Design and development of Rectangular fins for I.

C Engine of
Bajaj Pulsar
Sarang M.Pundea ,Dr.D.R.Wagholeb ,Prof.Nilesh.T. Dhokanec
abc
School of Mechanical Engineering,Dr.Vishwnath Karad MIT WPU,Pune,Maharashtra,India
*Email : sarangmpunde5@gmail.com,nilesh.dhokane@mitwpu.edu.in,dnyaneshwar.waghole@mitwpu.edu.in

Abstract
Extended surfaces fins are used on Cylinder head of IC engine of bike to dissipate the heat generated during
combustion process of I.C engine. Here we have designed and analyzed current model of fins of Bajaj Pulsar 150
and tried to optimized the heat transfer rate using new design of fins. After the design and analysis of new model
we found that there is significant amount increase in heat transfer rate and fin effectiveness.

Keywords: I.C engine, fins, effectiveness, heat transfer rate

1. Introduction

Fins are the extended surfaces used to enhance the heat transfer of the object by means of convection and
conduction.
The amount of heat fin can transfer depends on several factors like type of the fin, thickness of the fin,
arrangement of fin arrays, fin material.

2. Literature Review:

Heat Transfer, Tenth Edition (McGraw-Hill Series in Mechanical Engineering) by Jack P. Holman: For studying
different cases of fins and fin numerical and basic concepts of fins.

Heat transfer analysis of engine cylinder fin by varying extension geometry Xinyu Zhang, Yunting Ge , Jining
Sun . Journal – Energy Built and Development Source – Elsevier: They designed and compared various fin
geometries for fin extension and got the conclusion based on the output.

3. Methodology

Basic as well as optimized model is designed to analyze and compare which one is more efficient among those.
Cad Model of cylinder head with fins is designed using solid works software. After meshing cad model is
thermally simulated using solidworks thermal analyzer. Analysis of temperature, temp.gradient, heat flux is done
by applying steady state thermal conditions and suitable temperatures.
Fin type and its suitable equations are identified and heat transfer rate, fin effectiveness, fin efficiency are
calculated using those equations.
We have also compared two models by considering grey cast iron and aluminum alloy.

4. Design of fins

1
 4.1 Required data for calculations for Model 1
Parameter Value Unit Symbol

Cross sectional area of 0.00164 m2 Afin

single fin

Perimeter of the fin 1.101 m P

−3
Thickness of fin 2*10 m t

No. of fins 6 -- N

−3
Corrected length of the fin 69 x 10 m Lc

Ambient Temperature 25 ℃ T∞

Base Temperature 200 ℃ Tb

2
Heat transfer coefficient 25 W/ m ∗k h

Thermal Conductivity 45 W/m*K k

4.2 Calculations:
 Qt = N*Qfin + Qexposed base Qexposed base = h A(exposed base)*(200-25)
 Considering the fin is of finite length and loses heat by
= 25*0.038*175 = 166.25 W
convection from its end. [1]
 Qt = 6*254.018 + 166.25 = 1272.34 W
 Qt = N*Qfin + Qexposed base
 Q Without fin = hAb * (Tb - T∞ )
Qfin =√ hpkAfin(Tb-T∞ ) * h/mk + tanh(mLc) = 25*0.042*(200-25) = 183.75 W
1+ (h/mk)* tanh(mLc) Q t /¿ ( N∗Q max ⁡)
 Fin efficiency η =

¿ √ 25∗1.101∗45∗1.164∗10−3*(175)*0.8773 = 1272.34/ 6*[h*A*(Tb- T∞) ]

= 184.34 W = 1272.34 /(6∗415.25)

Q(t ) = 0.511
 Fin effectiveness Ɛ= =
Q(without fin)

2
 1272.34 W
183.75W

= 6.92

4.3 Specifications for Model 2

Parameter Value Unit Symbol

Cross sectional area of single 0.00141 m2 Afin

fin

Perimeter of the fin 1.407 m P

−3
Thickness of fin 2.5*10 m t

No. of fins 6 --- N

−3
Corrected length of the fin 72.38 x 10 m Lc

4.4 Calculations
 Qt = N*Qfin + Qexposed base  Qexposed base = h A(exposed base)*(200-25) [3]
 Considering the fin is of finite length and loses heat by = 25*0.037*175
convection from its end. [1]
 Qfin = √ hpkAfin(Tb-T∞ ) * h/mk + tanh(mLc) = 161.875 W
1+ (h/mk)* tanh ( mLc )
 Qt = 6*244.96 + 161.875 = 1631.635
= √ 25∗1.401∗45∗1.413∗10−3* 175*0.938
= 244.96 W  Q Without fin = h *Ab * (Tb - T∞) = 25*0.0408*(200-
25) =183.75 W
Q(t ) Fin efficiency η = Q t /¿ ( N∗Q max ⁡)
 Fin effectiveness Ɛ = = 
Q(without fin)
1613.635W = 1613.635/ 6*[h*A*(Tb- T∞) ]
178.83W
= 1613.635/( 6∗445.375) =
0.6033
= 9.12
5. CAD Modelling using solidworks:
5.1 Model 1:

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Figure 1 Isometric view and Meshing of Model 1

5.2 Model 2:

Figure 2 Isometric view and Meshing of model 2

 In model 2 rectangular extension is added on surface of the fins to optimized the heat
transfer rate, fin effectiveness and fin efficiency

 Note: Grey cast iron is selected for doing thermal analysis.

6. Comparing Between Thermal Analysis of Model 1 and Model 2

6.1 Temperature Analysis

4
Figure 3 Temperature distribution along the fin

6.2 Temperature Gradient Analysis:

Figure 4 Temp.Gradient Analysis

7. Result summary
Similar analysis is conducted using Aluminium alloy 606-O .Here is the result summary from
calculations and software analysis for model 1 and model 2

7.1 Result summary for model 1:

Parameters Grey Cast Iron 6063 O Unit
Heat Transfer Rate 1272.34 1690.36 W
Fin Effectiveness 6.92 9.2 --
Fin Efficiency 0.511 0.67 --
Temperature variation 200 – 133.7 200 – 182.2 ℃
Max.Heat Flux 6.538*104 7.911*104 W/m 2
Max. Temperature Gradient 22.44 5.620 ℃ /cm

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7.2 Result Summary for Model 2:
Parameters Grey Cast Iron 6063 O Unit
Heat Transfer Rate 1272.34 2414.88 W
Fin Effectiveness 9.12 13.5 --
Fin Efficiency 0.6063 0.90 --
Temperature variation 200 – 117.5 200 – 175.8 ℃
Max.Heat Flux 1.899105 2.144*105 W/m 2
Max. Temperature Gradient 48.82 1.093 ℃ /cm

8. Concluding Remarks and Discussion

1. By doing analysis and calculations we found that fins with extension (model 2) can give
more effectiveness than fin without extension (model 1).
2. Maximum temperature gradient in model 2 is 43% more than model 1.
3. However temperature distribution for model 2 is not as uniform as model 1 but
overall temperature drop is more in model 2 than model 1.
4. Grey Cast Iron fins have more temperature drop across the fin surface than aluminium
alloy so Cast iron is more suitable for this application than 6063 O.
5. However from calculation it is found that heat transfer rate, fin efficiency and fin
effectiveness is more for 6063 O than grey cast iron.
6. Since fin effectiveness is sufficiently greater than 1 in both the models, attaching fins is
justifiable considering cost and added material.

9. References:
[1] Heat Transfer, Tenth Edition (McGraw-Hill Series in Mechanical Engineering) by Jack P.
Holman.
[2] A Heat Transfer Textbook – Fifth Edition, by John Lienhard IV and John Lienhard V
[3] Heat Transfer - Department Academic Mentorship Program Mechanical Engineering | IIT
Bombay