Structural Analysis of the Aluminum Cylinder Head for a High-Speed Diesel Engine 2007-01-2562
This paper presents the methodology for structural analysis of a high-speed Diesel engine aluminum cylinder head for Pick-up application, considering the finite element method. As boundary conditions, it was considered the loads from the bolts tightening process, combustion peak pressure, and thermal loading. The stresses generated during the assembly of the valve seats and valve guides were also evaluated. The valve train dynamic loads were not analyzed or considered in this paper, due to its negligible effects at the critical regions.
The FE model contains the upper part of the crankcase and the entire cylinder head. Heat transfer coefficients at the water jackets were obtained from a CFD calculation and used at the heat transfer analysis to evaluate the thermal stresses.
The residual stresses generated by the casting and manufacturing processes, as well the heat treatments for the alloy mechanical properties improvements, are also considered on this analysis.
Fatigue safety factor shall be evaluated considering the critical loading cycle, focusing the reliability of the component at severe operational conditions. The cylinder head design shall consider its application, taking into account high combustion peak pressures to attempt the current environmental legislation and higher engine output power required by modern vehicular applications.