Title: Design optimisation of interference limits for cup-plug installation in HHP cylinder head

Authors: Rajeev Verma; Jagjit Singh Randhawa; Durgaprasad Pitcha; Jawed Ali

Addresses: Department of Industrial and Production Engineering, Dr B R Ambedkar National Institute of Technology Jalandhar, Jalandhar, Punjab, 144011, India ' Centre of Excellence (Industrial and Product Design), Punjab Engineering College, Chandigarh, 160012, India ' Centre of Excellence (Industrial and Product Design), Punjab Engineering College, Chandigarh, 160012, India ' Cummins Technologies India Pvt. Ltd., Pithampur, Madhya Pradesh, 453331, India

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.

Keywords: interference fit analysis; cup-plug; cylinder head; push-out force; lames equations; FEA; finite element analysis.

DOI: 10.1504/IJHVS.2022.123243

International Journal of Heavy Vehicle Systems, 2022 Vol.29 No.1, pp.71 - 94

Received: 10 Feb 2021
Accepted: 01 Jul 2021
Published online: 06 Jun 2022 *

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