MODELLING AND ANALYSIS

OF
12 CYLINDER DIESEL ENGINE V-TYPE

SUBMITTED BY:
SUBMITTED TO:
ARPIT
2015DN07
SKYLAB PAULAS BHORE
SUDHANSHU

2015DN02

ANURAG

2015DN06

PRADEEP

2015DN15

NEERAJ

2015DN16

DR.
(MED)

(DESIGN DEPARTMENT)

ABSTRACT
This project aims at modelling and analysis of 12 cylinder v
diesel engine. Here model of cylinder, cylinder liner, cylinder
head are designed using Catiav5 and analysis is done on
Ansys15.the Analysis include steady state thermal and static
structural.In the analysis the variation of the stress,
deformation and thermal variation are carried out .These
variations are observed using different material like aluminium
alloy, structuralsteel, cast iron for cylinder ,cylinder
head,cylinder liner .The results are studied and comparative
study is performed.

MODELLING OF CYLINDER HEAD, CYLINDER LINER

1. Actual images of cylinder head, cylinder

Fig1: Top view of the cylinder head

Fig2: Front view of cylinder head

Fig3: Front view of cylinder

Fig4: front view of cylinder head and cylinder assembly

2. CATIA modelling of cylinder, cylinder liner, cylinder head

and cylinder head and cylinder assembly

Cylinder

Cylinder-Liner Assembly

Liner

Cylinder Head

THEORETICAL CALCULATIONS

Diameter of cylinder (D) = 158mm

Length of cylinder(L) = 253mm
L
Length of stroke(l) = 1.15
l
ratio
D

=220mm

= 1.3924 which lies between standard limit(1.25 to 2)

Reboring allowance, C = 4.368mm

Area ,A =

D2/4 = 18145.84 mm2

Indicated mean effective pressure (Pm) = 0.4

So, maximum pressure , Pmax = Pm

106 Pa

10 = 4 106 Pa

Yield tensile strength of aluminium alloy strength of aluminium alloy,( AL)yt

= 280 106 Pa
Yield tensile strength of aluminium alloy strength of structural steel
( ) = 250 106 Pa
steel yt

CYLINDER :
Factor of safety = 4
Allowable stresses in cylinder for aluminium alloy , (AL )= (280
= 70

106 Pa

Allowable stresses in cylinder for structural steel , (steel) = (250

106)/4 = 62.5

106 Pa

Thickness of cylinder wall, t =

pmax
2

+C

For aluminium alloy = 8.882 mm

For structural steel

= 9.424 mm

Calculated Stresses in cylinder wall is given by relation

106)/4

DPmax = 2
For Aluminim alloy,
calulated

AL =

35.57

106 Pa

This is less than allowable stress in aluminium alloy.

For structural steel,

calculated

steel =

33.53

106 Pa

this is less than allowable stresses in structural steel.

CYLINDER HEAD:
Taking factor of safety = 4
Thickness of cylinder head is given by relation, th = D
K (constant) = 0.162
For structural steel , th = 16 mm
For aluminium alloy, th = 15.20 mm

KPmax
)

ANALYSIS
Material selected for analysis
Cylinder = grey cast iron, structural steel, aluminium alloy
Cylinder liner = grey cast iron
Cylinder head = grey cast iron,structural steel,aluminium alloy

1. Structural Analysis
Boundary condition
Maximum pressure = 4MPa
a. stress distribution of cylinder and cylinder liner assembly

Fig5. Aluminium alloy stress distribution

Fig6 :Stress distribution of grey cast iron

Fig7: Stress distribution of structural steel

Deformation

b. Total deformation in cylinder and cylinder liner

assembly

Fig8: Deformation of Aluminium alloy

Fig9: Deformation of grey cast iron

Fig10: Deformation of structural steelcylinder

c. Stress distribution of cylinder head

Fig11:Aluminium alloy cylinder head Stress distribution

Fig12: Grey cast iron cylinder head stress distribution

Fig13: Structural steel cylinder head stress distribution

d. Deformation of cylinder head

Fig14: Aluminium alloy cylinder head deformation

Fig15: Cast iron cylinder head deformation

Fig16:Structural steel cylinder head deformatio

2.Thermal analysis
Boundary conditions
Maximum temperature =500
W

Convective heat transfer coefficient for cylinder = 50 Km 2

Convective heat transfer coefficient for cylinder head = 10
W
2
Km
a. Cylinder thermal analysis

Fig17: Temperature distribution of cast iron cylinder alloy

Fig18: Temperature distribution of aluminium alloy cylinder

Fig19: Temperature distribution of structural steel cylinder

b. Cylinder head thermal analysis

Fig20: Temperature distribution of grey cast iron cylinder head

Fig21: Temperature distribution of aluminium alloy cylinder head

Fig22: Temperature distribution of structural steel cylinder head

RESULT TABLE

S
NO.

Components

1
2

Cylinder

3
4
5
6

Cylinder Head

Material

Max.
Stress(MPa)

Temp.
Range(0C )

Gray cast Iron

66.4

500.01-482.57

68.3

500.02-452.60

63.9

500.02-458.33

66.4

500.01-491.33

Gray cast Iron

68.1

500.00-472.43

Structural
Steel

67.4

500.00-476.14

Aluminium
Alloy
Structural
Steel
Aluminium
Alloy

CONCLUSION

From the above analysis, wecan conclude in thermal

analysisthat aluminium alloy proves to be a better material
amongst the given materials areconcerned. The higher thermal
conductivity of aluminium alloy provides fast cooling of the
cylinder.
As per the structural analysis is concerned the selection of
material depends on the geometry of the concerned
component. As we can see in the given analysis that
aluminium alloy proves to be better for cylinder while
structural steel gives high value of stress for the cylinder head.
It has high wear resistance and high strength so can be
employed to the heavy engines. It has high density so more
weight.
Gray Cast Iron is chosen material for the cylinder liner
throughout the analysis because of its hardness and wear
resistance properties.
Also, Analysis shows that aluminium alloy shows the maximum
deformation among the given materials and structural steel
shows the last deformation

DISCUSSION
In large engines we use a separate cylinder liner. The cylinder
liner, water jacket and frame are manufactured separately and
then assembled. The use of separate cylinder liner has the
following advantages
1. Cylinder liners are more economical because they can be
easily replaced after being worn out.it is not necessary to
replace the complete assembly of cylinder.
2. Instead of using better grade material for all part of
cylinder assembly only the cylinder liner is made of better
grade wear resistant cast iron.

Cylinder and cylinder liner are usually made of grey cast iron
with homogenous and grain structure .for heavy duty
cylinders, nickel cast iron and nickel chromium cast iron, cast
steel and aluminium alloys are used.

Reference:
Design of Machine Elements by V B Bhandari.
ANSYS Alberta Tutorials.
Design Data Book by P. S. G.