Thermal and structural analysis of 4 cylinder inline engine

INTERNATIONAL JOURNAL
OF PROFESSIONAL ENGINEERING STUDIES Volume VI /Issue 4 / AUG 2016
IJPRES
Thermal and structural analysis of 4-cylinder inline engine
AKSHATHA SHARMA.T, V. SIVA RAMA KRISHNA (Asst.Professor)
DEPARTMENT OF MECHANICAL ENGINEERING
MALLA REDDY ENGINEERING COLLEGE (AUTONOMOUS)
(An Autonomous Institution approved by UGC and affiliated to JNTUH, Approved by AICTE, Accredited by
NAAC with ‘A’ Grade and NBA & Recipient of World Bank Assistance under TEQIP Phase- II S.C.1.1)
Maisammaguda, Dhulapally (Post. Via.Kompally), Secunderabad – 500 100.
Abstract
The inline-four cylinder engine or straight-four
engine is an internal combustion engine with all
four cylinders mounted in a straight line, or plane
along the crankcase. The single bank of cylinders
may be oriented in either a vertical or an inclined
plane with all the pistons driving a
common crankshaft. Where it is inclined, it is
sometimes called a slant-four. In a specification chart
or when an abbreviation is used, an inline-four engine
is listed either as I4 or L4.
The main objective of the project is how to
develop the prototype of four cylinder engine
assembly using CAD tool SOLIDWORKS.These
Engine assembly consists major components they are
Piston, Connecting Rod Assembly, Crank Shaft,
Cylinder head,CamShaft,Valves,crank case ,oil tank
and spark plug with required dimensions.
The components which are developed in
SOLIDWORKS software and analysis are carried out
in ansys work bench.
Introduction:
We almost take our Internal Combustion Engines for
granted don’t we? All we do is buy our vehicles, hop
in and drive around. There is, however, a history of
development to know about. The compact, well-
toned, powerful and surprisingly quiet engine that
seems to be purr under your vehicle’s hood just
wasn’t the tame beast it seems to be now. It was loud,
it used to roar and it used to be rather bulky. In fact,
one of the very first engines that had been conceived
wasn’t even like the engine we know so
well of today. An internal combustion engine is
defined as an engine in which the chemical energy of
the fuel is released inside the engine and used directly
for mechanical work, as opposed to an external
combustion engine in which a separate combustor is
used to burn the fuel. The internal combustion engine
was conceived and developed in the late 1800s. It has
had a significant impact on society, and is considered
one of the most significant inventions of the last
century. The internal combustion engine has been the
foundation for the successful development of many
commercial technologies. For example, consider how
this type of engine has transformed the transportation
industry, allowing the invention and improvement of
automobiles, trucks, airplanes and trains.
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In Line Engine
The inline-four engine or straight-four engine is an
internal combustion engine with all four cylinders
mounted in a straight line, or plane along the
crankcase. The single bank of cylinders may be
oriented in either a vertical or an inclined plane with
all the pistons driving a common crankshaft. Where it
is inclined, it is sometimes called a slant-four. In a
specification chart or when an abbreviation is used,
an inline-four engine is listed either as I4 or L4. The
inline-four layout is in perfect primary balance and
confers a degree of mechanical simplicity which
makes it popular for economy cars. However, despite
its simplicity, it suffers from a secondary imbalance
which causes minor vibrations in smaller engines.
These vibrations become worse as engine size and
power increase, so the more powerful engines used in
larger cars generally are more complex designs with
more than four cylinders.
Literature review:
Ganesan (1999) had presented a comprehensive
simulation producer for SI engine processes. In this
literature, the simulation for compression,
combustion, expansion and gas exchange process are
explained, along with various heat transfer model for
IC engines. A computer code for general Otto cycle,
fuel-air cycle and actual cycle is presented.
Jerald A. Caton (2000) analysed complete version of
thermodynamic engine cycle simulation for spark-
ignition engine. The instructional version of cycle
simulation used constant specific heats as compared
to using variable properties and composition for the
complete simulation. Mass fraction burned was
calculated using Wiebe function. Woschni heat
transfer coefficient model was used to calculate heat
transfer to the cylinder gases. For the proper selection
of constant properties, the global engine performance
parameters and were obtained the instructional
version of the simulation were in close 17 agreement
to the values obtained from using the complete
version of the simulation.
Kodah et al (2000) describes a simple analysis for the
prediction of pressure within a spark ignition engine.
This is done by modeling the combustion process
using the Wiebe function approach, which is an
exponential function in the form m 1- e to calculate
the rate of fuel-ax y burned. By careful selection of
a and m, any spark ignition engine with any
combustion chamber shape and any specified
dimensions can be assessed by this model. Validity of
this model has been tested by comparing the model
results with those obtained from running the engine
under the same operating conditions. The results
obtained from the theoretical model were compared
with those from the experimental data which show a
good agreement. Effects of the many operating
conditions, such as compression ratio, engine speed,
and spark timing have also been studied in this work.
Lawrence Mianzo and Huei Peng (2000) developed
the cylinderby-cylinder model of an variable valve
timing 4-cylinder engine. The model includes the
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cylinder and manifold mass, temperature, burned gas
residual, and pressure dynamics, including
combustion effects, as well as the valve actuator
dynamics. The cylinder-by-cylinder model is used to
obtain a cycleaveraged mapping between torque at a
given engine speed and intake valve timing, which is
suitable for future control design implementations.
Main components of the engine
Piston :
Piston is one of the main parts in the engine
Its purpose is to transfer force from expanding gas in
the ylinder to the crankshaft via a connecting rod.
Figure: piston
Piston Rings :
A ring groove is a recessed area located around the
perimeter of the piston that is used to retain a piston
ring. Ring lands are the two parallel surfaces of the
ring groove which function as the sealing surface for
the piston ring. A piston ring is an expandable split
ring used to provide a seal between the piston an the
cylinder wall.
Figure : piston rings
Connecting Rod :
The connecting rod is a major link inside of a
combustion engine. It connects the piston to the
crankshaft and is responsible for transferring power
from the piston to the crankshaft and sending it to the
transmission. There are different types of materials
and production methods used in the creation of
connecting rods. The most common types of
connecting rods are steel and aluminum. The most
common type of manufacturing processes are casting,
forging and powdered metallurgy.
Figure : connecting rod
Crankshaft :
The crankshaft is the part of an engine which
translates reciprocating linear piston motion into
rotation. To convert the reciprocating motion into
rotation, the crankshaft has crankpins, additional
bearing surfaces whose axis is offset from that of the
crank, to which the “big ends” of the connecting rod
from each cylinder attach.
Figure : crankshaft
Camshaft :
Camshaft is frequently called “brain” of the engine.
This is so because its job is to open and closed at just
the right time during engine rotation, so that the
maximum power and efficient cleanout of exhaust to
be obtained. The camshaft drives the distributor to
electrically synchronize spark ignition. Camshafts do
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their work through eccentric "lobes" that actuate the
components of the valve train. The camshaft itself is
forged from one piece of steel, on which the lobes are
ground. On single-camshaft engines there are twice
as many lobes as there are cylinders, plus a lobe for
fuel pump actuation and a drive gear for the
distributor. Driving the camshaft is the crankshaft,
usually through a set of gears or a chain or belt. The
camshaft always rotates at half of crank rpm, taking
two full rotations of the crankshaft to complete one
rotation of the cam, to complete a four-stroke cycle.
Figure : cam shaft
Modelling Of Four Cylinder Engine
connecting rod:
Piston
Crankshaft
cam shaft
spark plug
cylinder head
crank case
Assembly Of 4-Cylinder Engine :
different views of four cylinder engine
Analysis:
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Static structural analysis on Piston:
Load: 500N
Grey cast iron:
Results:
Aluminum alloy
Static structural analysis on connecting rod
Load:1000N
Material: grey cast iron
Aluminum alloy
Static structural analysis on crank shaft
Load: 1000N
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Aluminum alloy
Static structural analysis on cylinder block
Pressure: 1Mpa
Aluminum alloy
Static structural analysis on cam shaft
Load 500N
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Aluminum alloy
Static structural analysis on valves
Load 500N
Aluminum alloy:
Thermal analysis on piston
Thermal loads
Temperature 750C
Results :
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Aluminum alloy
Thermal analysis on cylinder block
Thermal loads
Temperature – 500C
Results:
Aluminum alloy:
Thermal analysis on valve
Material: gray cast iron
Thermal loads
Temperature 150C
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Results:
Aluminum alloy:
Results:
PISTON
Load: 5000N
Temperature: 750deg
Radiation: 30 deg
CONNECTING ROD:
Load : 1000N
CRANK SHAFT:
Load: 1000N
CYLINDER BLOCK:
Pressure: 1MPa
Temperature: 500deg
Radiation: 30deg
CAM SHAFT:
Load : 500N
VALVES:
Load: 500 N
Temperature: 150deg
Radiation: 22deg
Conclusion:
Internal Combustion engine is one of the most
important inventions of the last Century. It has been
developed in the late 1800s and from there on it has
had a significant impact on our society. It has been
and will remain for foreseeable future a vital and
active area of engineer research.
 Using a cad tool called solidworks “FOUR
CYLINDER ENGINE ASSEMBLY
“Straight In-Line order is developed
including few sub-assemblies.
 This assembly consists few sub-assemblies
they are Middle Crank Shaft, Connecting
Rod, Piston, Valves, Cam Shaft, Belt, Valve
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Springs, crank case, oil tank, cylinder head
spark plug.
 The main objective of this project is to
knowing of designing process using CAD
tool (SOLIDWORKS) and also preparing
components and assembly. This project is
deals with the
 Modeling and analysis of a Four Cylinder
Engine Assembly. and analysis is done
using cae tool (solidworks simulation), using
these software, here we chosen different
type of materials for every component which
are developed in cad tool.
 The materials are not existing material and
materials are chosen which are better than
existing materials. The main objective of
analysis is to showing the heat
transformations from one component to
other applying boundary conditions and
thermal loads are applied. This process is
done for Cylinder Head, Inlet valves, Crank
Shaft, piston components.
 The components having different materials.
These Analysis process is done in every
manufacturing industries before assembling
(Individual component Analysis).
 Why because this individual analysis is to
decide the capability of component before
they going to work. Finally the materials
which are chosen (not existing) are better in
weight & thermal conduction.
 Thus analysis is carried out on inline 4
cylinder engine in ansys work bench
 Two different materials grey cast iron and
aluminum alloy is applied to individual parts
 Required parameters such as stress, strain,
deformation, temperature distribution and
heat flux values are obtained and tabulated.
 From the results aluminum alloy is
showing best results compared to
grey cast iron.
References
 Colin R. Ferguson (1986), “Internal
Combustion Engine Applied
Thermosciences”
 John B. Heywood (1988), “Internal
Combustion Engine Fundamentals”
 Richard Stone (1999), “Introduction to
Internal Combustion Engines” (3rd edition)
 Charles Fayette Taylor (1985), “The Internal
Combustion Engine in the Theory and
Practice, Volume 1”
 Charles Fayette Taylor (1985), “The
Internal-Combustion Engine in the Theory
and Practice, Volume 2”
 J. H. Weaving (1990), “Internal Combustion
Engineering”
 Dimitrov L. (2001), “Principle of
Mechanical Engineering Design”
 Rowland S. Benson (1979), “Internal
Combustion Engines, Volume 2”
 Ricardo (1933), “The High-Speed Internal
Combustion Engine”
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Thermal and structural analysis of 4 cylinder inline engine

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