Thermal and Structural Analyses of a Locally Developed Internal Combustion (IC) Engine Cylinder Head Using Finite Element Analysis (FEA)

Abstract

This paper presents thermal and structural analyses of a locally
developed cylinder head using Finite Element Analysis (FEA). A
composite material that comprises coconut shell charcoal (CSC) and
cow bone ash (CBA) as reinforcements and aluminium scraps as the
matrix element was used to develop the cylinder head of a 4-stroke
(107cc) IC engine. The cylinder head for the 107cc 4-stroke IC
engine block was modelled using SOLIDWORKS software. Design of
experiment was done using D-Optimal Mixture Design. The
composite was prepared based on the different percentage by ratio
of coconut shell charcoal, cow bone ash and aluminium matrix as
obtained from the design expert system. Stir casting method was used
for the casting process. The following results were obtained from the
analysis. Temperature distribution was 200.0000C maximum and
19.5950C minimum, Total heat flux was 9.821 x 106 W/m2 maximum
and 96.969 x 10-4 W/m2minimum, Equivalent (Von Mises) stress was
6.650 x 108 Pa maximum and 1.384 Pa minimum, Equivalent elastic
strain was 9.521 x 10-3 maximum and 2.601 x 10-11minimum, Total
deformation was 2.557 x 10-4 m maximum and 0.000m minimum,
Fatigue damage was 250.000 maximum and 250.000 minimum,
Fatigue life was 1.000 x 108 maximum and 1.000 x 108 minimum and
Fatigue safety was 15.000 maximum and 1.275 minimum. The results
obtained were satisfactory when compared with existing literature.