• International Journal of Automotive Technology
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• v.8 no.2
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• pp.243-248
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• 2007

The durability of a cylinder head is influenced by the thermal and mechanical history during the manufacturing process, as well as engine operation. In order to improve the durability of cylinder head, both load from engine operation and the preload conditions from the manufacturing process must be considered. The aluminum cylinder head used for a HSDI diesel engine is investigated to reduce the possibility of high cycle fatigue crack in this study. FE analysis is performed to elucidate the mechanism of high cycle fatigue crack in the HSDI diesel cylinder head. Two separate approaches to increase the durability of the cylinder head are discussed: reducing load from engine operation and re-arranging preload conditions from the manufacturing process at the critical location of the cylinder head. Local design changes of the cylinder head and modification of pretension load in the cylinder head bolt were investigated using FE analysis to relieve load at the critical location during engine operation. Residual stress formed at the critical location during the manufacturing process is measured and heat treatment parameters are changed to re-arrange the distribution of residual stress. Results of FE analysis and experiments showed that thorough consideration of the manufacturing process is necessary to enhance the durability of the cylinder head.

• International Journal of Automotive Technology
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• v.7 no.1
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• pp.69-74
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• 2006

Residual stresses are introduced in aluminum cylinder head during quenching at the end of the T6 heat treatment process. Tensile residual stress resulted from quenching is detrimental to fatigue behavior of a cylinder head when it is overlapped with stresses of engine operation load. Quenching simulation has been performed to assess the distribution of residual stress in the cylinder head. Analysis revealed that in-homogeneous temperature distribution led to high tensile residual stress at the foot of the long intake port, where high stresses of engine operation load are expected. Measurements of residual stress have been followed and compared with the calculated results. Results successfully proved that high tensile residual stress, which was large enough to accelerate fatigue failure of the cylinder head, are formed during quenching process at the end of heat treatment at the same critical position. Effect of quenching parameters on the distribution of residual stress in cylinder head has been investigated by choosing different combination of heat treatment parameters. It was demonstrated that changes of quenching parameters led to more homogeneous temperature distribution during cooling and could reduce tensile residual stress at the critical region of the cylinder head used in this study.

• Transactions of Materials Processing
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• v.18 no.8
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• pp.607-616
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• 2009

There are three sub-processes associated with the assembly of the valve seat and cylinder head; heat fitting, cold fitting, and shrink fitting. In the heat fitting stage, the cylinder head is heated to a specified temperature and then squeezed toward the outer diameter of the valve seat. The cold fitting process cools the valve seat and safely squeezes it toward the inner diameter of cylinder head. However, these methods increased the installations & running cost and curtailed productivity. To address these problems, we analyzed the shrink fitting process using the contact pressure caused by fitting interference between the outer diameter of the valve seat and the inner diameter of the cylinder head. In this study, a closed form equation for predicting the contact pressure and fitting load is proposed. For quality control of the assembly line, principal factors of the shrink fitting process influenced in contact pressure were simulated by the FEM. Actual loads measured in the field showed good agreement with the results obtained by theoretical and finite element analysis.

• International Journal of Automotive Technology
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• v.3 no.2
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• pp.47-52
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• 2002

The integration of CAD/CAM/CAE in product development is the key to realize concurrent engineering. Generally, different systems are employed in product development departments. These different systems create a lot of trout)toes such as difficulty in communication, misunderstanding and so on. A new approach to integrate CAD/CAM/CAE in one system based on CATIA thor the end-to-end process in cylinder head development is presented. Hulti Model Technology (MMT) is used to create consistent and associated CAD models for the end-to-end process in cylinder head development. The concept and method to create and organize multi models are discussed. A typical four-layer structure of HHT for mechanical products is defined. The multi level structure of the cylinder head models based on MMT is provided. The CAD models of cylinder head created based on MMT can be used as the consistent model. All models in the downstream of cylinder head development such as structure analysis, CFD, sand core design , casting simulation and so oil are associated with the CAD models. Practice shows the approach in this paper enables the development process to be carried concurrently and can obviously shorten time to the market, reduce product cost and improve product quality.

• Journal of the korean Society of Automotive Engineers
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• v.14 no.5
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• pp.117-127
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• 1992

In this work, the possibility to diagnose valve lashes of an automotive diesel engine via cylinder head vibration/noise analysis is studied. First of all the measurement signals and conditions are selected after considering which signals and conditions are most suitable to diagonse valve lashes. Both accelerometer and microphone are used to measure cylinder head accelerations and acoustic pressure due to valve impact on cylinder head. The signals are measured in both cranking and engine firing conditions. Finally, it was found that acceleration signal obtained in engine operating condition is the most reliable signal to diagnose the valve lash condition. The valve closing angle and the peak acceleration due to valve close are chosen to analyze the valve lash condition. The measured cylinder head acceleration signals are statistically tested to derive information which are useful to judge the valve lash. In conclusion, it was found that the developed technique can be one of feasible methods to diagnose the valve conditions while the engine is in operation.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.13 no.6
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• pp.81-86
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• 2004

Generally, automotive cylinder head is manufactured by FCD45 material that is hard to cutting materials, and it needs the accurate machining tool fir higher output of engine. This paper is concerned with a study on TiN coated 6 edges reamer for improving machining accuracy of cylinder head guide pin. The reamer shape is changed from 4 edges to 6 edges for the improvement of machining accuracy. Also, TiN coating is applied to the improvement of surface roughness of cylinder head guide pin and tool life of 6 edges reamer. It is noted that 6 edges reamer are effective in controlling the dimensional accuracy and surface roughness as well as increasing tool life.

• Transactions of the Korean Society of Automotive Engineers
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• v.5 no.3
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• pp.147-158
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• 1997

This paper presents the analysis technique and procedure of main engine components-cylinder block, cylinder liners, gasket and cylinder head-using the finite element method, which aims to assess mainly the potential of lower oil consumption in a view point of engine design and to decide subsequently the accuracy of engine design which was done. The F.E. model of an engine section consisting of one whole cylinder and two adjacent half cylinders is used, whereby the crankcase is cut off at the block bottom deck. By means of a 3-dimensional F.E. model-including cylinder block, liners, gasket, cylinder head, bolts and valve seat rings as separate parts a linear analysis of deformations and stresses was performed for three different loading conditions;assembly, thermal and gas loads. For the analysis of thermal boundary conditions also the temperature field had to be evaluated in a subsequent step.

• Transactions of the Korean Society of Automotive Engineers
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• v.2 no.5
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• pp.48-57
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• 1994

The specific power output and thermal effeciency of any two-stroke engine are dependent on its scavenging behavior. Among the many factors which influence on the scavenging process, the cylinder head shape is one of the important factor. Hence in this study three different type models of cylinder head shape which are the cylindrical, the spherical and the arbitrary shape are studied to show the effects of the turbulent scavenging process in the cylinder with one inlet port, two side ports and one exhaust port. A modified version of KIVA-II which strip out of or add planes of cells across the mesh above the piston for flow simulation of two-stroke engine is used. The $k-{\varepsilon}$ turbulent model is used. The results show that the flow in a two-stroke engine cylinder of the spherical head shape among the three different type model is a desirable for efficient scavenging.

• Transactions of the Korean Society of Machine Tool Engineers
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• v.14 no.6
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• pp.88-94
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• 2005

A swirl ratio of a charge in the cylinder could be calculated by measuring both the rotary speed of paddle and the intake air flow rate in the swirl measurement apparatus fur several positions of valve lift. The automation of the swirl ratio measurement for a cylinder head is achieved by controlling both the valve lift of cylinder head and a suction pressure of the surge tank, instead of controlling them manually. PID control of the surge tank pressure and positioning a valve lift of the cylinder head are also achieved by using two step motors, respectively. Rotating speed of a paddle are measured using an optical sensor and a counter. Flow rate are measured from ISA 1932 flow nozzle by reading a differential pressure gauge position using IEEE-1394 camera. Time to measure the swirl ratio for a port in the cylinder head is drastically reduced from an hour to 3 minutes by automation control of the apparatus.

• Proceedings of the KSME Conference
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• 2001.06d
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• pp.790-795
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• 2001

Since the characteristics of combustion and pollutant in Diesel engines were mainly affected by the characteristics of in-cylinder gas flow and fuel spray, an understanding of those was essential to the design of the D.I. Diesel engines. The improvement of volumetric efficiency of air charging into combustion chamber is a primary requirement to obtain better mean effective pressure of an engine. Since the air resistances in intake and exhaust flow passages, valve lift and valve shape influence greatly to the volumetric efficiency, it is very important to investigate the flow characteristics of intake and exhaust port which develops air motion in the combustion chamber. This paper presents the results of an experimental investigation of steady flow through the various kinds of commercial cylinder head ports, and the development procedures of HHI's H21/32 prototype cylinder head ports.