CAD System for Cylinder Head Used in High-Speed and Heavy-Power Diesel Engine

A CAD system for the cylinder head is developed. As an integrated system, it can be used in 3 D modeling, 2 D drawing and finite element structural analysis and optimization. The key problems in system designing are introduced. Design flow, system structure and how to solve the key problems are focused on. All of those would form the base for more research on how to use the modern CAD technology to design complex engine parts. And it is also a good example of using the modern CAD technology.

Grain refinement of gravity die cast secondary AlSi7Cu3Mg alloys for automotive cylinder heads

The effects of AITi5B1 grain refinement and cooling rate on the microstructure and mechanical properties of a secondary AlSi7Cu3Mg alloy were reported. Metallographic and image analysis techniques have been used to quantitatively examine the macrostructural and microstructural changes occurring with the addition of grain-refining agent at different cooling rates by using a step casting die. The results indicate that the addition of AlTi5B1 produces a fine and uniform grain structure throughout the casting and this effect is more pronounced in the slowly solidified regions. Increasing the cooling rate, lower amount of grain refiner is necessary to produce a uniform grain size throughout the casting. On the other hand, the initial contents of Ti and B, present as impurity elements in the supplied secondary alloy, are not sufficient to produce an effective grain refinement. The results from the step casting geometry were applied to investigate a gasoline 16V cylinder head, which was produced by gravity semi-permanent mould technology. The grain refinement improves the plastic behaviour of the alloy and increases the reliability of the casting, as evidenced by the Weibull statistics.

Production technique of vermicular graphite iron cylinder head of vehicle diesel engine

The 25 years＇ production and application have proved that vermicular graphite iron cylinder heads with vermicularity ≥50% satisfy the machinability and performance demand of diesel engine. The method, in which using cupola-induction furnace duplex melting and pour-over process with rare earth-ferrosilicon or rare earthsilicon compound as vermJcularizing alloy plus rare earth-magnesium-ferrosilicon as stirring alloy, is an optimal vermicularizing process for obtaining satisfied vermicularity. Using top kiss risers, enlarging kissing areas and expanding covering width and making ingates to freeze earlier are the effective measures to eliminate shrinkage, blowhole and oxide inclusions in the vermicular graphite iron cylinder heads.

Parameter Study of Some Key Structures for Cylinder Head

Using the method of the parameter study, some important dimensions of the cylinder head of an internal-combustion engine are analyzed. Under the mechanical load, the variational rules of the von Mises maximum stress on cylinder head are obtained, which are influenced by the thickness of the floor plate, head plate, jobbing sheet, standing partition board, and side plate of inlet port and exhaust port. A hypothesis is verified that there is an ideal matching point among those above-mentioned main parameters. The quantificational proportion relations, between these key structural parameters and von Mises maximum stress of cylinder head, can provide a good help for the cylinder head's structural design.

Numerical simulation and optimization of the cylinder head water jacket based on the two-phase flow boiling heat transfer

Boiling heat transfer and the controllability of the thermal load of the cylinder head were studied.The thermodynamic phase change characteristics of the cylinder head coolant were considered and the mass,momentumand energy transfers between two phases were calculated with the interface transfer submodels by using the computational fluid dynamics software CFX. Results showed that compared with the single-phase flow without considering the boiling heat transfer,the sub-cooled boiling heat transfer of the cylinder head was greatly increased. According to the results of the numerical simulation,an optimized structure of the water jacket was proposed. Finally,temperature and velocity of coolant,diameter of flow passage and mean bubble diameter that influences sub-cooled boiling were studied using the orthogonal experiment method.

Influence of the cylinder head structure of a diesel engine on fatigue strength

Using finite element method,influence of diesel cylinder head structure on fatigue strength is investigated.A simplified head model with function characteristics is built for thermal-mechanical simulation.From the simulation results,the influence of valve bridge structure and roof transition fillet dimension on fatigue strength are obtained.And a new valve bridge structure which can effectively improve the fatigue life is proposed.

PIV Measurements of Coolant Flow Field in a Diesel Engine Cylinder Head

This paper presents experimental measurements of coolant flow field in the water jacket of a diesel engine cylinder head. The test was conducted at three different flow rates using a 2-D PIV system. Appropriate tracing particles were selected and delivery device was designed and manufactured before the test. The flow parameters, such as velocity, vorticity and turbulence, were used to analyze the flow field. The effects of vortex which was located between the intake valve and the exhaust valve were discussed. The experimental results showed an asymmetric distribution of velocity in the water jacket. This led to an asymmetric thermal distribution, which would shorten the service life of the cylinder head. The structure optimization to the water jacket of cylinder head was proposed in this paper. The experimental system, especially the 2-D PIV system, is a great help to study the coolant flow structure and analyze cooling mechanism in the diesel engine cylinder head.

Compacted graphite iron-A material solution for modern diesel engine cylinder blocks and heads

The demands for improved fuel economy,performance and emissions continue to pose challenges for engine designers and the materials they choose. This is particularly true for modern diesel engines,where the primary path to achieving improved engine performance and emissions is to increase the Peak Firing Pressure in the combustion chamber. The resulting increase in thermal and mechanical loading has required a change from conventional grey cast iron to Compacted Graphite Iron (CGI) in order to satisfy durability requirements without increasing the size or the weight of the engines. With at least 75% higher tensile strength,45% higher stiffness and approximately double the fatigue strength of conventional grey cast iron,CGI satisfies durability requirements and also provides the dimensional stability required to meet emissions legislation throughout the life of the engine. Currently,there are no CGI diesel engines running on the roads in North America. This is set to change considerably as new commercial vehicle and pick-up SUV diesel engines are launched with CGI cylinder blocks in 2008 and 2009. These initial programs will provide over 2 million CGI diesel engines when ramped to mature volume,potentially accounting for 10%-15% of the North American passenger vehicle fleet within the next four years.

Thermo-Mechanical Analysis of the Sealing Performance of a Diesel-Engine Cylinder Gasket

Taking the combustor composite structure of a high-strength diesel engine as the main research object,dedicated tests have been conducted to verify the accuracy of three distinct cylinder gasket pressure simulation models.Using the measured cylinder gasket compression rebound curve,a gasket unit has been designed and manufactured.For this unit,the influence of the bolt pretension,cylinder body and cylinder head material on gasket sealing pressure has been investigated systematically in conditions of thermo-mechanical coupling.The results show that the bolt pretension force is one of the most important factors affecting the cylinder gasket sealing pressure.The change of the body material has little effect on this pressure.The cylinder gasket seal pressure decreases progressively with the reduction of the elastic module of the cylinder head material.

Tensile ductility improvement of AlSi9Cu1 alloy by chemical composition optimization

Diesel engines, characterized by higher breakout pressure and compression ratio in comparison with gasoline engines, require particularly elevated tensile properties for their engine parts. In order to maintain both high strength and high ductility in the cylinder head, i.e., to obtain higher percent elongation without further reducing the tensile strength, Al Si9Cu1 alloy was used to prepare the cylinder head in an aluminum diesel engine. At the same time, the effect of different modification elements, Na or Sr, and Fe content on the reduction of secondary dendrite arm spacing(SDAS) was discussed, and the design of T7 heat treatment parameters were analyzed in order to improve the tensile ductility. The result shows:(1) The SDAS is as small as 18±3 μm for the Sr modified alloy.(2) The percent elongation of the alloy with Sr modification increases by 66.7% and 42.9%, respectively, compared with the unmodified alloy and the alloy with Na modification.(3) Lower Fe content alloy(0.10%) gives good results in percent elongation compared to the alloy with higher Fe content(0.27%); in particular, after Sr modification and T7 heat treatment, the elongation of over 5% is obtained.

加氢反应器的设计

加氢反应器高温、高压、临氢等特点使其在材料选用、结构等方面较为特殊,与常见的中低压容器有所不同,设计时应选用合理的材料、采用合理的结构才能确保其既能便于制造和检验,又能满足设备的使用要求,文章对加氢反应器的设计进行了简单的概述。

柱面内爆驱动下铅飞层对碰区动载行为的实验研究

采用光学阴影照相和脉冲X光照相,对柱面内爆对碰驱动下铅飞层对碰区凸起行为进行了实验研究。实验结果显示,铅飞层对碰区出现严重的射流状超前凸起,凸起行为表现出明显的失稳发展倾向。由于对碰产生高压,因此铅飞层对碰区可能完全熔化,变成名义上无剪切强度的流体。材料的低强度、低熔点(冲击熔化压力)性能是造成铅飞层对碰区出现射流状超前凸起现象的主要因素。还观察到对碰区出现3个超前凸起现象,初步分析可能是由于柱面滑移爆轰波对碰导致的波系反射、叠加造成的,具体原因还有待于进一步分析研究。