This document discusses computer-aided cylinder head design and development. It begins by describing the stock cylinder head of a Briggs & Stratton engine and testing it on a flow bench. CAD software was then used to design modifications to the intake port aimed at increasing air flow. CAE simulation analyzed the stock and modified port designs, showing improved air velocity and flow with the modifications. The goal is to enhance engine performance and efficiency through optimized cylinder head design.
A Novel Design and Computational Fluid Dynamics of Swirl Flow Enhancing Devic...IJSRD
The present paper work is directed to a device located at the intake port at the junction of the intake manifold and the engine head. This location allows the device to be used with any type of carburetor or fuel injection system. It is the object of the present device to utilize at least three fixed, helically twisted blades to impart additional swirl mixing of the fuel/air mixture. This fuel/air mixture has already been pre-heated by its travel through the intake manifold. The "violent swirl" created by the device provides a more uniform fuel/air mixture, thereby causing a more complete and efficient combustion. The overall result of using the device is better gas mileage, increased performance, easier starting, and less pollution. The object of the project work to improve the fuel/air mixture of the fuel injected engines, preventing valves from being burned or eroded by clogged injectors. As a result of forcing the air to enter the intake port in a high velocity swirl, there is disruption of any direct fuel streams upon the head of the cylinder intake valve which occur as a result of clogged injectors. Another object of the project work is to provide a device that improves the homogeneity of the fuel/air mixture delivered by the carburetor to the cylinders of an internal combustion engine with little or no obstruction in the mixture flow resulting in no starving of the engine. Another object to deliver the fuel/air mixture to the center of the cylinder for a uniform flame front. The swirling mixture delivered by the present invention results in cleaner, more-efficient combustion.
A Review Paper on Effects of Different Intake Manifold Designs on Diesel Engi...ijsrd.com
One of the objectives of car manufacturers is to improve engine performance, reduce consumption and reduce emissions. To achieve this objective, it is important to understand the phenomena involved in the combustion chambers of engines. There are various factors that influence the engine performance such as compression ratio, atomization of fuel, fuel injection pressure, and quality of fuel, combustion rate, air fuel ratio, intake temperature and pressure and also based on piston design, inlet manifold, and combustion chamber designs etc. Geometrical design of intake manifold is one such method for the better performance of an I.C. Engine. Air swirl motion in CI engine influences the atomization and distribution of fuel injected in the combustion chamber. Intake manifolds provides Air motion to the chamber. So, to get the maximum output with the least input on Diesel engine researchers are experimentally and computationally working on construction of the intake manifold configurations for increase in engine performance and reduction of Exhaust Emissions. In this paper i have studied few papers and also gone through basics of my topic from various books to understand the phenomena.
The aim of this study is to investigate a technique to enhance the air swirl to achieve
betterment in engine performance characteristics in a direct injection (DI) single cylinder diesel
engine. A good swirl promotes the fast combustion and improves the efficiency. The engine should
run at low speeds in order to have low mechanical losses and fast combustion, enabling good
combustion efficiency. Therefore to produce high turbulence prior to combustion within the cylinder,
swirl induced by the inlet manifold will be helpful. This paper aims at studying the effect of air swirl
generated by directing the air flow in intake manifold on engine performance. The turbulence is
achieved in the inlet manifold with different types of internal threads of constant pitch. In view this,
experimental investigation has been carried out to find the effect of swirl on the performance
characteristics of the engine, by inducing swirl in inlet manifolds with three different types of
internal threads viz. acme, buttress and knuckle threads of constant pitch. The results indicate that
inlet manifold with buttress threads is identified as optimum configuration based on performance
characteristics of engine. This is because inlet manifold with buttress threads achieved a higher swirl
coefficient and swirl ratio compared with inlet manifold having acme and knuckle threads
A Novel Design and Computational Fluid Dynamics of Swirl Flow Enhancing Devic...IJSRD
The present paper work is directed to a device located at the intake port at the junction of the intake manifold and the engine head. This location allows the device to be used with any type of carburetor or fuel injection system. It is the object of the present device to utilize at least three fixed, helically twisted blades to impart additional swirl mixing of the fuel/air mixture. This fuel/air mixture has already been pre-heated by its travel through the intake manifold. The "violent swirl" created by the device provides a more uniform fuel/air mixture, thereby causing a more complete and efficient combustion. The overall result of using the device is better gas mileage, increased performance, easier starting, and less pollution. The object of the project work to improve the fuel/air mixture of the fuel injected engines, preventing valves from being burned or eroded by clogged injectors. As a result of forcing the air to enter the intake port in a high velocity swirl, there is disruption of any direct fuel streams upon the head of the cylinder intake valve which occur as a result of clogged injectors. Another object of the project work is to provide a device that improves the homogeneity of the fuel/air mixture delivered by the carburetor to the cylinders of an internal combustion engine with little or no obstruction in the mixture flow resulting in no starving of the engine. Another object to deliver the fuel/air mixture to the center of the cylinder for a uniform flame front. The swirling mixture delivered by the present invention results in cleaner, more-efficient combustion.
A Review Paper on Effects of Different Intake Manifold Designs on Diesel Engi...ijsrd.com
One of the objectives of car manufacturers is to improve engine performance, reduce consumption and reduce emissions. To achieve this objective, it is important to understand the phenomena involved in the combustion chambers of engines. There are various factors that influence the engine performance such as compression ratio, atomization of fuel, fuel injection pressure, and quality of fuel, combustion rate, air fuel ratio, intake temperature and pressure and also based on piston design, inlet manifold, and combustion chamber designs etc. Geometrical design of intake manifold is one such method for the better performance of an I.C. Engine. Air swirl motion in CI engine influences the atomization and distribution of fuel injected in the combustion chamber. Intake manifolds provides Air motion to the chamber. So, to get the maximum output with the least input on Diesel engine researchers are experimentally and computationally working on construction of the intake manifold configurations for increase in engine performance and reduction of Exhaust Emissions. In this paper i have studied few papers and also gone through basics of my topic from various books to understand the phenomena.
The aim of this study is to investigate a technique to enhance the air swirl to achieve
betterment in engine performance characteristics in a direct injection (DI) single cylinder diesel
engine. A good swirl promotes the fast combustion and improves the efficiency. The engine should
run at low speeds in order to have low mechanical losses and fast combustion, enabling good
combustion efficiency. Therefore to produce high turbulence prior to combustion within the cylinder,
swirl induced by the inlet manifold will be helpful. This paper aims at studying the effect of air swirl
generated by directing the air flow in intake manifold on engine performance. The turbulence is
achieved in the inlet manifold with different types of internal threads of constant pitch. In view this,
experimental investigation has been carried out to find the effect of swirl on the performance
characteristics of the engine, by inducing swirl in inlet manifolds with three different types of
internal threads viz. acme, buttress and knuckle threads of constant pitch. The results indicate that
inlet manifold with buttress threads is identified as optimum configuration based on performance
characteristics of engine. This is because inlet manifold with buttress threads achieved a higher swirl
coefficient and swirl ratio compared with inlet manifold having acme and knuckle threads
Effect of spiral grooves in piston bowl on exhaust emissions of direct inject...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Ijaems apr-2016-20 Design, Modeling and Analysis of Structural Strength of Cy...INFOGAIN PUBLICATION
The proficiency of any automobile engine is deals with the structural strength of its cylinder and cylinder head. Cylinder and cylinder head are most important parts of an engine because the piston moving inside the cylinder, so friction between cylinder wall and piston is very higher and due to this the mechanical load or fatigue load acting on the cylinder. So that structure of cylinder should be stronger. The combustion chamber, crank case, piston, connecting rod, crankshaft and cylinder are placed under the cylinder head. Cylinder head provides the protection against the high thermal and mechanical load on an engine, so the cylinder head is “a protector” of an engine and its parts. The review of existing literature on design, modeling and analysis of cylinder and cylinder head is presented. 3D-model of cylinder and cylinder head were created using Pro/Engineer software and ANSYS was used to analyze the thermal and structural analysis. So finally design considerations, material specifications, failure analysis, these all are reviewed successfully over here.
Modification of airflow around a FSAE Race car using sidepods to increase the...EditorIJAERD
Aerodynamics pertaining to vehicles focuses on improving the drive-ability of the vehicle while also reducing
losses due to air drag. This paper focuses on maximizing the cornering performance of the formula student race car with
slight modifications to the airflow around the vehicle and meagre addition of weight. The undertray produces downloads
by altering the velocity of air flowing underneath it. The sidepods act to reduce flow velocity above the undertray, thus
increasing the pressure above it. This leads to an increased pressure difference over the surface of the undertray which
translates to increase in downforce. The car is able to have a 10% decrease in lap times on a 500m racetrack.
Dynamic Modeling and Simulation on GE90 Enginetheijes
The paper talks about a better numerical method for predicting on-design performance on a High-Bypass Turbofan engine GE90. A dynamic optimization turbofan engine for GE90 has been designed using MATLAB/Simulink software. Individual components including Ambient, Fan, Low Pressure Compressor (LPC), High Pressure Compressor (HPC), Combustion Chamber, High Pressure Turbine (HPT), Low Pressure Turbine (LPT), Exit Nozzle and Plenum volumes, Makes a combination to identify the performance characteristics of a turbofan engine throughout the flight condition. The specific engine characteristics are matched and adopted through the use of variables from developed a model. The results will validate through simulation with the software to look through for problems and understand the air flow from the intake to the nozzle. Good designs can intensify a better performance to the engine, which performance analysis can be applied and tested to each component of the GE90 engine during design point condition.
CFD Port Flow Simulation of Air Flow Rate in Spark Ignition EngineDr. Amarjeet Singh
In the early stages of development of internal combustion engine (ICE), limitations such as speed, range, and lifespan led to series of researches resulting in the reduction or elimination of these limitations. Combustion in ICE is a rapid and controlled endothermic reaction between air in oxygen and fuel which is accompanied by significant increase in temperature and pressure with the production of heat, flame and carbon particle deposits. This combustion process is a phenomenon that involves turbulence, loss of air-fuel mixture during inflow and outflow into the cylinder. The objection of this study is to perform port flow analysis on ICE to determine flow rate and swirl at different valve lift under stationary engine parts.Methodology employed to analyze and solve the ICE port flow simulation is the use of CFD software that uses the finite volume method of numerical analysis to solve the continuity, Navier-Stokes and energy equations governing the air medium in the internal combustion engine cylinder. The model geometry for the analysis was generated using the Ansys Design Modeller for one cylinder, one suction port and one exhaust port, and two valves. The domain considered is internal combustion engine suction port with 86741 nodes and 263155 elements.
Study results revealed that air mass was more concentrated around the valve and inlet port cross-section with swirling motion seen, air stream experienced turbulence as it flowed downwards inside the cylinder, air stream spread was turbulent which will eventually enhance smooth combustion, swirling air stream moves towards the cylinder wall where it experienced tumbling and turbulent which will eventually enhance smooth combustion. From the simulation it was revealed that mass flow rate of inlet air increases with valve lift.
Effect of spiral grooves in piston bowl on exhaust emissions of direct inject...eSAT Publishing House
IJRET : International Journal of Research in Engineering and Technology is an international peer reviewed, online journal published by eSAT Publishing House for the enhancement of research in various disciplines of Engineering and Technology. The aim and scope of the journal is to provide an academic medium and an important reference for the advancement and dissemination of research results that support high-level learning, teaching and research in the fields of Engineering and Technology. We bring together Scientists, Academician, Field Engineers, Scholars and Students of related fields of Engineering and Technology
International Journal of Engineering Research and Applications (IJERA) is an open access online peer reviewed international journal that publishes research and review articles in the fields of Computer Science, Neural Networks, Electrical Engineering, Software Engineering, Information Technology, Mechanical Engineering, Chemical Engineering, Plastic Engineering, Food Technology, Textile Engineering, Nano Technology & science, Power Electronics, Electronics & Communication Engineering, Computational mathematics, Image processing, Civil Engineering, Structural Engineering, Environmental Engineering, VLSI Testing & Low Power VLSI Design etc.
Ijaems apr-2016-20 Design, Modeling and Analysis of Structural Strength of Cy...INFOGAIN PUBLICATION
The proficiency of any automobile engine is deals with the structural strength of its cylinder and cylinder head. Cylinder and cylinder head are most important parts of an engine because the piston moving inside the cylinder, so friction between cylinder wall and piston is very higher and due to this the mechanical load or fatigue load acting on the cylinder. So that structure of cylinder should be stronger. The combustion chamber, crank case, piston, connecting rod, crankshaft and cylinder are placed under the cylinder head. Cylinder head provides the protection against the high thermal and mechanical load on an engine, so the cylinder head is “a protector” of an engine and its parts. The review of existing literature on design, modeling and analysis of cylinder and cylinder head is presented. 3D-model of cylinder and cylinder head were created using Pro/Engineer software and ANSYS was used to analyze the thermal and structural analysis. So finally design considerations, material specifications, failure analysis, these all are reviewed successfully over here.
Modification of airflow around a FSAE Race car using sidepods to increase the...EditorIJAERD
Aerodynamics pertaining to vehicles focuses on improving the drive-ability of the vehicle while also reducing
losses due to air drag. This paper focuses on maximizing the cornering performance of the formula student race car with
slight modifications to the airflow around the vehicle and meagre addition of weight. The undertray produces downloads
by altering the velocity of air flowing underneath it. The sidepods act to reduce flow velocity above the undertray, thus
increasing the pressure above it. This leads to an increased pressure difference over the surface of the undertray which
translates to increase in downforce. The car is able to have a 10% decrease in lap times on a 500m racetrack.
Dynamic Modeling and Simulation on GE90 Enginetheijes
The paper talks about a better numerical method for predicting on-design performance on a High-Bypass Turbofan engine GE90. A dynamic optimization turbofan engine for GE90 has been designed using MATLAB/Simulink software. Individual components including Ambient, Fan, Low Pressure Compressor (LPC), High Pressure Compressor (HPC), Combustion Chamber, High Pressure Turbine (HPT), Low Pressure Turbine (LPT), Exit Nozzle and Plenum volumes, Makes a combination to identify the performance characteristics of a turbofan engine throughout the flight condition. The specific engine characteristics are matched and adopted through the use of variables from developed a model. The results will validate through simulation with the software to look through for problems and understand the air flow from the intake to the nozzle. Good designs can intensify a better performance to the engine, which performance analysis can be applied and tested to each component of the GE90 engine during design point condition.
CFD Port Flow Simulation of Air Flow Rate in Spark Ignition EngineDr. Amarjeet Singh
In the early stages of development of internal combustion engine (ICE), limitations such as speed, range, and lifespan led to series of researches resulting in the reduction or elimination of these limitations. Combustion in ICE is a rapid and controlled endothermic reaction between air in oxygen and fuel which is accompanied by significant increase in temperature and pressure with the production of heat, flame and carbon particle deposits. This combustion process is a phenomenon that involves turbulence, loss of air-fuel mixture during inflow and outflow into the cylinder. The objection of this study is to perform port flow analysis on ICE to determine flow rate and swirl at different valve lift under stationary engine parts.Methodology employed to analyze and solve the ICE port flow simulation is the use of CFD software that uses the finite volume method of numerical analysis to solve the continuity, Navier-Stokes and energy equations governing the air medium in the internal combustion engine cylinder. The model geometry for the analysis was generated using the Ansys Design Modeller for one cylinder, one suction port and one exhaust port, and two valves. The domain considered is internal combustion engine suction port with 86741 nodes and 263155 elements.
Study results revealed that air mass was more concentrated around the valve and inlet port cross-section with swirling motion seen, air stream experienced turbulence as it flowed downwards inside the cylinder, air stream spread was turbulent which will eventually enhance smooth combustion, swirling air stream moves towards the cylinder wall where it experienced tumbling and turbulent which will eventually enhance smooth combustion. From the simulation it was revealed that mass flow rate of inlet air increases with valve lift.
En esta oportunidad, DÁVILA ha invitado a Mauricio Rodríguez, conferencista de talla internacional con amplia experiencia en pensamiento estratégico y creatividad, para despertar en los asistentes el amor por la estrategia, como herramienta de éxito en el mundo del mercadeo y la publicidad. La conferencia permitirá a los participantes:
Incentivar la creatividad como motor de estrategias acertadas.
Dar herramientas de creatividad para personas que no están en la industria creativa.
Fomentar el descubrimiento de tendencias como parte clave a la hora de diseñar estrategias con resultados.
Enseñar a pensar en personas no en consumidores, pues así se hace mas rentable no solo las campañas sino la operación.
A Philadelphia distilling company asked our team to create a creative brief, which is a one page research summary. We gave the brief to copywriters and art directors to execute two creative Advertisements.
Design and Analysis of Air Intake System for Single Cylinder Engineijtsrd
Our understanding of Air flow behavior around an object makes us better designer in order to achieve better performances from our automobiles. In this paper we present an analysis of air flow via air-intake system required to meet FSAE norms in SUPRA Vehicles.The aim of this project is to create a flow restriction device to be fitted in the SAE (Society of Automotive Engineers) car being built by Team Zenith, GB Pant Engineering College, New Delhi. The car is an open wheeled race vehicle, designed to go from 0-60 mph in under 4 seconds and have a top speed of about 80-90 mph.An Air-intake system in a FSAE SUPRA Vehicle consists of various components as followed: -1) Air Filter2) Air Restrictor3) Plenum4) Intake Manifold.Air enters at the filter and passes through restrictor, which is used to increase velocity and drop pressure and then enters into plenum which is used to provide better distribution of air flow and to prevent further drop in pressure.Design of Air restrictor is critical as per norms of FSAE due to fixed minimum neck diameter of 20 mm as demonstrated below. Fig: - Basic structure of restrictor, plenum and runnerThis is done primarily to limit the power capability from the engine. Since the maximum mass flow rate is now a fixed parameter because of the restrictor, the aim is to allow the engine to achieve the maximum mass flow with minimal pull from the engine. In short, the pressure difference between atmosphere and the pressure created in the cylinder should be minimal, so that maximum airflow into the engine at all times.Our study revolves around finding such combination of angles of inclination and rise of the restrictor which should provide the vehicle maximum performance within limits directed by FSAE.We have simulated various design of Air restrictors based on different pair of angles for the Air-restrictor that could make a significant impact in the performance of the engine. The software we used for the same are ANSYS, SolidWorks. Sushil Pant | Pankaj Kumar | Ranjan Kishor"Design and Analysis of Air Intake System for Single Cylinder Engine" Published in International Journal of Trend in Scientific Research and Development (ijtsrd), ISSN: 2456-6470, Volume-2 | Issue-2 , February 2018, URL: http://www.ijtsrd.com/papers/ijtsrd8388.pdf http://www.ijtsrd.com/engineering/automotive-engineering/8388/design-and-analysis-of-air-intake-system-for-single-cylinder-engine/sushil-pant
EXPERIMENTAL STUDIES ON THE INTAKE PORT OF A DIESEL ENGINE TO DETERMINE SWIRLijmech
This paper focuses on experimentalstudies of intake port of a four cylinder diesel engine for different
vacuum pressures and valve lift positions. In this study, the cylinder head is experimented through a paddle
wheel flow setup, which gives the flow coefficient and swirl number asoutput. Main scope of the work is to
understand the flow behaviour through the intake port and finally to determine mean flow coefficient and
mean swirl number for different valve lift ratios L/D, where L is valve lift and D is bore diameter.
Fluid flow dynamics inside an engine combustion cyl inder plays an important role for air-fuel mixture preparation. IC Engine model is developed u sing CATIAV5R20 tool. The model is then imported to Finite Element pre-processing tool HYPER MESH for the meshing analysis. The model is then imported to Finite Element solver tool. ANSYS FLUENT is used for post processing the results. The flow dynamics inside th e cylinder for different minimum valve lift is studied using FEA. Dynamic motion is visualized and velocity magnitude is plotted for different crank angle from 0� to 730�. Finally velo cities and crank angles for various valve lifts are compared.
PERFORMANCES EVALUATION AND BLADE NUMBER OPTIMIZATION OF RADIAL INFLOW TURBINEIAEME Publication
The energy exhaust recovery in engines is obtained using turbochargers which are widely used in the automotive industry. A turbocharged engine leads to a better overall system efficiency and a reduction in exhaust emissions compared, at constant power, with a naturally aspirated engine. The numerical approach in the present work is to explore ways of improving the performances of the radial inflow turbine. This work investigates the performances of a radial inflow turbine under steady states conditions and how they are affected by the rotor geometry. The radial inflow turbine is investigated numerically using 3D Reynolds averaged Navier-Stokes equations, the objective hear is to determine the optimum of performance characteristics of the turbine. The building of the geometry and the generation of unstructured meshes are achieved using ANSYS-ICEM software whereas in order to simulate the flow, the ANSYS-CFX code is applied. The numerical method is also used to determine optimum geometrical characteristics such as the optimum of blade number. It has been found that the rotor with 12 blades gives better performances.
PERFORMANCE ANALYSIS OF SINGLE CYLINDER (DI) DIESEL ENGINE BY AIR SWIRL INDUC...IAEME Publication
The aim of this study is to investigate a technique to enhance the air swirl to achieve betterment in engine performance characteristics in a direct injection (DI) single cylinder diesel
engine. A good swirl promotes the fast combustion and improves the efficiency. The engine should run at low speeds in order to have low mechanical losses and fast combustion, enabling good combustion efficiency. Therefore to produce high turbulence prior to combustion within the cylinder,
swirl induced by the inlet manifold will be helpful
Study of Performance & Cavitation Characterization of Mixed Flow Centrifugal ...
Computer-Aided Design and Development of a Cylinder Head
1. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
1
ABSTRACT
The Automotive industry of today is a very
modern, robust and efficient field of
engineering. Through the years from its
inception in the 1930’s, the industry has
expanded massively bringing along with
itself, a multitude of technological changes
and inventions. These changes focussed on
improved driveability, increased vehicle
performance and to provide high levels of
comfort to the user. Various design changes
and developments are made to the heart of
the vehicle i.e. the engine and its parts to
improve the torque, power, and the fuel
efficiency. The performance of any engine
is based largely on the quantity and quality
of air flowing into the combustion chamber.
Promoting better air flow means the
engines breathes well and performs better.
Therein lies the core of this research project
work i.e. designing and developing the
Cylinder Head modifications using
engineering techniques and computer-aided
software programs.
The focus of this project lies at carrying out
research work on a Briggs & Stratton
Animal 206 engine’s cylinder head.
Evaluating the stock head, its air flow
numbers, deciding on modification factors
by designing the intake port, performing a
C.A.E. Simulation of the stock port are
included in the basic study. The
modifications done on the cylinder head
based on the Simulation results, evaluating
the performance increase by testing the
modified cylinder head and testing the head
on the engine dynamically are defined as
the research process of the project. The
conclusion of this project report
demonstrates the effect of the modifications
performed and its applications in real life
performance and fuel efficiency
improvements of the engine.
INTRODUCTION
Air is a fluid which is responsible for the
combustion of fuel in the combustion
chamber. This combustion of the fuel-air
mixture in turn causes a force to be exerted
on the reciprocating parts of the engine. The
force produced is the torque that is
transmitted via the crankshaft to the
driveline thus propelling the vehicle. Air
flow is the primary factor which either
reduces or boosts the performance and
efficiency of the engine. The technique of
modifying the, intake manifolds, intake
ports and cylinder heads is called as
cylinder head porting. Cylinder head
porting is done to help the engine to breathe
better and thereby produce greater output
by consuming lesser fuel. The
fundamentals of porting are to increase the
quantity of air, promote better swirl
characteristics and increase the velocity of
the air moving through the intake of the
engine. The swirling movement of air
causes the fuel-air mixture to mix properly
and combust efficiently. The quantity of air
and its velocity help in increasing the
compression ratio of the engine. Thus,
effectively ported cylinder heads produce
better air flow and improve the efficiency
of the engine and the driveability of the
vehicle.
OBJECTIVES AND GOALS
The objectives of this project include:
1. Studying and Analysing the stock
Cylinder Head and Engine.
2. Utilization of Computer-Aided Tools to
design modifications and simulate results.
3. To modify the cylinder head on the basis
of simulated results.
4. Verify results by dynamic testing.
2. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
2
STOCK CYLINDER HEAD AND
ENGINE DESCRIPTION
The stock cylinder head that was used for
the project is from a Briggs & Stratton IC
206 Animal Engine. The engine in itself is
used for a multitude of purposes ranging
from small scale applications to racing. The
Animal 206 [1] is a single cylinder
carburetted engine with the model number
124332. It has a displacement of 12.48
Cu.in or 206 cc, a compression ratio of
8.5:1, a bore diameter of 2.6885 in, a
stroke length of 2.2 in and a power output
of 6 HP.
The stock Cylinder Head [2] is a casted
type head with the part number being
555635. It features a race inspired intake
port with 3-way valve retainers and high-
silicon valve springs. It also has a nitrited
dished exhaust valve along with a Fire-
Ring Head Gasket. The Intake valve
diameter was .925” and the Exhaust valve
diameter was 0.875”. The Animal 206
engine is illustrated below.
Fig. 1. Picture of the Animal 206 Engine.
STOCK TEST RESULTS AND
ANALYSES
INTAKE
The stock cylinder head was mounted onto
an SF-60 Flow bench. Attached to the flow
bench was a swirl meter that was used to
record the swirl values of the intake air
flow. The cylinder head was flowed at a test
pressure of 15” of 𝐇 𝟐 𝐎. The stock head was
tested at a test temperature ranging from
94.7⁰F to 101.4⁰F and Flow Temperature
ranging between 74.0⁰F and 78.9⁰F. The
Barometric Pressure and Relative
Humidity conditions at the time of testing
were 27.91” of Hg and 26% respectively.
The intake valve flowed 10.35 CFM of air
at the first lift point, and 26.87 CFM of air
at peak lift. A peak swirl value of 2330
RPM was recorded on the swirl meter. The
figure below illustrates the intake flow table
and graph. (Refer Appendix A)
Fig. 2. Intake Air Flow Table.
Fig. 3. Intake Air Flow Graph.
3. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
3
EXHAUST
In addition to the intake, the exhaust valve
side was also flowed at the same test
conditions. The peak air flow recorded was
26.58 CFM at peak lift. The figures below
illustrate the exhaust flow table and graph.
Fig. 4. Exhaust Air Flow Table.
Fig. 5. Exhaust Air Flow Graph.
The stock test results provided vital
information about the cylinder head. The
conclusions that were derived from the
testing were that the peak air flow could be
improved significantly and that the air mass
swirl could also be increased to a greater
number. On observation, the cylinder head
had sharp edges and the port area near the
short side radius was significantly large [3].
Hence, with these observations in place
Computer-Aided Tools were used to design
and simulate modifications. The next
section deals with the process of using CAD
and CAE to determine possible design
solutions and their simulated outcomes.
COMPUTER-AIDED DESIGN AND
SIMULATION ANALYSES
COMPUTER-AIDED DESIGN
The most important part of this project was
to use Computer-Aided Design and
Computer-Aided Engineering to design
the modifications and to simulate and
analyse results in unison with the design
changes. The goal was to maximize the
intake air flow and hence, the first step was
to design the stock intake port using CAD
followed by adding modifications to the
design in order to improve the quality of air
and the quantity of air flow.
1. STOCK PORT DESIGN
The software used to design the intake port
was PTC CREO v2.0. The intake port on
the cylinder head was filled with a mould
substance and a mould of the intake port
was extracted. This mould was used to
measure the intricate dimensions of the
intake port on the short-side radius, the
valve guide area and the valve seating
area. The design of the intake port is
illustrated as follows.
Fig. 6. Stock Intake Port Design.
4. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
4
2. MODIFIED PORT DESIGN
The intake port modification process was
based on the ideas derived from the S.A.E.
Paper named “Cylinder Head Intake
Flow Analysis” [4] published by the
authors Jawad, B. and Arslan, S. The idea
involves the maximization of the area of the
inlet port at the opening and necking it
down towards the short-side radius. Also,
the focus is placed on the roof of the inlet
port as the air flow is maximum. Thus, the
modified port design included the filling up
of the floor of the port and causing an
upward movement of air flow towards the
roof. The CAD Design was then
implemented as shown in the figure below.
Fig. 7. Modified Intake Port Design.
The modified port design was completed
and the next step in the process was to
simulate the air flow through the port. The
simulation process helps in understanding
the differences between the stock and
modified results without the need of
making any actual changes to the cylinder
head. The next section deals with the CAE
simulation of the stock and the modified
intake port respectively.
COMPUTER-AIDED SIMULATION
The CAE Simulation [5] of the intake port
included the analysis of the intake air flow
velocity gradient, its vector flow, scalar
flow and its swirl characteristics. The tool
used for the simulation was STAR CCM +
v 9.0. The steps included in each of the
simulation procedures were to create a
parasolid of the CAD Design, to create a
velocity inlet and a pressure outlet, assign
individual values, mesh the parasolid and
create a scalar and vector scene. A
residuals plot of 500 iterations was
performed to estimate the air flow with
consistency.
1. STOCK PORT SIMULATION
The stock intake port having flown 26.87
CFM of air on the flow bench was
simulated for air flow. The velocity of the
air in the scalar flow scene was 0 m/s at
minimum and 336.59 m/s at peak. In the
vector flow scene, the velocity of air was
31.690 m/s at minimum and 361.92 m/s at
peak. The results of the stock intake port
are illustrated as follows. (Refer Appendix B).
Fig. 8. Stock Port Flow Velocity.
5. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
5
2. MODIFIED PORT SIMULATION
The modified port was simulated for air
flow and it produced significantly better
results in comparison to the stock intake
port design. The flow velocity in the scalar
flow scene increased to a peak of 401.33
m/s from the original 336.59 m/s which is
effectively a 19.23% increase. In the
vector flow scene, the velocity of air
improved from 31.690 m/s to 40.801 m/s at
minimum which implies a 28.75%
increase. At peak velocity levels, the
increase in velocity was from 361.92 m/s to
432.62 m/s resulting in an increase of
19.53%. This increase in velocity when
tuned precisely, leads to a good swirl which
helps the fuel-air mixture to mix properly
and increases the fuel efficiency of the unit.
[6] The figure below represents the velocity
flow gradient of the modified intake port.
(Refer Appendix C).
Fig. 9. Modified Port Flow Velocity.
The improvements were recorded across all
lift ranges and a significant rise in air flow
was recorded across all points. Thus, with
the simulation being completed, the
modifications could now be implemented
onto the cylinder head.
MODIFICATIONS PERFORMED
The simulated head design included the
alteration of the shape of the port. The
theoretical results had been confirmed by
the simulated results. Hence, one of the
major modifications that was performed on
the intake port was to fill up the floor and
the side walls with clay to cause an
upward displacement of the air towards
the roof of the port. [7] This upward
displacement meant that the velocity would
increase causing greater swirling
movement of the air.
In addition to this, as discussed earlier, the
air movement was being restricted by sharp
edges in many parts of the intake port. To
eliminate this, the cylinder head was fixed
onto a clamp and the sharp edges on the
short-side radius, valve seating area and
the valve guide area were smoothened out.
[8][9][10] The tools that were used were
carbide cutters and sand papers. The
intake area was expanded to facilitate the
allowance of larger quantity of air into the
port. The area of the port near the short side
radius was necked down slightly in order to
promote greater swirl. The modified port is
illustrated in the picture below.
Fig. 10. Modified Intake Port.
In addition to this, the exhaust port was also
smoothened to allow the exit of hot exhaust
gases at faster rates and in smooth fashion.
6. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
6
MODIFIED TEST RESULTS AND
ANALYSES
INTAKE
The modified cylinder head was flowed on
the flow bench. The head was tested at a
test temperature ranging from 88.8⁰F to
97.8⁰F and Flow Temperature ranging
between 74.7⁰F and 80.3⁰F. The
Barometric Pressure and Relative
Humidity conditions at the time of testing
were 28.47” of Hg and 26% respectively.
The air flow was 8.81 CFM at first lift point
which was a reduction from the stock head
standard. At peak lift though, the air flow
was 28.25 CFM which was a 5.13%
increase in flow. The main aspect of the
modification however, was to increase the
swirl and flow velocity. The swirl recorded
at each lift point showed a steady 3-7%
increase. The swirl figures were 2460
RPM vs. 2330 RPM for modified vs. stock
head. The figure below illustrates the intake
flow table and graph. (Refer Appendix D).
Fig. 11. Intake Port Air Flow Table.
Fig. 12. Intake Port Air Flow Graph.
DYNAMIC TESTING REPORTS
STOCK
The stock cylinder head was tested
dynamically on the engine dynamometer
for performance evaluation. The tests
performed were a Sweep Test, a Step Test
for warm-up and a 2- Minute WOT Peak
Torque Test for performance evaluation.
The stock cylinder head had a Peak Torque
of 8.7 Ft_Lb at 2350 RPM and a Peak
Power of 4.2 HP at 3750 RPM. The graph
illustrates the Stock Head performance.
Fig. 13. Torque, Power vs. RPM Graph
MODIFIED
The modified cylinder head was tested on
the engine dynamometer. A similar
procedure of warm-up and peak torque tests
was performed on the modified cylinder
head. The cylinder head produced a Peak
Torque of 9.9 Ft_Lb at 2300 RPM and a
Peak Power of 5.1 HP at 2900 RPM. The
graph illustrates the performance analysis
of the Modified Head. (Refer Appendix E).
Fig. 14. Torque, Power vs. RPM Graph
7. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
7
CONCLUSIONS
Thus, as a conclusion to the project report,
the cylinder head had a better performance
output and greater port velocity for air flow.
In addition to this, the air had better
swirling properties which were confirmed
by a Brake Specific Fuel Consumption
Value of 0.632 g/KW-Hr. Also, for a full
two minute run at WOT, the Fuel
Consumption value would be 0.086 gms.
Thus, the modifications performed have a
positive effects on the engine performance.
COMPLETE AUTHOR
INFORMATION
Aditya Sripathi Venkata, is currently a
graduate student pursuing his Master of
Sciences degree in Automotive
Engineering Technology at Minnesota
State University, Mankato. Having
completed his Bachelors of Technology in
Mechanical Engineering in 2014, his
passion towards the Automotive industry
has led him to work at Volkswagen Group
Sales India Pvt. Ltd. and Mercedes-Benz
(Mahavir Motors), India. The areas of
focus and expertise include Automotive
Powertrain and Drivetrain development.
Ch. Kiran Kumar Reddy, is currently a
graduate student pursuing his Master of
Sciences degree in Automotive
Engineering Technology at Minnesota
State University, Mankato. He has
completed his Bachelors of Technology in
Mechanical Engineering in the year 2014.
G.V. Satya Prakash, is currently a
graduate student pursuing his Master of
Sciences degree in Automotive
Engineering Technology at Minnesota
State University, Mankato. He has
completed his Bachelors of Technology in
Mechanical Engineering in the year 2015.
ACKNOWLEDGEMENTS
We would like to thank Dr. Bruce Jones
(Department Chair and Professor,
AMET Dept.) for his valuable teaching,
encouragement for our group and the
immense confidence he has imparted to us.
It is with his guidance and supervision that
we could make this research paper possible.
REFERENCES
[1] Briggs & Stratton Animal Engine
Technical Manual:
http://www.quartermidgets.org/docume
nts/Tech/Briggs/2015_Animal_Tech_Ma
nual.pdf .
[2] Briggs & Stratton Official Website:
http://www.briggsandstratton.com/us/en
[3] Engineering Fundamentals of the
Internal Combustion Engine (2nd
Edition):
Author: Willard W. Pulkrabek
[4] Cylinder Head Intake Flow
Analysis: http://papers.sae.org/2013-01-
1409/
Authors: Jawad, B. and Arslan, S.
Date: April 8, 2013.
[5] CAE-Based Port Development and
Flow Design for SI Engines:
http://papers.sae.org/2005-01-0243/ .
Authors: Adomeit, P., Hopp, M.,
Schmidt, A. and Lang. O.
Date: April 11, 2005.
8. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
8
[6] A Study on Combine Effects between
Swirl and Tumble Flow of Intake Port
System in Cylinder
Head: http://papers.sae.org/2000-05-
0098/
Authors: Jeong-Eui Yun, Jae-Joon Lee
Date: June 12, 2006.
[7] Basics of Cylinder Head Air Flow
Science and Porting Techniques:
http://www.enginebuildermag.com/2005
/12/cylinder-head-design-and-
modification-getting-started/ .
Date: December 2005. Author: Ken
Weber. First Edition: April 15, 2015.
Updated: May 18, 2015. Author: Jerry
Mostek
[8] Step by Step Head Porting:
http://www.superchevy.com/how-
to/95518-small-block-cylinder-head-
porting/ . –
Date: May 1, 2002.
Author: Scott Crouse.
[9] How to port a cylinder head:
http://www.howrah.org/cylinder-
head.html .
[10] Cylinder Head Porting & Polishing:
http://www.speedstore.ca/head_porting.
html .
DEFINITIONS, ACRONYMS AND
ABBREVIATIONS
CFM – Cubic Feet per Minute
Cu.in – Cubic Inches
CC – Cubic Centimetres
HP – Horsepower
“Of Hg – Inches of Mercury
RPM – Revolutions Per Minute
C.A.D – Computer-Aided Design
C.A.E – Computer-Aided Engineering
A.M.E.T – Automotive and
Manufacturing Engineering Technology
9. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
9
APPENDIX
APPENDIX A – STOCK CYLINDER HEAD GRAPHS AND TABLES
1. Stock Intake Port Flow Graph
2. Stock Intake Port Flow Table
10. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
10
3. Stock Intake Port Flow Graph and Table
4. Stock Exhaust Port Flow Table
11. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
11
5. Stock Exhaust Port Flow Graph
12. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
12
6. Stock Exhaust Port Flow Graph and Table
13. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
13
APPENDIX B – STOCK INTAKE PORT SIMULATION OUTPUTS
1. Geometry Mesh Bottom View
2. Geometry Mesh Isometric View
14. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
14
3. Geometry Mesh Front View
4. Residuals Plot
15. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
15
5. Scalar Flow Scene Velocity
6. Vector Flow Scene Velocity
16. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
16
APPENDIX C – MODIFIED INTAKE PORT SIMULATION OUTPUTS
1. Geometry Mesh Bottom View
2. Geometry Mesh Isometric View
17. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
17
3. Geometry Mesh Front View
4. Residuals Plot
18. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
18
5. Scalar Flow Scene Velocity
6. Vector Flow Scene Velocity
19. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
19
APPENDIX D – MODIFIED CYLINDER HEAD GRAPHS AND TABLES
1. Modified Intake Port Flow Graph
2. Modified Intake Port Flow Table
20. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
20
3. Modified Intake Port Flow Graph and Table
21. COMPUTER-AIDED CYLINDER HEAD DESIGN AND DEVELOPMENT
ADITYA SRIPATHI VENKATA, CH.KIRAN KUMAR REDDY AND G.V. SATYA PRAKASH
TEAM FORCE INDIA
21
APPENDIX E – DYNAMIC ENGINE PERFORMANCE TESTING RESULTS
1. Stock Cylinder Head Performance Results
2. Modified Cylinder Head Performance Results