International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
International Journal of Research and Innovation in Mechanical Engineering (IJRIME) STRUCTURAL AND MODAL ANALYSIS OF AN ENGINE BLOCK BY VARYING MATERIALS Patnala N V Srilakshmi Sowbhagya1, K.Vijay2, V Srinivasa Rao3. 1 Research Scholar, Department of Mechanical Engineering, Aditya College of Engineering and Technology, Surampalem, Andhra Pradesh, India. 2 Assistant professor, Department of Mechanical Engineering, Aditya College of Engineering and Technology, Surampalem, Andhra Pradesh, India. 3 Professor, Department of Mechanical Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India.
Abstract The largest part of the engine is cylinder block. The upper section of the cylinder block consists of cylinders and pistons. Crankcase is supported by the crankshaft and it is placed in the lower section. Aluminum cylinder blocks are lighter than the cast-iron cylinder blocks of the same size. Cylinder block, pistons, cylinder head, crankshaft and connecting rods are the major elements of the engine. IC engine cooling uses either a liquid or gas to remove the unnecessary heat from an internal combustion engine. For special purpose and small engines, air cooling makes for a lightweight and relatively simple system, if we use the materials with better waste heat dissipation it will help in achieving better efficiencies and long life of the engine. This thesis was conducted to study the structural and vibrational behaviour of the engine block for various materials of engine block. The modeling of the engine block is done using Catia V5 and the structural and modal analysis is done in ANSYS, on the engine block by varying the materials. Presently, we considered Aluminium 7475, Graphite Cast Iron, Nickel Aluminium Bronze Alloy and Sand Cast Magnesium Alloy.
*Corresponding Author: Patnala N V Srilakshmi Sowbhagya, Research Scholar, Department of Mechanical Engineering, Aditya College of Engineering and Technology, Surampalem, Andhra Pradesh, India. Email: pentasowbhagya@gmail.com Year of publication: 2016 Review Type: peer reviewed Volume: III, Issue : I Citation: Patnala N V Srilakshmi Sowbhagya, Research Scholar, "Structural And Modal Analysis of An Engine Block By Varying Materials" International Journal of Research and Innovation in Mechanical Engineering (IJRIME)3.1 (2016): 213-216
INTRODUCTION V8 ENGINE / 8 CYLINDER ENGINE A V8 engine is also called as the 8 cylinder engine which consists of 8 cylinders where the cylinders are placed on the crankcase in two sets of four cylinders. In many of the cases, the 4 cylinders are set at a right angle to each other. Sometimes, they are constructed at a narrower angle, with all the eight pistons driving a common crankshaft. In the simplest form, it is constructed in a position that where the two inline-four engines sharing a common crankshaft. The dynamic imbalance problems are same with the flat or single plane crankshaft as in the large engine displacements results in vibrations. To eliminate the vibrations most V8 engines are used to have complex crossplane crankshaft with heavy counterweights. By using this method of heavy counterweights, the V8 engine
is smoother than V6 engine and is also much inexpensive than V12 engine. Faster acceleration and efficient exhaust system designs are attained by using V8 engines with single plane crankshafts. ENGINE BLOCK Engine block is the main component in the vehicles which runs on internal combustion which is used to prevent overheating. The water which is being used in the engine becomes very hot and it is being returned to the radiator where it is cooled by the fans in the radiator, and then returned back to the engine. The engine blocks core is capped with the cylinder head. The size of the powerhouse of the vehicle is determined by the number of cylinders in it. It consists of a solid cast part which houses the cylinders in it where the components are lubricated and cooled within the crankcase. The failure of the engine block results in the failure of the entire car and it will not function properly until it is repaired or replaced . Therefore, the engine block is designed to be very strong. Many of the engine blocks are made of cast iron, and some are made from plastic and some other experimental materials were being used in newly designed cars with the hope of developing more lightweight, efficient vehicles. A cast iron engine block makes most of the weight of the car, and requires multiple people to be worked on it safely. Most of the cars contains four to eight cylinders which releases extreme heat from it. So, the engine blocks are designed in such a way that there should more number of passages and channels inside the cooling jackets. Working from the outside in, this part starts with a solid metal outside, designed to seal everything inside.
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
MATERIAL PROPERTIES
TOTAL DEFORMATION
AL 7475 Density 2.81g/cc Young’s Modulus 70.3GPa Poisson’s Ratio 0.33 COMPOSITION: Aluminum 91.5% Copper 1.9% Zinc 6.2% NICKEL ALUMINUM BRONZE ALLOY Density 7.53 g/cc Young’s Modulus 110GPa Poisson’s Ratio 0.32 GRAPHITE CAST IRON
Total deformation results in model of engine block with Al 7475
DIRECTIONAL DEFORMATION
Density 7.19 g/cc Young’s Modulus 99GPa Poisson’s Ratio 0.21 SAND CAST MAGNESIUM ALLOY Density 1.8 g/cc Elastic Modulus 45GPa Poisson’s Ratio 0.35 COMPOSITION: Aluminium 10.7% Magnesium 90% Zinc 0.3% ANALYSIS
Directional deformation results in model of engine block with Al 7475
STRUCTUAL ANALYSIS:
MODAL ANALYSIS:
STRESS
Total deformation 1 of model of engine block with Al 7475 Stress results in model of engine block with Al 7475
STRAIN
Strain results in model of engine block with Al 7475
Total deformation 2 of model of engine block with Al 7475
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International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
CONCLUSION Here in this thesis we have taken an engine block of a v-8, 4 cylinder engine of a 4 wheeler vehicle. As in the present days with the temperature conditions and the load conditions many engines are getting deformed and damaged very quickly, so here we are going to decrease the stress formation and even the deformations. In this project we have designed a engine block of v-8 model in Pro-e and Ansys is done in Ansys software, structural and modal analysis is done to it with different materials to find the stress formations. Total deformation 3 of model of engine block with Al 7475
As if we observe in this project we have taken the materials AL 7475, GRAPHITE CAST IRON, NICKEL ALUMINUM BRONZE ALLOY AND SAND CAST MAGNESIUM ALLOY. These are the materials taken for the structural and modal analysis. As if we compare the results obtained in the tabular and graph form from the ansys results of structural analysis the stress (4.84e+007) and strain (1.08e-03) and deformations are low to the sand cast magnesium alloy than the other materials. As per the structural analysis we can conclude that the material with sand cast magnesium alloy can withstand the stress at higher pressures for a 4 cylinder v-8 model.
Total deformation 4 of model of engine block with Al 7475
As if we compare the results obtained in the modal analysis here the results are varying from each deformation, as if we take less deformation the material with the nickel aluminum bronze alloy is the best suited material for the v-8 4 cylinder engine block. And sand cast iron magnesium alloy will be the next better product here in the less deformed shape. So from the above results obtained we can conclude that sand cast magnesium alloy will be the best suited material for the better life of the engine block and with better outputs. REFERENCES
Total deformation 5 of model of engine block with Al 7475
As we calculated the deformations with Al 7475, in the same way we can also calculate the deformations with some of the other materials like Graphite cast iron alloy, Ni.Al.Bronze alloy and Sand cast Mg alloy. The stress, strain, total and directional deformations for the taken alloys are: STRESS
STRAIN
MIN
MAX
MIN
MAX
AL 7475
2.19E05
4.88E+07
3.11E16
6.95E04
GRAPHITE .CAST IRON
2.19E05
4.88E+07
1.48E16
Ni.Al. BRONZE ALLOY
1.89E05
4.93E+07
SAND CAST Mg. ALLOY
2.44E05
4.84E+07
TOTAL DEFORMATION
DIRECTIONAL DEFORMATION
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MIN
MAX
2.26E05
-2.47E06
1.42E05
3.30E04
1.07E05
-1.17E06
6.76E06
[5] E.urip, S.L yang. Arici, “Conjugate Heat Transfer for Internal Combustion Engine Application Using KIVA code”[1998]
1.35E16
3.52E04
1.13E05
-1.25E06
7.13E06
[6] R.T Green, J.Jambunathan, “Heat transfer through diesel engine cylinder liner “Applied energy 14 (1983) 175-196 [1999]
5.42E16
1.08E03
3.54E05
-3.82E06
2.22E05
[7] John B Heywood, “Thermal loading and temperature measurement in diesel engine component “Fundamentals of I.C engines [1988] 215
International Journal of Research and Innovation on Science, Engineering and Technology (IJRISET)
[8] Dr.S.MKhot, “Comparative cooling of engine cooling jacket models of diesel engine using CFD”.Third Biennial national conference of Nascent Technologies, NCNTE [2010] [9] Toyoshige Shibata, Hideo Matsui, Masao Tsubouchi, “Evaluation of CFD tools applied to engines coolant flow analysis through cylinder block” Mitshibushi motors, Technical review no.16 [2004] AUTHORS
Patnala N V Srilakshmi Sowbhagya, Research Scholar, Department of Mechanical Engineering, Aditya College of Engineering and Technology, Surampalem, Andhra Pradesh, India.
K.Vijay, Assistant professor, Department of Mechanical Engineering, Aditya College of Engineering and Technology, Surampalem, Andhra Pradesh, India.
V Srinivasa Rao, Professor, Department of Mechanical Engineering, Aditya Engineering College, Surampalem, Andhra Pradesh, India.
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