Title: Engine cylinder head development methodology using CFD and FEM analyses

Authors: Cengizhan Cengiz; Serdar Güryuva; Yiğit Yazıcıoğlu; Ahmet Hamdi Güzel

Addresses: Ford Otomotiv Sanayi A.Ş., Sancaktepe R&D Center, İstanbul, 34885, Turkey ' Ford Otomotiv Sanayi A.Ş., Sancaktepe R&D Center, İstanbul, 34885, Turkey ' Ford Otomotiv Sanayi A.Ş., Sancaktepe R&D Center, İstanbul, 34885, Turkey ' Ford Otomotiv Sanayi A.Ş., Sancaktepe R&D Center, İstanbul, 34885, Turkey

Abstract: The demand in the automotive market for low fuel consumption engines with higher power density and engine torque is forcing development of engines that work on the edge of limits, with longer life and lower weight while complying with emission regulations. The development process can be accelerated and costs can be reduced only by replacing engine development tests with effective CAE methods during the design and development stage. This paper describes engine cylinder head development methodology by coupled combustion, conjugate heat transfer (CHT) and finite element analysis methodologies for assessment of high cycle and thermo-mechanical fatigue (TMF) failures for a heavy duty cylinder head and gives details about the thermal and fatigue life results obtained. This combined methodology is used to approximate engine durability status at the initial stage of engine development, improve the engine design and avoid any critical engine failures in advance of engine durability tests.

Keywords: thermal fatigue; engine combustion; coupling; engine cylinder head; CHT; conjugate heat transfer; high cycle failure; thermomechanical fatigue; boiling; CFD; computational fluid dynamics; FEA; finite element analysis; engine development; fatigue life; engine durability.

DOI: 10.1504/IJVD.2016.078777

International Journal of Vehicle Design, 2016 Vol.71 No.1/2/3/4, pp.389 - 409

Received: 08 Nov 2014
Accepted: 26 Oct 2015

Published online: 02 Sep 2016 *

Full-text access for editors Access for subscribers Purchase this article Comment on this article