See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/286084321

Design and Development of Cylinder and Cylinder Head of 4-Stroke SI Engine

for Weight Reduction

Article · December 2015

CITATIONS READS

0 3,526

1 author:

Muhammad SHAHRIN Sabri

Universiti Malaysia Pahang
5 PUBLICATIONS   0 CITATIONS   

SEE PROFILE

All content following this page was uploaded by Muhammad SHAHRIN Sabri on 07 December 2015.

The user has requested enhancement of the downloaded file.

 Design and Development of Cylinder and Cylinder Head of 4-Stroke SI Engine for Weight
Reduction
M.S.Sabri
Faculty of Mechanical Engineering, Universiti Malaysia Pahang (UMP), 26600 Pekan, Pahang,
Malaysia, Phone: +60145137591
Email: shahrinsabri93@gmail.com

ABSTRACT

The present paper deals with design of cylinder & cylinder head with air cooling system for 4
strokes 4 cylinder SI engine. The main objective of design is to reduce weight to power ratio & will
result in producing high specific power. The authors have proposed preliminary design cylinder &
cylinder head of a horizontally opposed SI engine, which develops 120 BHP and possess the maximum
rotational speed of 6000rpm. Four stroke opposed engine is inherently well balanced due to opposite
location of moving masses and also it provides efficient air cooling. For the requirement of weight
reduction the material selected for design of cylinder and cylinder head is Aluminum alloy that is LM-
13. The cylinder bore coating using NIKASIL coating was done to improve strength of cylinder with
minimum weight..

INTRODUCTION
Horizontally opposed four stroke four cylinder si engine:-
A flat-4 or horizontally-opposed-4 is a flat engine with four cylinders arranged horizontally in
two banks of two cylinders on each side of a central crankcase. The pistons are usually mounted on the
crankshaft such that opposing pistons move back and forth in opposite directions at the same time. The
general layout of this engine is shown in fig. 1

Fig 1. Layout of horizontally opposed 4 cylinders, 4 stroke SI Engine

The configuration results in inherently good balance of the reciprocating parts, a low centre of
gravity, and a very short engine length. The layout also lends itself to efficient air cooling. However, it
is an expensive design to manufacture, and somewhat too wide for compact automobile engine
compartments, which makes it more suitable for cruising motorcycles and aircraft than ordinary
passenger cars.
This is no longer a common configuration, but some brands of automobile use such engines and
it is a common configuration for smaller aircraft engines such as made by Continental. Although they
are somewhat superior to in-line 4stroke engines in terms of vibrations, they have largely fallen out of
favour because they have two cylinder banks thus requiring twice as many camshafts as for in-line
engines.
 EXPERIMENTAL SET UP
Material Selection
As means for reducing weight, there are several methods available substituting lightweight materials
for conventional materials, that is to decrease specific gravities, rationalization of structure (decrease
the number of parts through integration), & downsizing (decrease the volume of each part).
In the past, the engine performance has been compromised in order to improve emission. The methods
presented here, however are fundamentally different from the past one.

Fig 2. Material Composition of Weight-Reduced Engine & Base Engine [1]

The engine weight has reduced by 37 Kg from a base one of 162 Kg (excluding engine oil).This
corresponds to 23% weight reduction. As shown in fig. 2 the component weight ratio of the materials
are 53% steel for the weight-reduced engine (86% in the base engine), 33% (13%) Aluminum alloys,
7% (1%) plastics & elastomers, 6% (0%) other lightweight materials such as titanium alloys &
magnesium alloy, & 1% (0%) ceramics.
The materials substitutions applied for the engine structure component represented by a cylinder is no
more than simple weight reduction. But, when applied this to several moving & functional
components, it not only weight reduction method but also contributes to improve engines & emission
performance.
Basic Engine Design
Cylinder Head Design:

Table 1 Cylinder Head Dimensions.

Deign Parameter Calculated values
Cylinder wall thickness t 5 mm
Cylinder head thickness t’ 9 mm

Valve Spacing On Cylinder Head:-

Fig 3. Valve spacing diagram [2]

Figure shows the empirical relation for inlet & exhaust valve spacing.
Clearance between valve & bore = 2.3 mm
Space between valves (inlet & exhaust) = 9.36 mm
Inlet and Exhaust Manifold Design:-

Fig. 4. Inlet Manifold. Fig. 5. Exhaust Manifold.

Valve Seat:

Fig 6. Valve Seat design [6]

From figure we get the relation for valve seat outside diameter & height.
Inlet Valve Seat Design: -
Thickness of valve seat (t)i =
3.517 mm
Height of valve seat (h)i 9.0558 mm
Exhaust Valve Seat Design:-
Diameter of valve seat (De):-
24.57 mm
Thickness of valve seat (t) e = 3.003 mm
Height of valve seat (h)e = 7.37 mm

Table 2. Dimensions of valve seats:-

PARAMETER INLET VALVE EXHAUST VALVE
(mm) SEAT SEAT

D 30.186 24.57
t 3.517 3.003
h 9.0558 7.37

Design of Cooling Fins

Material: - Aluminum alloy (Thermal conductivity =109 web/mK)
 Table 3 Dimensions of cooling fins
Required parameter Calculated value
Root thickness of the fin, 3 mm
Space between two fins 3.96 mm
Number Of fins 24
length of fin 25 mm

RESULTS AND DISCUSSION

Solid modelling of Cylinder

Fig. 7. Model of cylinder Fig. 8. Model of cylinder head

FEA ANALYSIS of Cylinder and Cylinder Head
Table 4 Input parameters for analysis

PARAMETER VALUE
Maximum pressure 1.38e+007 N/m2
Maximum temperature 1032 K
Young’s modulus 7e+010 N/m2
Poisons ratio 0.34
Density 2700 Kg/m3
Thermal expansion 2.968 e-004 (1/K)
Yield strength 346e+008 N/m2

Fig. 9 Analysis of cylinder

 Fig. 10 Analysis of cylinder head
CONCLUSION
From the analytical solution & the analysis result we get the values of stresses produced in cylinder
and cylinder head due to application of temperature and pressure are within permissible limit. Hence
we concluded that the basic design of cylinder and cylinder head is safe with reference of pressure and
temperature basis. Due to the use of light weight material i.e. LM-13 with NIKASIL cylinder bore
coating, we can effectively reduce the weight of cylinder and cylinder head with improved strength.
Also due to the use of air cooling system an efficient and faster cooling of engine achieved.
REFERENCES
1. Sae Paper ‘Weight Reduced Engine’(1992): Volume-101 “Journals Of Engine Section”
2. Chrles Fayette Taylor- “The Internal Combustion Engine In Theory”.
3. A Kolchin & V. Demidov – “Design Of Automotive Engines” (Page No.- 439).
4. V.L.Maleev - “I.C.Engines” (Page No. – 310, 297).
5. Colin R Ferguson - “The Internal Combustion Engine” (Page No. - 313).
6. William H Crouse - “Automotive Engine Design” (Page No. - 218).
7. Julius Mackerle - “Air Cooled Automotive Engines” (Page No. – 204) .
8. V.Ganesan - “I.C.Engines”, Second Edition, Pub: Tata Mcgraw Hill (Page No. 4-
492)
9. V.Ramanujachari - “Internal Combustion Engine & Combustion” (Page No. –
115,116)
10. Sharma & Purohit - “Design Of Machine Element” (Page No. – 634,635)
11. R.K. Jain - “Machine Design” (Page No.- 1214)
12. B.L. Singhal -”Applied Thermodynamics” (Page No. – 6-4)
13. M. M. Noor, K. Kadirgama, M. M. Rahman, M. R. M. Rejab, C. H. C. Haron and K.
A. Abou-El-Hossein, “Surface Roughness Prediction Model Of 6061-T6 Aluminium
Alloy Machining Using Statistical Method”, European Journal of Scientific Research
ISSN 1450-216X, Vol.25 No.2 (2009), pp.250-256, 2009.
14. K.Kadirgama, M.M.Noor, R. Daud, M.M.Rahman, N.M.Zuki.N.M, M.R.M.Rejab,
B.Mohammad, “Design And Development Of Blow Mould Using Machining
Optimization Parameters”, National Conference on Design and Concurrent
Engineering.
15. K.Kadirgama, M.M.Noor, R.Daud2, M.R.M.Rejab, M.S.M.Sani, Z.Ghazalli,
Z.Hamedo, “Development Of New Genetic Algorithm Software For Blow Mould
Process”, Malaysian Science and Technology Congress, MSTC08, 16~17 Dec, KLCC,
Malaysia, 2008.
16. K.Kadirgama, M.M.Noor, M.R.M.Rejab, M.M.Rahman, M.S.M.Sani, T.T.Mon, “The
Effect of End Milling Parameters on Surface Roughness When Machining Corrosion
Resistance Alloy”, International Conference on Advance Mechanical Engineering
(ICAME09), 22~25Jun, Concorde Hotel, Shah Alam, Selangor, 2009.
17. K.Kadirgama, M.M.Noor, M.M.Rahman, M.S.M.Sani, A.K.Ariffin, “Surface
 Roughness Analysis In End Milling With Response Ant Colony Optimization”, 6th
International Conference on Numerical Analysis in Engineering (NAE2009), 15 -16
May, 2009, Lombok Island, Mataram City, West Nusa Tenggara Province, Indonesia.
18. K. Kadirgama ,, M. M. Noor and Ahmed N. Abd Alla , “Response Ant Colony
Optimization Of End Milling Surface Roughness”, Molecular Diversity Preservation
International, Basel, Switzerland, 2010.
19. K.Kadirgama, M.M.Noor, K. V Sharma, “Tool Life And Wear Mechanism When
Machining Hastelloy C-22HS”, K. Kadirgama et al. / Wear 270 (2011) 258–268, 2011.
20. K. Kadirgama, M.M. Noor, M.M. Rahman, M.R.M. Rejab, M.S.M. Sani, N.M. Zuki
N.M. and Rosli A. Bakar, “Prediction Modeling Of Torque In End-Milling”,
Proceedings of EnCon2008 2nd Engineering Conference on Sustainable Engineering
Infrastructures Development & Management December 18 -19, 2008, Kuching,
Sarawak, Malaysia E&CO&2008-E-27
21. K.Kadirgama, M.M.Noor, M.M.Rahman, M.S.M.Sani, Rosli A.Bakar & K.A.Abou-
El-Hossein, “Prediction Modelling Of Power And Torque In End-Milling”, 11th
International Conference on Optimum Design of Structures and Materials in
Engineering, OPTI09, 8 – 10 June 2009, Algarve, Portugal.
22. K. Kadirgama, M.M. Noor, M.M. Rahman, M.R.M. Rejab, S. A. Kesulai, “Fatigue
Life Prediction Of Lower Suspension Arm Using Strain-Life Approach”, European
Journal of Scientific Research ISSN 1450-216X Vol.30 No.3 (2009), pp.437-450
EuroJournals Publishing, Inc. 2009.
23. M.M.Noor1, M.M.Rahman1, A.K.Ariffin2, Rosli A.Bakar, A.K Ariffin and M.A.
Maleque, “Finite Element Based Fatigue Life Prediction Of Cylinder Head For Two-
Stroke Linear Engine Using Stress-Life Approach”, Journal of Applied Sciences, 8
(19). pp. 3316-3327. ISSN 1812-5654, 2008.
24. M.M. Rahman, A.K. Ariffin, S. Abdullah, M.M. Noor and Rosli A.B, “Durability
Assessment Of Cylinder Block For Two Stroke Free Piston Linear Engine Using
Random Loading”, American Journal of Applied Sciences 6 (4): 726-735, 2009 ISSN
1546-9239.
25. M. M., Rahman and M. M., Noor and A. K., Ariffin and N. , Jamaludin and S.,
Abdullah, “Finite Element Based Fatigue Life Prediction of a New Free Piston Engine
Mounting”, Journal of Applied Sciences , 9 (8). pp. 1612-1621. ISSN 1812-5654.
26. Z. Husin, M.M. Rahman, K. Kadirgama, M.M. Noor and Rosli A. Bakar, “Prediction
Of Fatigue Life On Lower Suspension Arm Subjected To Variable Amplitude
Loading”, National Conference in Mechanical Engineering Research and Postgraduate
Studies (2nd NCMER 2010) 3-4 December 2010, Faculty of Mechanical Engineering,
UMP Pekan, Kuantan, Pahang, Malaysia; pp. 100-116 ISBN: 978-967-0120-04-1.
27. M.M.Noor, Andrew P.Wandel and Talal Yusaf, “The Development of MILD
Combustion Open Burner Experimental Setup”, International Conference on
Mechanical Engineering Research (ICMER2013), 1-3 July 2013, Bukit Gambang
Resort City, Kuantan, Pahang, Malaysia.
28. M.M. Noor, Andrew P.Wandel and T.F.Yusaf, “MILD Combustion: A Technical
Review towards Open Furnace Combustion”, 2nd Malaysian Postgraduate Conference
(MPC2012), 7-9 July, Bond University, Gold Coast, Queensland, Australia.
29. M.M.Noor and Andrew P.Wandel, “The Study of Air Fuel Ratio for Open Furnace
MILD Combustion of Biogas on Bluff-body Burner”, Southern Regional Engineering
Conference, 1-2 September 2012, Toowoomba, Australia.

View publication stats