Design optimisation of interference limits for cup-plug installation in HHP cylinder head Online publication date: Mon, 06-Jun-2022
by Rajeev Verma; Jagjit Singh Randhawa; Durgaprasad Pitcha; Jawed Ali
International Journal of Heavy Vehicle Systems (IJHVS), Vol. 29, No. 1, 2022
Abstract: The strain developed due to the plastic deformation at the interference fitted cup-plugs in cylinder head bore of internal combustion (IC) engine can increase the contact force, whereas stress due to inappropriate interference fits may lead to crack failure. A new salvage method for the high horsepower (HHP) cylinder head of a water-cooled diesel engine has been introduced by developing a standard procedure based on modified Lame's equations. Experimentally validated results in reference to the finite element analysis (FEA) simulation were used to verify the accuracy of the proposed method. The analytically predicted contact pressure and push-out force considering maximum interference for baseline cylinder head and standard expansion plug assembly were found to be 225 MPa, 7.6 kN respectively, while those for the salvaged oversized assembly were 151 MPa, 7.27 kN; whereas, the complying range of interference fit for the corresponding push-out force was 170-350 μm.
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