Srinivasa Institute of Engineering and Technology

Department of Mechanical Engineering

DESIGN AND ANALYSIS OF ENGINE BLOCK

P.AKHIL 216N5A0319
D.SAI KIRAN 216N5A0309
D.V.V.DURGA PRASAD 216N5A0332
G.ARJUN 206N5A0312

Under the Supervision of

Mr.S.DURGA PRASAD M.Tech
Assistant Professor
Department of Mechanical Engineering,
Srinivasa Institute of Engineering and Technology
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
CONTENTS
 ABSTRACT.

 INTRODUCTION.

 TYPES OF ENGINE BLOCKS.

 NOMENCLATURE.

 LITERATURE SURVEY.

 OBJECTIVE.

 METHODOLOGY.

 SELECTION OF MATERIALS.

 CATIA MODELLING.

 ANSYS WORK BENCH.

 GRAPHICAL REPRESENTATION.

 CONCLUSION.
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
ABSTRACT
The cylinder block is like the heart of an engine. It provides a strong structure to hold the cylinders and
withstand the forces of combustion. This report investigates the structural integrity of an engine block
under combined static pressure and transient thermal loads. The analysis utilizes both static structural
analysis and transient thermal analysis to predict the stress, strain, and total deformation experienced by
the engine block during operation. Key factors considered include internal combustion pressure,
temperature distribution, and heat flux. The findings from this analysis are crucial for optimizing engine
design to ensure its ability to withstand operational stresses without excessive deformation or failure.

Modelling is carried out by using CATIA software. Static structural analysis and transient thermal analysis is
carried out by using ANSYS software.

Keywords: cylinder block, static structural analysis, transient thermal analysis, CATIA and ANSYS.
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
INTRODUCTION

The cylinder block is the heart of any internal combustion

engine. It's the foundation upon which the entire engine is
built. This cast iron or aluminum engine component
houses the cylinders, pistons, and coolant passages. It also
provides support for the crankshaft and camshaft.

TYPES OF ENGINE BLOCK Fig: 01

 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
TYPES OF ENGINE BLOCK

 Inline Cylinder Block.

TYPES OF DIESEL ENGINE NOZZLES Diesel engine nozzles are mainly classified into 2 types, they are : • Single-hole nozzles: These have a single orifice that creates a conical spray pattern. They are a relatively simple design and offer good fuel atomization, but the spray
pattern may not be ideal for all engine configurations.

 V-Shaped Cylinder Block.

 Flat Cylinder Block.
From the above types of cylinder blocks. We have chosen inline cylinder block for
this project.
Inline Cylinder Block :
An inline cylinder block, also known as a straight engine block, is the foundation of
an inline engine. An inline engine is a type of internal combustion engine where the
cylinders are arranged in a straight line, one behind the other . This is the simplest and
most common type of engine block. Inline engines are known for their simplicity,
Fig: 02
durability, and ease of maintenance.
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
NOMENCLATURE
Cylinder walls: The cylinder walls form the inner surface of the
cylinders.

Deck Surface: The cylinder head forms a seal with the deck surface
to contain the combustion chamber.

Cylinder Bore: This is the cylindrical cavity in the block where the
piston travels up and down.

Water Jacket: This is the space between the cylinder walls and the
outer wall of the block.

Block Mounts: These are the threaded holes on the sides of the block
that are used to mount the engine to the chassis of the vehicle.

Crankshaft Housing: This is the cavity in the bottom part of the Fig: 03
cylinder block where the crankshaft is positioned.
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
LITERATURE SURVEY
S.NO AUTHOR TITLE YEAR OBJECTIVE

A static structural analysis is performed on a single-stroke

1 Yash Godekar Static structural and thermal
analysis of single-cylinder
engine.
2021 engine and its components (piston, crankshaft, and
connecting rod) using ANSYS software. The analysis aims
to determine the effects of loads and boundary conditions
on the engine's deformation, equivalent stress, and
equivalent strain.

It describes the cylinder block, a key part of a

2 Rushikesh G. Kolhe Static, Modal & Thermal 2020 reciprocating engine. It houses the cylinders and pistons,
Analysis of Engine which create the engine's power. The block is analyzed to
Block understand how it behaves under various loads.

Thermal stress in an internal combustion engine and its

3 Mubarak F. AL-Dhafiri Thermal analysis for 2019 impact, using SolidWorks to compare materials. Cast iron
internal combustion has lower stress but higher displacement/strain than alloy
cylinder block. steel.
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
OBJECTIVE

To evaluate the structural and thermal performance of a cylinder block design using different materials through
static structural and transient thermal analysis, identifying the optimal material for a specific application.
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
METHODOLOGY
Collection of design data

Design of cylinder block

using CATIA

Material Selection

Static structural analysis Analysis of cylinder block Transient thermal analysis

using Ansys

Material change Material change

Result from the analysis

Compare the result from the analysis
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
Selection of Materials for analysis
• Al 7475.
• Grey Cast Iron.
• Forged Steel.

Element Content Element Content Element Content

Aluminum 90.3% Iron 97
Iron 93%
Zinc 5.7%
Manganese 0.3-0.9
Magnesium 2.3% Carbon 2.5%-4%
Silicon 1.5% High carbon 0.55-0.95
Silicon 1%-3% steel
Chromium 0.22%
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
PROPERTIES OF MATERIALS

S.NO. MATERIALS YOUNG’S MODULUS DENSITY POISION’S RATIO

GPa

1 Aluminium 7475 71.7 2.81 0.3

2 Cast Iron 100 - 170 6.9 – 7.8 0.21 – 0.3

3 Forged Steel 190 – 210 7.8 – 7.9 0.27 – 0.3

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Department of Mechanical Engineering
Line Diagram of Engine Block
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Department of Mechanical Engineering
CATIA INTERFACE
2D Drafting Tools
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3D Modelling Tools
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Department of Mechanical Engineering
CATIA MODELLING
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Department of Mechanical Engineering
DIMENSIONS OF ENGINE BLOCK
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Department of Mechanical Engineering
ANSYS WORK BENCH
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ANSYS

Fig: 05: GEOMETRY Fig: 06: MESHED

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Department of Mechanical Engineering
Input Parameters
Structural Inputs : Thermal Inputs :

Materials Temperature Convection

Materials Pressure MPa
°c W/mm .°c

Al 7475 11.6 Al 7475 800 9.1e-005

Cast Iron 11.6 Cast Iron 800 9.1e-005

Forged Steel 11.6 Forged Steel 800 9.1e-005

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Structural inputs : Thermal inputs :

Structural inputs

Fig: 07 Fig: 08
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Structural Analysis

Parameter : Stress

Fig: 09: Aluminium Fig: 10: Cast Iron Fig: 11: Forged Steel
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Department of Mechanical Engineering

Structural Analysis

Parameter : Strain

Fig: 12: Aluminium 7475 Fig: 13: Cast Iron Fig: 14: Forged Steel
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Department of Mechanical Engineering

Structural Analysis

Parameter : Deformation

Fig: 15: Aluminium 7475 Fig: 16: Cast Iron Fig:17: Forged Steel
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
STATIC STRUCTURAL ANALYSIS RESULTS :

Stress Strain
MPa Deformation
Material mm

Max Min Max Min Max Min

Aluminium 7475 153.01 0.042626 0.002692 1.8411e-6 0.14496 0

Cast Iron 152.62 0.069898 0.0018087 1.2619e-6 0.091788 0

Forged Steel 152.43 0.060743 0.00092951 6.4001e-7 0.048252 242424

 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
GRAPHICAL PRESENTATION
Static Structural Analysis :
1000

100

10

0.1

0.01

0.001

0.0001
Stress Strain Deformation
Aluminium 153.01 0.002692 0.14496
Cast Iron 152.62 0.0018087 0.091788
Forged Steel 152.43 0.00092951 0.048252

Aluminium Cast Iron Forged Steel

 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering

Transient Thermal Analysis

Parameter : Temperature

Fig: 18: Aluminium 7475 Fig:19: Cast Iron Fig: 20: Forged Steel
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Department of Mechanical Engineering

Transient Thermal Analysis

Parameter : Total Heat Flux

Fig: 21: Aluminium 7475 Fig: 22: Cast Iron Fig: 23: Forged Steel
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Department of Mechanical Engineering

Transient Thermal Analysis

Parameter : Directional Heat Flux

Fig: 24: Aluminium 7475 Fig: 25: Cast Iron Fig: 26: Forged Steel
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Transient Thermal Analysis

Parameter : Thermal Error

Fig: 27: Aluminium 7475 Fig: 28: Cast Iron Fig: 29: Forged Steel
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
TRANSIENT THERMAL ANALYIS RESULTS :

Temperature Total Heat Flux Directional Heat Flux Thermal Error

°c w/mm2 w/mm2
Material

Max Min Max Min Max Min Max Min

Aluminiu 0.000969
800.18 501.33 3.179 1.2619 -2.2237 9.7791e⁵ 0.025556
m 7475 81

Cast Iron 804.06 -290.14 0.019478 2.2731e-11 0.019421 -0.019478 7.0145ze⁵ 6.9548e-13

Forged 0.017237 -0.017082 6.3682e⁵ 5.0988e

804.09 -309.32 0.017237 1.8375e-11
Steel
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering

Transient Thermal Analysis :

1024
512
256
128
64
32
16
8
4
2
1
0.5
0.25
0.125
0.0625
0.03125
0.015625
Directional Heat
Temperature Total Heat Flux Thermal Error
flux
Aluminium 800.18 3.179 1.2619 0
Cast Iron 804.06 0.019478 0.019421 0
Forged Steel 804.09 0.017237 0.017237 0
Aluminium Cast Iron Forged Steel
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
Conclusion

In this project we have designed a cylinder block. Here we have taken the real time dimensions of the
cylinder block by using CMM reverse engineering technique. Here the CMM means coordinate
measuring machine. Using CATIA software, a cylinder block design was created, and then static
structural analysis and transient thermal analysis was performed using ANSYS software. Here we have
taken three different types of materials such as aluminium 7475, cast iron and forged steel. We are done
static structural analysis and transient thermal analysis for this three materials. The static structural
analysis and transient thermal analysis revealed that forged steel has the most favourable results. This
outcome can be attributed to forged steel's superior strength, durability, and thermal properties, making
it well-suited for the demanding conditions within a cylinder block. The forged steel material has less
stress, strain, deformation, total heat flux, directional heat flux and thermal error compared to the other
three materials. So, forged steel is the best material for cylinder block.
 Srinivasa Institute of Engineering and Technology
Department of Mechanical Engineering
REFERENCES
[1] “Design And Analysis of Cylinder Block using ANSYS” by Nirmal Kumar R, Department of Mechanical Engineering, Agni College of
Technology, Thalambur, - Volume 6 Issue 2, March- April 2020.
[2] “Design and Analysis of Four Cylinder Engine Block by Using F.E.A” by Mukesh Annamneedi, Jithendra, IJMETMR, Volume no :3 (2016) <
issue no: 9 (sept).
[3] MODELING & ANALYSIS OF ENGINE BLOCK D. R. Parthasarathi1, Y. Srinath2, S. Madhusudhana3 ISSN (PRINT): 2393-8374, (ONLINE):
2394-0697, VOLUME-4, ISSUE-11, 2017.
[4] DESIGN AND ANALYSIS OF CYLINDER HEAD OF AN ENGINE Vishal Sapkal#1, Kamal Ukey#2 International Research Journal of
Engineering and Technology Volume: 05 Issue: 05 | May-2018.
[5] A FEM Investigation for I C Engine Cylinder Block by Varying Thicknesses of Water Jacket 2017 IJEDR | Volume 5, Issue 1 | ISSN: 2321-9939
[6] Modal Analysis of V-12 Engine Cylinder Block Using Abaqus Software for Different Materials. International Journal of Recent Technology and
Engineering (IJRTE) ISSN: 2277-3878, Volume-7, Issue-ICETESM, March 2019.
[7] THERMOMECHANICAL ANALYSIS OF ENGINE BLOCK OF ICENGINE Suresh R1, Anil Kumar B N2, Shyam Sunder N3, Shridhar
Deshpande International Journal For Technological Research In Engineering Volume 2, Issue 11, July-2015.
[8] DESIGN AND THERMAL ANALYSIS OF CYLINDER BLOCK T. Rohith Goud1, Mohd. Naseeruddin2, C. Raghavendra3, Jyotsna Santhi4
IJARSE volume no: -6 issue no :- 1 january 2017.