D = 10.5 mm
2- No. of active turns:

g
Y= 8
g YY YQ.P
7.35 =
RgHo.Po Y.QP
= 6.05
Take = 7 turns
Assume square and ground end
= + 2
= 9 turns
3- Free length
Q x d + y + a
a = 0.25 y
Q (9 x 1.05) + 7.35 + (0.25 x 7.35)
Q 18.64 mm
Take Q = 19 mm
4- Pitch
NB8
P =

YNB.Y
P=
o
P = 2.5
11
DESIGN OF INTAKE PORT:
In the cylinder head, the importance parts to increased the performance is the intake and
exhaust port. The importance of both port effect the performance of the engine and also the
engine efficiency. The instantaneous valve flow area depends on valve lift and the geometric
details of the valve head, seat and stem. There are 3 separates stages to the flow area
developments valve lift increases.
In the intake port, the air-flow motions are in turbulent motions. In turbulent flow, the rates of
transfer and mixing are several times greater than the rates due to molecular diffusion. This
turbulent diffusion results from the local fluctuations in the flow field. It leads to increase rates
of momentum and heat and mass transfer and is essentials to the satisfactory operation of spark
ignition.
Flow losses in an intake port:

In order to increase the intake flow performance, the
flow losses in the intake port area must be analyzed.
Those losses have restrict the mass air-flow rate entered
the intake port. Thus, the air-flow rate enter decreased.
Before the modification works is done, it needs to
overcome the losses. Generally, the intake port is design
to limited with the engine bore specifications. To
eliminates all the losses is impossible and the easiest
ways is to smoothen the air-flow entered and increased
the intake port scale by modification.
12
Design Parameters:
=valve seat angle
Lv=valve lift [mm]
Dv=valve head diameter
W=Seat width
Dm= mean seat diameter (Dv-W)
Dp= port diameter
Dp= valve stem diameter
From previous calculation:
Dv=24 mm, Lv=7.35 mm, W=1.6 mm, =45
= y = 24 1.6 = 22.4
Dp= 20.8 mm, Ds= 6.6 mm
1. First Stage:
For low valve lifts, the minimum flow area corresponds to a frustum of a right circular cone
where the conical face between the valve and the seat, which is perpendicular to the seat,
defines the flow area.
The minimum area is;
Am = Lv cos (Dv 2w + (Lv/2) sin 2)
7.35
= 7.35 cos 45 24 21.6 + sin 90
2
= 399.62 B
2. Second Stage:
For the second stage, the minimum area still the slant surface of a frustum of a right circular
cone, but his surface is no longer perpendicular to the valve seat. The base angle of the cone
increases from (90-) toward that of a cylinder, 90
12
Am = Dm [ (Lv w tan )2 + w2]
13
B
= 22.4[ 7.35 1.645 + 1.6 B ]
= 420 B
3. Third Stage:
Finally, when the valve lift is sufficiently large, the minimum flow area is no longer between
the valve head and seat; it is the port flow area minus the sectional area of the valve stem.
Am = /4 (Dp2 Ds2)
= /4(20.8B 6.6)
= 305.6
DESIGN OF EXHAUST PORT:

From previous calculation:
Dv=20.88 mm, Lv=6.675 mm, W=1 mm, =45
= y = 20.88 1 = 19.88
Dp= 18.88 mm, Ds= 6.35 mm
1. First Stage:
For low valve lifts, the minimum flow area corresponds to a frustum of a right circular cone
where the conical face between the valve and the seat, which is perpendicular to the seat,
defines the flow area.
Am = Lv cos (Dv 2w + (Lv/2) sin 2)
6.675
= 6.675 cos 45 20.88 21 + sin 90
2
= 329.33 B
14
2. Second Stage:
For the second stage, the minimum area still the slant surface of a frustum of a right circular
cone, but his surface is no longer perpendicular to the valve seat. The base angle of the cone
increases from (90-) toward that of a cylinder, 90
12
Am = Dm [ (Lv w tan )2 + w2]
B
= 19.88[ 6.675 145 + 1 B]
= 359.9 B
3. Third Stage:
Finally, when the valve lift is sufficiently large, the minimum flow area is no longer between
the valve head and seat; it is the port flow area minus the sectional area of the valve stem.
Am = /4 (Dp2 Ds2)
= /4(18.88B 6.35)
= 248.3
15
DESIGN OF PUSH ROD:
Pushrods transfer and redirect the upward motion of the lifters,
which goes in one direction, to the rocker arms which move in
another direction. Consequently, they are subjected to bending
forces as the load and engine speed increases.
failure in push rod is due to :
1- crushing .
2- buckling .
But for long column, the value of buckling load will be less than the crushing load.
The push rods are used in overhead valve and side valve engines. Since these are designed a
long column, therefore Eulers formula should be used. The push rods may be treated as pin
end columns because they use spherical seated bearings.
Design Parameters:
D: Diameter of the push rod.
d: Diameter of the hole through the push rod. (d=0.8D)
Take the material of push rod 1018 steel
E=200 GPa
Assume the length of push rod (L=300 mm)
From cam design calculation the force acting on push rod
Fintake = 550 N
Fexhaust 1633 N
Diameter Calculation:
From Euler equation

: =

: = W x F.O.S
W: load acting on push rod
I: Moment of inertia of the push rod

H
= 1.25 H = 0.07 H
RH
F.O.S = 2.5
16
1- For intake push rod
BQQYQ Q.Qo8
2.5 550 =
<QQ
d = 5.5 mm
D = 6.84 mm
2- For Exhaust push rod

BQQYQ Q.Qo8
2.5 1633 =
<QQ
d = 7.2 mm
D = 9 mm
No. Intake push Rod Exhaust Push Rod
d (mm) 5.5 7.2
D (mm) 6.84 9
DESIGN OF ROCKER ARM:

A rocker arm is a valve train component in internal combustion
engines. As a rocker arm is acted on by a camshaft lobe, it pushes
open either an intake or exhaust valve. This allows fuel and air to
be drawn into the combustion chamber during the intake stroke or
exhaust gases to be expelled during the exhaust stroke.
The rocker is an oscillating lever that conveys radial movement
from the cam lobe into linear movement at the poppet valve to open
it. The drive cam is driven by the camshaft. This pushes the rocker
arm up and down about the pin or rocker shaft.
Design Parameters:
mv = Mass of the valve
dv= Diameter of the valve head
h = Lift of the valve
a = Acceleration of the valve
Pc = Cylinder pressure or back pressure (Pc: BMEP = 1.16 MPa )
Ps = Maximum suction pressure (Ps = 0.02 MPa)
17
d1 = is diameter of fulcrum pin
D1 = is diameter of boss
l = Length of arm
1- For Exhaust rocker arm

Force Calculation:
1. Gas load on the valve:
P1 = /4(dv)2 Pc = = /4 x (20.88)2 x 2
=684.82 N
Weight of associated parts with the valve

w=mxg
w = 0.09 x 9.8 = 0.882 N
Total load on the valve,
P = P1 + w = = 684.82 + 0.882 = 685.7 N
2. Spring Force:
(Initial spring force considering weight of the valve)
Fs = /4 (dv)2 Ps w
= /4 x (20.88)2 x 0.02 0.882
= 5.966 N
3. Force due to acceleration of valve:
NC = N 2 = 4500 2 = 2250 rpm

BBPQ
= x 360 = 13500 deg s
RQ
YYQ
t= = = 0.00814 s
d Y<PQQ
BG
a = 2 x r = ( )2x r = 1988.23 m s2
@
Fa = m x a + w = 0.09 x1988.23 + 0.882 = 179.82 N

4. Reaction at fulcrum pin
F e = P + Fs + F a
= 685.7 +5.968 +179.82 = 871.486 N
F c = 2 Fe
Fc = 1742.97 N
RF = Fe B + Fc B 2FeFc cos
= 871.48 B + 1742.97 B 2x871.481742.97 cos 176
= 2613 N
18
Stress Calculation
1. shear stress at the pin:
G
Rf = 2 d2 x
H
G
2613 =2x (8)2 x =26 N mm2
H
2. bending moment (M) of cross section:

Yg
M = Fe ( I- ) = 871.486 ( 27- ) = 15686.64 N.mm
B B
3. Section module Z of I-section:

Y
YB B.P@ R@ <NY.P@ H@ <
Z= R@ t = 3 mm
B
z = 332.91 mm3
4. Bending stress:
YPRgR.RH
= = = 47.12 N mm2
<<B.Y
2- For intake rocker arm

Force Calculation:
1. Gas load on the valve:
P1 = /4(dv)2 Pc = = /4 x (24)2 x 2
=904.78 N
Weight of associated parts with the valve

w=mxg
w = 0.09 x 9.8 = 0.882 N
Total load on the valve,
P = P1 + w = = 904.78+ 0.882 = 905.66 N
2. Spring Force:
(Initial spring force considering weight of the valve)
Fs = /4 (dv)2 Ps w
= /4 x (24)2 x 0.02 0.882
= 8.16 N
3. Force due to acceleration of valve:
NC = N 2 = 4500 2 = 2250 rpm

BBPQ
= x 360 = 13500 deg s
RQ
19
YYQ
t= = = 0.00814 s
d Y<PQQ
BG
a = 2 x r = ( )2x r = 1988.23 m s2
@
Fa = m x a + w = 0.09 x1988.23 + 0.882 = 179.82 N

4. Reaction at fulcrum pin
F e = P + Fs + F a
= 905.66 +8.16 +179.82 = 1093.645 N
Fc = 2 Fe
Fc = 2187.3 N
RF = Fe B + Fc B 2FeFc cos
= 1093.645 B + 2187.3 B 2x1093.6452187.3 cos 176
= 3279 N
Stress Calculation
1. shear stress at the pin:
G
Rf = 2 d2 x
H
G
3279=2x (8)2 x =32.62 N mm2
H
2. bending moment (M) of cross section:

Yg
M = Fe ( I- ) = 1093.645 ( 27- ) = 19685.61 N.mm
B B
3. Section module Z of I-section:

Y
YB B.P@ R@ <NY.P@ H@ <
Z= R@ t = 3 mm
B
z = 332.91 mm3
4. Bending stress:
YRgP.RY
= = = 59.13 N mm2
<<B.Y
20
DESIGN OF HEAD GASKET:
A cylinder head gasket is required to affect a seal between
the cylinder head and block of a gasoline or diesel engine.
It is an integral component of the engine and is required to
perform many functions at the same time during engine
operation. The head gasket must maintain the seal around
the combustion chamber at peak operating temperature and
pressure. The gasket must seal against air, coolants,
combustion and engine oil at their respective peak
operating temperature and pressure. The materials used and
design employed must be thermally and chemically
resistant to the products of combustion and the various
chemicals, coolants and oils used in the engine.
The compression in the cylinder will cause a leak to form in the gasket and the gasket will have
to be replaced, or severe damage can take place (a "blown" head gasket). This problem has
been exacerbated by the use of alumina epoxy cylinder head gasket. In carbon fiber, Kevlar
fiber, pyrosic ceramic glass fiber has a much greater thermal expansion rate, which in turn
causes a great deal more stress to be placed on the head gasket.
The most widely used materials are as follows:

Steel and stainless steel of various grades and forms.
Fiber based composite materials.
Graphite in various densities.
Chemical formulations containing poly tetra fluoro thylene, silicone, nitrides,
neoprene, polymeric resins and others.
MATERIAL SELECTION OF GASKET

1. Stainless steel head gasket
Stainless steel cylinder head gaskets (CHG) play the main role in the todays sealing industry
for internal combustion engines for the automotive industry and become more and more
important for the heavy duty applications. The stainless steel CHG consists of metal of the
gasket cross section. Now days we are using the stainless steel gasket to diesel engine.
Stainless steel does not readily corrode, rust or stain with water as ordinary steel does; but,
despite the name, it is not fully stain-proof, most notably under low-oxygen, high-salinity, or
poor-circulation environments. There are different grades and surface finishes of stainless
steel to suit the environment the alloy must endure. Stainless steel is used where both the
properties of steel and corrosion resistance are required.
21
Table 1 Material and mechanical properties of stainless steel:
2. Carbon Fiber head gasket

Carbon fibers are usually combined with other materials to form a composite. When combined
with a plastic resin and wound or molded it forms carbon fiber reinforced polymer (often
referred to as carbon fiber) which has a very high strength-to-weight ratio, and is extremely
rigid although somewhat brittle. However, carbon fibers are also composed with other
materials, such as with graphite to form carbon-carbon composites, which have a very high
heat tolerance.
Table 2 Mechanical and material properties of carbon fiber
3. Pyrosic Glass- Ceramic

Ceramic matrix composite materials (CMC) and composite materials featuring glass, metal and
synthetic matrices and reinforced with silicon carbide fiber, for use in the manufacture of
structural components in the nature of heat shields, insulating panels, exhaust pipes and ducts,
and insulating refractory material.
22
Table 3 Mechanical and material properties of pyrosic glass- ceramic

4. Kevlar Fiber
Kevlar is the registered trademark for a para-aramid synthetic fiber, related to other aramids
such as Nomex and Technora. Developed by Stephanie Kwolek at DuPont in 1965, this high-
strength material was first commercially used in the early 1970s as a replacement for steel in
racing tires. Typically it is spun into ropes or fabric sheets that can be used as such or as an
ingredient in composite material components.
Table 4 Mechanical and Material Properties Kevlar Fiber
GASKET DESIGN:
Every application requires a unique cylinder head gasket design to meet the specific
performance needs of the engine. The materials and designs used are a result of testing and
engineering various metals, composites and chemicals into a gasket that is intended to maintain
the necessary sealing capabilities for the life of the engine.
Head gasket thickness calculation

C= 18.46 (t3 x H)1/4
Since:
C =100 mm
H = 0.1 mm
therefore: t = 3 mm where t: is the thickness of the head gasket
23
CONCLUSION:
By using Engine Analyzer application and creating a model with the current engine
specifications and the parameters calculated from our design we found that the peak power
changed from 175 HP@600RPM to 142 HP @ 5500 RPM and the peak torque changed from
170 lb.-ft.@ 4000 RPM to 147 lb.-ft. @5000 RPM.
Engine Analyzer Pro v3.9 B Your name and phone # can go This Report Printed:
Eng: 2016 Ford fusion ICE mini project here. Click on Preferences. 12:10:17 am 12-02-17
Calculated Test Results Performance Trends (C) 2016 Page: 1
Report Comment: Final Conclusion

Engine Comments:
GROUP 2
ICE MINI PROJECT 2017
Projected Performance
Engine RPM 2000 2500 3000 3500 4000 4500 5000 5500 6000 6500
Brk Tq, ft-lbs 142.8 129.1 127.1 133.2 140.1 146.4 147.3 135.9 120.1 86.4
Brake HP 54.4 61.4 72.6 88.8 106.7 125.4 140.2 142.3 137.2 106.9
Exh Pres, PSI .3 .4 .6 1.0 1.4 1.9 2.4 2.8 3.0 2.8
Int Vac, "Hg .6 .8 1.2 1.9 .8 1.1 1.5 1.7 1.9 1.8
Vol Eff, % 80.4 75.3 76.2 81.2 86.2 91.2 93.9 92.1 87.5 79.8
Actual CFM 70.5 82.5 100.2 124.6 151.2 180.0 205.9 222.1 230.1 227.4
Fuel Flow, lb/hr 24.61 28.82 35.00 43.54 52.83 62.87 71.91 77.60 80.38 79.45
Nitrous, lb/hr .00 .00 .00 .00 .00 .00 .00 .00 .00 .00
Ntrs Fuel, lb/hr .00 .00 .00 .00 .00 .00 .00 .00 .00 .00
BMEP, PSI 142.2 128.5 126.5 132.6 139.4 145.7 146.6 135.2 119.6 86.0
A/F Mxtr Qlty, % 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0
BSFC, lb/HP-hr .453 .469 .482 .491 .495 .501 .513 .545 .586 .743
Thermal Eff, % 34.19 34.07 33.88 33.63 33.63 33.54 33.35 32.58 32.02 28.84
IMEP, PSI 164 153 154 163 173 183 187 179 167 137
Frctn Tq, ft-lbs 21.92 24.69 27.59 30.62 33.78 37.08 40.52 44.10 47.81 51.67
Frctn HP 8.35 11.75 15.76 20.40 25.73 31.77 38.58 46.18 54.62 63.94
FMEP, PSI 21.81 24.57 27.46 30.47 33.62 36.91 40.33 43.89 47.58 51.42
Mech Eff, % 86.7 83.9 82.2 81.3 80.6 79.8 78.4 75.5 71.5 62.6
Motoring HP 9.01 13.47 18.82 25.11 31.96 39.67 49.21 60.95 73.21 87.21
Pumpng Work, HP -.66 -1.72 -3.06 -4.70 -6.23 -7.89 -10.64 -14.77 -18.59 -23.27
Residual Exh, % 5.9 7.4 6.5 4.7 5.7 5.8 5.2 4.8 4.8 6.1
Shrt Circuit, % .0 .0 .0 .0 .0 .0 .0 .0 .0 .0
Exh Temp, deg F 1241 1244 1269 1299 1323 1340 1352 1362 1360 1282
Mx Cyl Pres, PSI 920 855 860 912 976 1034 1065 1036 980 854
Mx Cyl Tmp, deg F 4664 4583 4619 4677 4673 4678 4724 4713 4698 4420
In Port Tmp, deg F 132 128 124 117 114 111 107 105 106 106
Piston Spd, ft/min 1312 1640 1969 2297 2625 2953 3281 3609 3937 4265
Piston Gs @ TDC 300 470 680 920 1200 1520 1880 2270 2710 3180
Coolant HP 24.27 28.82 34.19 39.90 46.01 52.18 59.26 65.62 72.32 74.31
Blow By, CFM 1.6 1.5 1.5 1.6 1.7 1.8 1.9 1.8 1.7 1.6
In Tun Pres, PSI .7 .1 -.1 .5 .9 2.3 3.3 3.6 3.4 3.1
Avg In Vel, ft/sec 131 164 197 230 263 295 328 361 394 427
Avg Ex Vel, ft/sec 153 191 229 267 305 343 381 420 458 496
Mach # .154 .193 .232 .270 .309 .347 .386 .425 .463 .502
Act In FlowArea,% 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0
Act Ex FlowArea,% 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0 100.0
Valve Toss PmpUpPmpUp
Knock Index 1.5 1.1 1.1 1.1 1.2 1.2 1.2 1.1 .9 .6
Spark Advnc, deg 14.1 15.7 16.5 16.7 17.4 17.8 18.1 18.7 19.5 20.6
Injctr Dty Cyc, %
Inj Plse Wdth, ms
Calc Error 0 0 0 0 0 0 0 0 1 1
PkTq=147 @ 5000 Avg=131
PkHP=142 @ 5500 Avg=104
24

Special Calculations
------ Valve Flow & Cam Calculations ------------------- --Int-- --Exh--

Overlap Area, deg*sq-in 2.0 Vlv Area, deg*sq-in 244.4 186.5
Total Exh/Int % 76.3 Total Avg Flow Coef 0.660 0.663
Lobe Separation, deg 115.5 Lobe Area, inch*deg 20.82 19.22
Overlap, deg 32 Duration @ .003, deg 262 263
Overlap @ .050, deg -26 Opening Events, deg 16 68
Closing Events, deg 66 16
-------------------- --Int-- --Exh-- Duration @.050, deg 206 205
Duration @.200, deg 116 103 Opn Evnts @.050, deg -12 39
TDC Tappet Lift, mm 0.561 0.519 Cls Evnts @.050, deg 38 -14
Gross Valve Lift, mm 14.700 13.400 Lobe Centerlns, deg 114.5 116.5
Net Valve Lift, mm 14.548 13.248 Grss Tappet Lft, mm 7.350 6.700
Bind Clearance, mm na na
------ General Engine Calculations --------------------------------------

Displacement, ccs 2483.3 Displacement, cu in 151.51
Dynamic Comp. Ratio 7.75 Compression Ratio 9.70
Theo. Crank Comprssn,PSI 196 Clearance Volume, ccs 71.4
Engine Input Specs
Short Block, File: 2016 Ford fusion ICE mini project
GROUP 2
Block/Pistons/Rods Accessories
Bore, mm 88.9 Fan Type: Solid Steel
Stroke, mm 100 Wtr Pump: Production Size
# of Cylinders 4 Engine Inertia/Crank Design
Rings: 3 Standard Tension Inertia: Eng Only, Std Flywhl
Rod Length, mm 144.78 Crank Design: Typical Windage
Pstn Skrt: Typical Skirt
Bearing Size .65
Pstn Top: No Coating
Cyl Lckg: Typical Leakage
Head(s), File: 2016 Ford fusion ICE mini project
GROUP 2
Intake Port Specs Exhaust Port Specs
Port Layout: 2 valves join to 1 port Port Layout: 2 valves join to 1 port
Valve Diameter, mm 24 Valve Diameter, mm 21
Avg Port Diameter, mm 36.83 Avg Port Diameter, mm 38.86
Port Length, mm 60 Port Length, mm 52
Single Flow Coefficient na Single Flow Coefficient na
Anti-Reversion, % 0 Anti-Reversion, % 0
Combustion Chamber Miscellaneous
Compression Ratio 9.7 Mtrl/Coating: Aluminum
Chamber Design: Pent Roof Burn Rating: Much Faster
Int Valve Primary Angle Exh Valve Primary Angle

Int Valve Canted Angle Exh Valve Canted Angle
Int Valve-Deck Distance . Exh Valve-Deck Distance .
Hemi-4 Valve Separation
Deck Ht Clearance 25.4 Head Gasket Thickness .
----- Int Head Flow @ 28" ----- ----- Exh Head Flow @ 28" -----
Lift L/D CFM FlCf Lift L/D CFM FlCf
.100 .106 83 .914 .100 .121 58 .730
.200 .212 153 .842 .200 .242 112 .705
.300 .318 192 .895 .300 .363 160 .974
.350 .370 198 .923 .350 .423 167 1.017
.400 .423 208 .970 .400 .484 172 1.047
.450 .476 210 .979 .450 .544 175 1.065
25

Engine Input Specs
Intake System, File: 2016 Ford fusion ICE mini project
GROUP 2
Manifold Specs (1 runner /cyl) Throttle Body(s)
Runner Dia @ Head, mm 36.07 Total CFM Rating 300
Runner Design: Straight Runners, No Secondaries: Open @ 4000 RPM
Runner Length, mm 157.48 Air Cleaner CFM Rating 300
Runner Flow Coef 1.62 Air Meter CFM Rating 400
Runner Taper, deg na Restrictor CFM Rating na
Type: Single Plenum-EFI Plenum
Int Heat: Reduced Heat Plenum Volume, CCs est
Exhaust System, File: 2016 Ford fusion ICE mini project
GROUP 2
Header Primary (1 runner /cyl) Full Exhaust System
Straight Primary (no diameter change CFM Rating 200
Section 1, Inside Dia, mm 33.02 Collector (Simple)
Section 1, Length, mm 457.2 Collector Length, mm 635.
Section 2, Inside Dia, mm na Collector Dia, mm na
Section 2, Length, mm na Collector Taper, deg na
Section 3, Inside Dia, mm na
Section 3, Length, mm na
Runner Flow Coef 2.1
Cam/Valve Train, File: 2016 Ford fusion ICE mini project
GROUP 2
Intake Cam Profile Exhaust Cam Profile
Centerline, deg 115 Centerline, deg 116
Duration @ .050" 206 Duration @ .050" 205
Opening @ .050" -12 Opening @ .050" 38.5
Closing @ .050" 38 Closing @ .050" -13.5
Max Lobe Lift, mm 7.35 Max Lobe Lift, mm 6.7
Actual Valve Lash, mm hyd Actual Valve Lash, mm hyd
Designed Valve Lash, mm hyd Designed Valve Lash, in hyd
Rocker Arm Ratio 2 Rocker Arm Ratio 2
Profile Type: Aggr Hyd Roller Profile Type: Aggr Hyd Roller
Gross Valve Lift, mm 14.7 Gross Valve Lift, mm 13.4
Dwell over Nose: 0 Deg-Std Profile Dwell over Nose: 0 Deg-Std Profile
Asymmetry 0 Asymmetry 0
Use a Cam File No Use a Cam File No
Total Cam Adv:
Lobe Separation, cam deg 115.5
Lift for Rating: .050 inches
Variable Valve Timing
Intake Cam Profile Exhaust Cam Profile
Centerline, deg ATDC
Duration @ .050"
Opening @ .050"
Closing @ .050"
Max Lobe Lift, mm
Actual Valve Lash, mm
Designed Valve Lash, mm

Rocker Arm Ratio
Calculation Conditions, File: 2016 Ford fusion ICE mini project

Test Conditions Fuel Specs
CorFctr: SAE Conds (77 deg, 29.6") Fuel Type: Gasoline
Barometric Pressure, "Hg na Fuel Octane (R+M)/2 87
Intake Air Temp, deg F na Fuel Richness: Typical for best power
Dew Point, deg F na
Elevation, feet na Use Nitrous Oxide = No
Cooling Sys: Liquid Cooled
Coolant Temp, deg F 180 Program Sets Spark for Best Power
Accel Rate: 0 Steady State
RPM to Run
Starting RPM 2000
Number of RPM Steps 10
RPM Step Size 500
26
Part 2
SIMULATION OF INTAKE VALVE:
Model Information
Model name: Intake Valve

Current Configuration: Default
Solid Bodies
Document Name and Document Path/Date
Treated As Volumetric Properties
Reference Modified
Fillet1
Mass:0.033071 kg
Volume:4.59319e-006 m^3 G:\ICE SOLID\Intake
Solid Body Density:7200 kg/m^3 Valve.SLDPRT
Weight:0.324096 N Dec 01 09:54:26 2017
27
Study Properties
Study name Static 1
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from Off
SOLIDWORKS Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document (G:\ICE SOLID)
Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2
28
Material Properties
Model Reference Properties Components
Name: Gray Cast Iron SolidBody 1(Fillet1)(Intake
Model type: Linear Elastic Isotropic Valve)
Default failure Unknown
criterion:
Tensile strength: 1.51658e+008 N/m^2
Compressive 5.72165e+008 N/m^2
strength:
Elastic modulus: 6.61781e+010 N/m^2
Poisson's ratio: 0.27
Mass density: 7200 kg/m^3
Shear modulus: 5e+010 N/m^2
Thermal expansion 1.2e-005 /Kelvin
coefficient:
Curve Data:N/A
Loads and Fixtures

Fixture name Fixture Image Fixture Details
Entities: 1 face(s)
Type: Fixed Geometry
Fixed-1
Resultant Forces
Components X Y Z Resultant
Reaction force(N) 7.7486e-007 49.6573 -1.54972e-006 49.6573
Reaction Moment(N.m) 0 0 0 0
Load name Load Image Load Details

Entities: 1 face(s)
Type: Normal to selected face
Value: 1.106e+006
Pressure-1 Units: N/m^2
Phase Angle: 0
Units: deg
Entities: 1 face(s)
Type: Apply normal force
Value: 550 N
Force-1
29
Study Results
Name Type Min Max

Stress1 VON: von Mises 1.019e+006N/m^2 5.417e+007N/m^2
Stress Node: 1472 Node: 70640
Intake Valve-Static 1-Stress-Stress1
Name Type Min Max

Displacement1 URES: Resultant 0.000e+000mm 1.739e-
Displacement Node: 1 002mm
Node: 1564
Intake Valve-Static 1-Displacement-Displacement1
Name Type Min Max

Strain1 ESTRN: Equivalent Strain 1.489e-005 6.244e-004
Element: 13646 Element: 10256
30
Intake Valve-Static 1-Strain-Strain1
Name Type
Displacement1{1} Deformed shape
Name Type Min Max

Factor of Safety1 Automatic 9.901e+000 1.000e+016
Node: 231 Node: 276
Intake Valve-Static 1-Factor of Safety-Factor of Safety1
31
SIMULATION OF EXHAUST VALVE:
Model Information
Model name: Exhaust Valve

Solid Bodies
Reference Modified
Fillet1
Mass:0.0292921 kg
Volume:3.72768e-006 m^3 G:\ICE SOLID\Exhaust
Solid Body Density:7858 kg/m^3 Valve.SLDPRT
Weight:0.287062 N Dec 01 10:01:52 2017
Units
Temperature Kelvin
32
Study Properties
Study name Static 1
Thermal Effect: On
Include fluid pressure effects from SOLIDWORKS Off
Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Friction Off
Material Properties
Name: 1023 Carbon Steel SolidBody 1(Fillet1)(Exhaust
Sheet (SS) Valve)
Model type: Linear Elastic Isotropic
criterion:
Yield strength: 2.82685e+008 N/m^2
coefficient:
Curve Data:N/A
33
Loads and Fixtures
Entities: 1 face(s)
Fixed-1
Resultant Forces
Reaction force(N) -2.23517e-006 1235.8 2.38419e-006 1235.8

Entities: 1 face(s)
Value: 1.16e+006
Phase Angle: 0
Units: deg
Entities: 1 face(s)
Value: 1633 N
Force-1
Resultant Forces
Reaction forces
Selection set Units Sum X Sum Y Sum Z Resultant
Entire Model N -2.23517e-006 1235.8 2.38419e-006 1235.8
Reaction Moments
Entire Model N.m 0 0 0 0
34
Study Results
Name Type Min Max

Exhaust Valve-Static 1-Stress-Stress1
Name Type Min Max

Node: 1764
Exhaust Valve-Static 1-Displacement-Displacement1
Name Type Min Max

35
Exhaust Valve-Static 1-Strain-Strain1
Name Type Min Max

Node: 73578 Node: 1656
Exhaust Valve-Static 1-Factor of Safety-Factor of Safety1
36
SIMULATION OF INTAKE PUSH ROD:
Model Information
Model name: Intake push rod

Solid Bodies
Reference Modified
Boss-Extrude1
Mass:0.0307793 kg
Volume:3.89611e-006 m^3 G:\ICE SOLID\Intake push
Solid Body Density:7900 kg/m^3 rod.SLDPRT
Weight:0.301637 N Dec 01 13:40:48 2017
Units
Temperature Kelvin
37
Study Properties
Study name Static 1
Thermal Effect: On
Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Friction Off
Material Properties
Name: AISI 1020 SolidBody 1(Boss-
Model type: Linear Elastic Isotropic Extrude1)(Intake push rod)
criterion:
Elastic modulus: 2e+011 N/m^2
Shear modulus: 7.7e+010 N/m^2
coefficient:
Curve Data:N/A
38
Loads and Fixtures
Entities: 1 face(s)
Fixed-1
Resultant Forces
Reaction force(N) 0.0013444 -549.988 0.00199652 549.988

Entities: 1 face(s)
Force-1 Value: 550 N
Resultant Forces
Reaction forces
Entire Model N 0.0013444 -549.988 0.00199652 549.988
Reaction Moments
39
Study Results
Name Type Min Max

Intake push rod-Static 1-Stress-Stress1
Name Type Min Max

Node: 5319
Intake push rod-Static 1-Displacement-Displacement1
40
Name Type Min Max
Intake push rod-Static 1-Strain-Strain1
Name Type Min Max

Node: 567 Node: 7265
Intake push rod-Static 1-Factor of Safety-Factor of Safety1
41
SIMULATION OF EXHAUST PUSH ROD:
Model Information
Model name: Exhaut Push rod

Solid Bodies
Reference Modified
Boss-Extrude1
Mass:0.0542782 kg
Volume:6.87066e-006 m^3 G:\ICE SOLID\Exhaut Push
Solid Body Density:7900 kg/m^3 rod.SLDPRT
Weight:0.531927 N Nov 30 18:23:00 2017
Units
Temperature Kelvin
42
Study Properties
Study name Static 1
Thermal Effect: On
Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Friction Off
Material Properties
Name: AISI 1020 SolidBody 1(Boss-
Model type: Linear Elastic Isotropic Extrude1)(Exhaut Push rod)
criterion:
Elastic modulus: 2e+011 N/m^2
coefficient:
Curve Data:N/A
43
Loads and Fixtures
Entities: 1 face(s)
Fixed-1
Resultant Forces
Reaction force(N) -0.00439173 -1633.04 0.000170231 1633.04

Entities: 1 face(s)
Value: 1633 N
Force-1
Resultant Forces
Reaction forces
Entire Model N -0.00439173 -1633.04 0.000170231 1633.04
Reaction Moments
44
Study Results
Name Type Min Max

Exhaut Push rod-Static 1-Stress-Stress1
Name Type Min Max

Node: 7317
Exhaut Push rod-Static 1-Displacement-Displacement1
45
Name Type Min Max
Exhaut Push rod-Static 1-Strain-Strain1
Name Type Min Max

Node: 5615 Node: 4
Exhaut Push rod-Static 1-Factor of Safety-Factor of Safety1
46
SIMULATION OF CYLINDER HEAD:
Model Information
Model name: Part2

Solid Bodies
Reference Modified
Cut-Extrude25
Mass:2.92944 kg
Volume:0.001085 m^3 G:\ICE
Solid Body Density:2699.95 kg/m^3 SOLID\Part2.SLDPRT
Weight:28.7085 N Dec 01 10:13:42 2017
Units
Temperature Kelvin
47
Study Properties
Study name Static 1
Thermal Effect: On
Include fluid pressure effects from Off
SOLIDWORKS Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Friction Off
Material Properties
Name: 1060 Alloy SolidBody 1(Cut-
Model type: Linear Elastic Extrude25)(Part2)
Isotropic
Default failure Max von Mises
criterion: Stress
Yield strength: 2.75742e+007
N/m^2
Tensile strength: 6.89356e+007
N/m^2
Thermal 2.4e-005 /Kelvin
expansion
coefficient:
Curve Data:N/A
48
Loads and Fixtures
Entities: 1 face(s)
Fixed-1
Resultant Forces
Reaction force(N) -0.0227795 -47509.3 -0.0372024 47509.3

Entities: 5 face(s)
Value: 1.16e+006
Phase Angle: 0
Units: deg
Resultant Forces
Reaction forces
Entire Model N -0.0227795 -47509.3 -0.0372024 47509.3
Reaction Moments
49
Study Results
Name Type Min Max

Part2-Static 1-Stress-Stress1
Name Type Min Max

Node: 13256
Part2-Static 1-Displacement-Displacement1
50
Name Type Min Max
Part2-Static 1-Strain-Strain1
Name Type Min Max

Node: 13665 Node: 37006
Part2-Static 1-Factor of Safety-Factor of Safety1
51
SIMULATION OF INTAKE ROCKER ARM:
Model Information
Model name: Intake rocker arm

Solid Bodies
Reference Modified
Extrude-Thin1
Mass:0.0856485 kg
Volume:1.18956e-005 m^3 H:\ICE SOLID\Intake
Solid Body Density:7200 kg/m^3 rocker arm.SLDPRT
Weight:0.839355 N Dec 01 19:22:54 2017
Units
Temperature Kelvin
52
Study Properties
Study name Static 1
Thermal Effect: On
Flow Simulation
Solver type FFEPlus
Inplane Effect: Off
Soft Spring: Off
Large displacement On
Friction Off
Result folder SOLIDWORKS document (H:\ICE SOLID)
Material Properties
Name: Gray Cast Iron SolidBody 1(Extrude-
Model type: Linear Elastic Isotropic Thin1)(Intake rocker arm)
Default failure Mohr-Coulomb Stress
criterion:
Compressive 5.72165e+008 N/m^2
strength:
coefficient:
Curve Data:N/A
53
Loads and Fixtures
Entities: 1 face(s)
Type: Fixed Hinge
Fixed Hinge-1
Resultant Forces
Reaction force(N) 135.319 -833.619 0.336413 844.531
Entities: 2 face(s)
Fixed-1
Resultant Forces
Reaction force(N) -135.343 284.074 0.07184 314.667

Entities: 1 face(s)
Value: 550 N
Force-1
Resultant Forces
Reaction forces
Entire Model N -0.0247347 -549.545 0.408232 549.546
Reaction Moments
54
Study Results
Name Type Min Max
Stress1 VON: von Mises Stress 4.434e+004N/m^2 9.525e+007N/m^2
Node: 83350 Node: 76341
Intake rocker arm-Static 1-Stress-Stress1
Name Type Min Max
Displacement1 URES: Resultant Displacement 0.000e+000mm 9.900e-002mm
Node: 305 Node: 67695
Intake rocker arm-Static 1-Displacement-Displacement1
55
Name Type Min Max
Intake rocker arm-Static 1-Strain-Strain1
Name Type Min Max
Node: 72095 Node: 67398
Intake rocker arm-Static 1-Factor of Safety-Factor of Safety1
56
Part 3
SIMULATION OF INTAKE VALVE:
Thermal Loads

Entities: 3 face(s)
Temperature: 250 Celsius
Temperature
-1
Entities: 1 face(s)
Temperature
-2
Entities: 1 face(s)
Temperature
-3
Entities: 5 face(s)
Temperature
-4
Entities: 1 face(s)
Convection Coefficient: 20 W/(m^2.K)
Time variation: Off
Convection-1 Temperature variation: Off
Bulk Ambient Temperature: 333 Kelvin
Time variation: Off
Entities: 1 face(s)
Heat Flux Value: 1e+007 W/m^2
Heat Flux-1
57
Study Results
Name Type Min Max

Thermal1 TEMP: Temperature 3.731e+002Kelvin 5.232e+002Kelvin
Node: 1 Node: 1280
Intake Valve-Thermal 1-Thermal-Thermal1
Name Type Min Max

Thermal2 HFLUXY: Y Heat -2.791e+006W/m^2 1.639e+007W/m^2
Flux Node: 62735 Node: 70257
Name Type Min Max

Thermal3 HFLUXN: Resultant 0.000e+000W/m^2 2.448e+007W/m^2
heat flux Node: 61003 Node: 63330
58
Name Type Min Max

Thermal4 GRADY: Y Temp -3.643e+005K/m 6.203e+004K/m
Gradient Node: 70257 Node: 62735
59
SIMULATION OF EXHAUST VALVE:
Thermal Loads

Entities: 4 face(s)
Heat Flux-1
Entities: 4 face(s)
Time variation: Off
Temperature variation: Off
Convection-1 Bulk Ambient Temperature: 723 Kelvin
Time variation: Off
Entities: 4 face(s)
Temperature
-1
Entities: 1 face(s)
Temperature
-2
Entities: 5 face(s)
Temperature
-3
60
Study Results
Name Type Min Max

Thermal1 TEMP: Temperature 150.000 Celsius 650.000
Node: 1 Celsius
Node: 1516
Exhaust Valve-Thermal 1-Thermal-Thermal1
Name Type Min Max

Thermal2 HFLUXY: Y Heat Flux -2.23e+007W/m^2 2.37e+007
Node: 73370 W/m^2
Node: 73420
61
Name Type Min Max
62
SIMULATION OF CYLINDER HEAD:
Thermal Loads

Entities: 1 face(s)
Temperature
-1
Entities: 8 face(s)
Time variation: Off
Time variation: Off
Entities: 8 face(s)
Time variation: Off
Time variation: Off
Entities: 4 face(s)
Temperature
-2
Entities: 4 face(s)
Heat Flux-1
Entities: 2 edge(s), 15 face(s)

Temperature
-3
Entities: 16 face(s)
Temperature
-4
63
Study Results
Name Type Min Max

Thermal1 TEMP: Temperature 4.731e+002Kelvin 1.267e+003Kelvin
Node: 2 Node: 4685
Part2-Thermal 1-Thermal-Thermal1
Name Type Min Max

64
Name Type Min Max
Thermal3 GRADY: Y Temp -1.978e+005K/m 2.219e+006K/m
Gradient Node: 4367 Node: 5314
Name Type Min Max

Thermal4 HFLUXY: Y Heat -4.437e+008W/m^2 3.956e+007W/m^2
Flux Node: 5314 Node: 4367
65
INTAKE & EXHAUST VALVE:
66
67
68
INTAKE & EXHAUST PUSH ROD:
69
70
INTAKE & EXHAUST ROCKER ARM:
71
72
73
74
75
CYLINDER HEAD:
76
77
78
79
80
81
REFRENCES:
1/ Course WH, and Anglin DL, (1985), Automotives Engine, Tata Mc Graw Hill.
2/ Heisler H, (1999), Vebicle and Engine Tecnology, Arnold Publishers.
3/ International Engineering Research Journal (IIERJ)) Volume 1, Issue 2 pp 788-797,2015
4/ James M Miller (1980), Rocker Arm Having Perpendicular Geometry at Mid Lift, United
States Patent Appl. No. 211, 638, December 1
5/ S.M. Husain, and Prof.S. Sheikh, Design and analysis of rocker arm International Journal
of Mechanical Engineering and Robotics Research
6/ Heywood, John B, Internal combustion engine fundamentals. (McGraw-Hill series in

mechanical engineering)
82

Cylinder Head Report

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Cylinder Head Report

Diunggah oleh

Hak Cipta:

Format Tersedia

ICE

mini project 2017

DESIGN OF INTAKE VALVE 4

DESIGN OF EXHAUST VALVE 7

DESIGN OF VALVE SPRING 10

DESIGN OF INTAKE PORTS 12

DESIGN OF EXHAUST PORTS 14

DESIGN OF PUSH ROD 16

DESIGN OF ROCKER ARM 17

DESIGN OF CYLINDER HEAD GASKET 21

PART 2 (STRESS ANALYSIS)

SIMULATION OF INTAKE VALVE 27

SIMULATION OF EXHAUST VALVE 32

SIMULATION OF INTAKE PUSH ROD 37

SIMULATION OF EXHAUST PUSH ROD 42

SIMULATION OF CYLINDER HEAD 47

SIMULATION OF INTAKE ROCKER ARM 52

PART 3 (THERMAL ANALYSIS)

SIMULATION OF INTAKE VALVE 57

SIMULATION OF EXHAUST VALVE 60

SIMULATION OF CYLINDER HEAD 63

PART 4 (PRODUCTION METHOD)

PRODUCTION OF INTAKE & EXHAUST VALVE 66

PRODUCTION OF INTAKE & EXHAUST PUSH ROD 69

PRODUCTION OF INTAKE & EXHAUST ROCKER ARM 71

PRODUCTION OF CYLINDER HEAD 76

Components of Cylinder Head

Cylinder Head Assembly

Power = 130.48 kwatt

DESIGN OF INTAKE VALVE:

D. Valve head thickness

F. Mean port diameter

Material properties Symbol Value

Density 7627 kg/m<

Youngs Modulus E 210 GPa

Ultimate Tensile Strength S>?@ 776 MPa

Yield Strength SA 314 MPa

composition Mn=0.4% , C=0.45%, Si=3.3%, S=8.6%

1- Valve head diameter

5- Thickness of valve disk

6- Diameter of valve head opening

d< = dY B + dVr@stu Js?Ju B

d< = 20.8B + 24B = 28.9 mm

=0.5 (24 20.8 ) = 1.6 mm

8- Diameter of valve stem

1 dY Port Diameter 20.8

2 h Valve Lift 7.35

3 t Thickness of Valve 1.63

6 de Valve steam 6.6

DESIGN OF EXHAUST VALVE:

D. Valve head thickness

F. Mean port diameter

4- Thickness of valve disk

dB = 18.88 + 2(1.47 (90 45))

6- Diameter of valve head opening

d< = dY B + dVr@stu Js?Ju B

d< = 18.88B + 20.88B = 28 mm

=0.5 (20.88 18.88) = 1 mm

8- Diameter of valve stem

Symbol Design Parameter Dimension ()

1 Y Port Diameter 18.88

2 h Valve Lift 6.675

3 t Thickness of Valve 1.47

5 y Valve Head Diameter 20.88