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

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
THERMAL INVESTIGATION (PRESSURE DISTRIBUTION) ON BOX TYPE CYLINDER
HEAD OF A 4 STROKE SINGLE CYLINDER WATER COOLED DIESEL ENGINE MATE-
RIAL 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.
*Corresponding Author:
Ch.Naga Mahalakshmi
Research Scholar, Department of Thermal Engineering,
Aditya Engineering College, Surampalem, Andhra Pradesh, In-
dia.
Email: ijripublishers@gmail.com
Year of publication: 2016
Review Type: peer reviewed
Volume: III, Issue : I
Citation: Ch.Naga Mahalakshmi, "Thermal Investigation (Pres-
sure Distribution) on Box Type Cylinder Head of A 4 Stroke Sin-
gle Cylinder Water Cooled Diesel Engine Material By Using An-
sys15.0" 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 me-
chanical energy. The first internal combustion engine was
created by Étienne Lenoir.
BOX TYPE CYLINDER HEAD
WORKING OF BOX TYPE CYLINDER HEAD
In the spark ignition engine an Air/Fuel mixture is formed
outside the combustion chamber. This mixture is gener-
ated in a Carburetor or by means of Fuel Injection, but in
either case the final Air/Fuel mixture is fed into the Cyl-
inder, through the Intake, past the Inlet Valve. The mix-
ture 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.
The combustion Heat given off increases the pressure of
the pre-compressed gasses. This after-combustion pres-
sure 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 forc-
ing 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 at-
mosphere 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 fos-
sil 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, in-
ternal combustion engines appear in the form of gas tur-
bines. These applications include jet aircraft, helicopters,
large ships and electric generators.
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 materi-
als 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
International Journal of Research and Innovation in
Thermal Engineering (IJRITE)

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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
INTRODUCTION TO CYLINDER HEAD
In an internal combustion engine, the cylinder head (often
informally abbreviated to just head) sits above the cyl-
inders on top of the cylinder block. It consists of a plat-
form 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 be-
tween; this simplicity leads to ease of manufacture and
repair, and accounts for the flathead engine's early suc-
cess in production automobiles and continued success in
small engines, such as lawnmowers. This design, howev-
er, 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 adop-
tion 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 wa-
ter-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 en-
gine 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 = "π/(4 )" * d2 * L = 0.000661452 m3
Total Volume of the Cylinder = Clearance volume + Swept
Volume = 0.001271452 m3
Density = 2680 Kg / m3
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 = "π/(4 )" * d2 * L = 0.000661452 m3
Total Volume of the Cylinder = Clearance volume + Swept
Volume = 0.001271452 m3
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
Heat Flux: q = k (Tb- T) w/m
Material
K ( Thermal
Conductiv-
ity)
in (w/m-k)
Bulk
Tempera-
ture
(K)
Cylinder
Head
Tempera-
ture
(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
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

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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 is showing equivalent strain value
THERMAL ANALYSIS OF CYLINDER HEAD USING
CAST IRON
The above image shows temperature
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 stress value
THERMAL ANALYSIS OF CYLINDER HEAD USING AL-
UMINIUM 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
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 col-
lection was done to know about previous researches, ap-
proach 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.
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.
In the next step a 3D parametric models of box type cyl-
inder head was prepared and converted into IGES file to
conduct Analysis work in ANSYS.
Coupled field (structural & thermal combinations) analy-
sis was conducted on parts us in Cast iron, Lm-6, LM-24
& LM-25 to evaluate the results. As per the obtained re-
sults 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 Tichánek, Ing. Miroslav Španiel,
CSc. Czech Technical University in Prague
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MENT 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 Cyl-
inder Head by Dr. M. Lakshman Rao from Prakasam En-
gineering College , Kandukur
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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 Engineer-
ing, Aditya Engineering College, Surampalem,
Andhra Pradesh, India.
Vallem Srinivasa Rao,
Associate Professor, Department of Mechanical Engineer-
ing, Aditya Engineering College, Surampalem,
Andhra Pradesh, India.