HEAD
PROJECT REPORT
Submitted by
K.RAJESH KUMAR
MASTER OF ENGINEERING
in
ENGINEERING DESIGN
i
ANNA UNIVERSITY COIMBATORE
COIMBATORE – 641 047
Department of Mechanical Engineering
PROJECT WORK
PHASE II
June 2010
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Project Guide Head of the Department
Mr. D.DHANSEKARAN M.E., Dr. M.SAKTHIVEL Ph.D.,
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Internal Examiner External Examiner
ii
DECLARATION
K.RAJESH KUMAR
081120100021
iii
ACKNOWLEDEMENT
iv
TABLE OF CONTENTS
ABSTRACT viii
LIST OF TABLES ix
LIST OF FIGURES x
LIST OF SYMBOLS xi
1. INTRODUCTION 2
1.1 Introduction-engine cylinder head 2
1.2 Importance of reliability in
automotive parts 3
2. PROJECT OVERVIEW 5
2.1 Research Overview 5
2.2 Objectives of the project 7
2.3 Scope of the project 7
3. LITERATURE REVIEW 9
3.1 Boundary element analysis of
thermally stressed interface cracks 9
3.2 A long circular cylinder with
a circumferential edge crack subjected
to a uniform shearing stress 10
3.3 Stress intensity factors in a finite length
cylinder with a circumferential crack 10
3.4 Spontaneous crack propagation
in functionally graded materials 11
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3.5 Wear of diesel engine inlet valves and
Seat inserts 14
3.6 Modelling of fatigue damage in aluminum
cylinder heads 15
4 CRACK BEHAVIOUR 18
4.1 Reasons for crack 18
4.2 Crack terminologies 19
4.2.1 What is fracture mechanics? 20
4.3 Classification of fracture mechanics 21
4.3.1 Linear Elastic Fracture Mechanics 21
4.3.1. I Stress Intensity Factor 22
4.3.1. II Fracture Toughness 22
4.3.1 III Strain Energy Release Rate 23
4.3.2 Elastic Plastic Fracture Mechanics 24
4.3.2 I Crack Tip Opening Displacement 25
4.3.2. II J – Integral 26
4.3.2. III R – Curve analysis 27
5 MODES OF FRACTURE 29
5.1 Mode I 30
5.2 Mode II 31
5.3 Mode III 32
6 ENGINE CYLINDER HEAD CRACK STUDY 35
6.1 Methodology of analysis of crack 35
6.2 Boundary condition for analysis 38
6.3 Results & Discussion 43
7 WELDING PROCESS 46
7.1 Welding process 46
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8 REINVESTMENT COST 53
9 CONCLUSION 55
9.1 Conclusion 55
9.2 Further Scope 55
10 REFERENCES 57
vii
ABSTRACT
viii
LIST OF TABLES
ix
LIST OF FIGURES
x
LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE
OF CRACK
A crack length
ν Poisson’s ratio
xi