This is a Static and Thermal Analysis of a V6 Engine Block using HyperWorks ans SolidWorks. By conducting the above analysis, stresses, deformations and temperature gradient conditions are found and the best material for the engine block is suggested.

1. Project Presentation
on
Under the guidance of:
Vishal Patil
Assistant Professor
Dept. of Mechanical Engg.
Analysis of Engine Block
Submitted by:
Manvay Soni (17/155)
Gaurav Parshar (17/146)
Final Year

2. Scenario to be Analyzed
 The solid model of the engine block is generated in
Solidworks..
 The model is imported to HYPERMESH and then
Analysis is to be done by using Hyperworks software.
 By conducting the above analysis stresses,
deformations and temperature gradient conditions are
found and the best material for the engine block is
suggested.
 Temprature of gases is taken as 1000˚C.
 Ambient Temperature is 30˚C.

3. Design a 3D
Model
Import to
Hypermesh
Meshing the
Model
Apply
Material
Properties to
component
Apply the
Boundary
Conditions
Create the
LoadStep
Visualization
Results
Procedure for Model Analysis

4. Hyperwork UI

5. Importing Geometry
• Since, this geometry was created in solid designing
software, we can import it using Import Geometry
feature in Hypermesh. (imports “.iges” file)

6. Importing Geometry

7. Meshing of Component
• To create a mesh of component, first go to to the 3D page and select tetramesh option.
• In the Tetramesh page select Volume tetra option, select enclosed area as solid.
• Select R trias as 2D elements and tetra as 3D elements.
• Check on use curvature and use proximity, select the appropriate element size, click on mesh.
• Meshing is done

8. Continue…

9. Describing Material
• After clicking on icon shown above, enter name as Stainless Steel, type as isotropic, card image as MAT1.
• Click on create/edit.
• Now select MAT4 from the list at the bottom Enter values for Stainless Steel as shown
• Similarly, create a other three materials. (with a different color code)

10. Material Properties
Material Density
(kg/m3)
Modulus of
elasticity
(N/m2)
Poisson
ratio
Thermal
Conductivi
ty
(W/m-k)
Specific
heat
capacity
(J/kg-k)
Al 7475 2810 70.3x109 0.33 163 880
Stainless
Steel
7850 210x109 0.3 73 440.5
Graphite
Cast iron
7900 99x109 0.21 46 490
Units are according to Hyperworks
inputs

11. Creating Properties
• Properties needs to be created for all the materials.
• We use PSOLID card image because we will be working on 3D solid elements for our analysis
• To create a property click on the above icon and set property name as stainless steel , card image as
PSOLID, and material as Stainless Steel. (in case of Stainless Steel is selected as current material)
• Click on Create
• Click on return
• Now the Property is created successfully.
• Similarly, create for other materials.

12. Assigning Property and Material to component
• Click on component icon shown above and select update.
• Click on comps (yellow button) and select V6_Engine
• Click on property button and select property Stainless steel.
• Click on update
• A message on bottom left corner saying components are updated.

13. Creating load Collectors
• Create a loadcol name as Ambient , by clicking on create.
• Create a next loadcol name as Temperature, by clicking on create
• To associate both the loadcol we create a new loadcol name as SPCADD, and card image is set to SPCADD
• Similarly, create a constraint loadcol. With different color code, name as spc_struct

14. Continue….
• All the loadcol are created succefully, now we can apply constraints and temperature load
to the component.

15. Applying Thermal Loading
• Make Temperature as current load collector by clicking on bottom rightmost corner.
• Go to analysis > constraints.
• Select faces of combustion chamber as shown.
• Uncheck all degree of freedoms from 1 to 6.
• Click on create/edit.
• Provide value under D equal to 1000.(for Temperature of gases)

16. Creating Ambient Temprature(30˚C)
• Create a node outside the model as shown
• Go to Geom page > select nodes .
• In node page click on as node option and click on create
• After creating the node click on return.

17. Creating Ambient Temprature(30˚C)
• Make Ambient as current load collector by clicking on bottom rightmost corner.
• Again go to Analysis > Constraints.
• Select the node created outside the model.
• Keeping all degrees of freedom unchecked, click on create/edit.
• Again provide the value under D equal to 30

18. Applying constraint to Engine block
• Make spc_struct as current load collector by clicking on bottom rightmost corner.
• Again go to Analysis > Constraints.
• Select the faces below the component to apply constraints.
• Keeping all degrees of freedom checked, click on create.

19. Defining Interface for Elements facing Convection
• We need to define the surface from which convection will actually occur.
• Go to Analysis > Interfaces.
• Give name Convection and card image as Convection.
• Go on add option and select face under slave Entity IDs
• Click on add solid faces and select all the faces for convection.
• Click on add and it will show interface create on the outer surface of component.

20. Interface of Convection on component

21. Applying convection scenario to interface
• Go to Card Edit (icon shown above)
• Select Elem in drop down menu and again click on elem and select by group.
• Now select Convection.
• Select config as slave3(for tetra elements) and click on edit.
• Click on TA1 and select the node we created outside the model.

22. Creating Loadsteps(Thermal)
• Go to analysis > Loadsteps.
• Give name Thermal and type as Heat Transfer (steady state).
• Check mark on SPC and click on equal to sign and then select SPCADD load collector
• Click on create and then click on edit.
• Then in the bottom list check mark on output and in output further check mark Flux and Thermal.
• Now, in the subcase list on top change formats to H3d for Flux and Thermal as shown.

23. Creating Loadsteps(Static)
• This loadstep is defined for static analysis of the elements. This will incorporate thermal expansion.
• Go to analysis > loadsteps and give name as static.
• For SPC click on equal to sign and select constraints.
• Click on create and click on edit.
• Scroll down in the list below and check mark on TEMP_LOAD.
• Then in list above click on Temp (yellow button) and select Temperature loadcol.
• In list below also check mark Output, further in which check mark Displacement, Stress.
• Then in list above, change formats for the Displacement, Stress and to H3D.

24. Creating Loadsteps(Static)

25. Run for Analysis
• Go to Analysis > Optistruct.
• Select export and analysis options as shown in image.
• Save your file in a separate desired folder with .fem extension.
• Click on Optistruct
• After the analysis gets completed, a pop-up will appear saying
• Analysis Completed (if no errors).
• Click on results and Hyperview Player will open up.

26. Results - HyperView
• Click on Contour icon.
• Select Subcase1 (Thermal) for viewing temperatures and
• element heat fluxes.
• Click on apply to view results.

27. Results
Stainless Steel Graphite cast iron Al 7475
Grid
Temprature
Element
Fluxes

28. Results – Element Displacement and Stress
• Change subcase to subace2 Structure.
• Then click on apply
• We can change Result type to Element stress and Element Displacement to view them

29. Results – Element Displacement and Stress
Displacement
Stresses
Stainless Steel Graphite cast iron Al 7475

30. Graphical Representation of Results
5508.1
4550.1
6980.6
0
1000
2000
3000
4000
5000
6000
7000
8000
Stainless Steel Graphite Cast
iron
AL 7475
Stress
Equivalent Stress
Series 1
0.012728
0.01193
0.02728
0
0.005
0.01
0.015
0.02
0.025
0.03
Stainless Steel Graphite Cast
iron
AL 7475
Heat
Flux
Total Heat Flux
Series 1
1.1832 1.4
3.434
0
0.5
1
1.5
2
2.5
3
3.5
4
Stainless Steel Graphite Cast
iron
AL 7475
Deformation
Total deformation
Series 1
Stress Contrast Total Heat Flux Contrast Total Deformation Contrast
Parameters Stainless Steel Graphite Cast iron AL 7475
Element Flux(W/mm2) 0.012728 0.01193 0.02728
Equivalent Displacement (mm) 1.1832 1.400 3.434
Equivalent Stress(MPa) 5508.1 4550.1 6980.6

31. Conclusion
I. Analysis on engine block is carried out by using HyperWorks software
II. Linear steady state heat transfer and Static analysis is carried out on engine block with three different materials, i.e. as
stainless steel, Graphite cast iron and AL 7475
III. Then steady state thermal analysis is carried out at maximum temperature of 1000deg Celsius and convection is done by
Outer surface from ambient temperature 30 deg Celsius.
IV. From the static analysis result tables it is concluded that graphite cast iron show least stress and Steel shows least
deformation on same static load condition.
V. From the thermal analysis result tables it is concluded that graphite cast iron shows high temperature distribution
VI. Aluminum metal can withstand more stresses and graphite cast iron can withstand the temperatures. Hence aluminum
metal is preferable and can withstand high temperatures and stresses if high load and thermal condition both concern.

32. Thank you