MAJOR PROJECT

HEAT TRANSFER ANALYSIS OF ENGINE

CYLINDER FINS BY VARYING FIN
GEOMETRY AND MATERIAL

BRANCH: MECHANICAL ENGINEERING

Submitted By: Mmehul Bhayana:2K17/ME/139

Mohit Bhankhar:2K17/ME/143
Neeraj Saini:2K17/ME/151
 INTRODUCTION

• Almost all of the present two wheelers use Air cooled engines, because Air-cooled
engines are the only option due to the impressive advantages like lighter weight and
lesser space requirement.
• In air cooled motorbikes engines, waste heat is dissipated through the cooling fins to
the cooling air flow created by the relative motion occurring due to the movement of
bike. One of the important engine subsystems is the cooling system. Most of the air-
cooling mechanism depends on the Fin design of the cylinder head and the block. One
of the other aspect it depends on is the velocity of the vehicle and the ambient
temperature.
• This heat transfer from the fin is due to many fixed and variable constraints mainly fin
array, fin geometry and shape, fluid flow velocity, and material etc. There are many
experimental methods available in literature to analyze the effect of these factors on the
heat transfer rate.
• The effect of cooling of internal combustion engine cylinder in free air has been
studied and various results are noted and analyzed. To increase the heat transfer rate,
analysis of fin is very important.
• After carrying Transient Thermal Analysis of model, heat flow analysis, improvements
are there in fin efficiency by changing fin geometry, fin pitch, number of fins, fin
material and climate condition.
 MODEL SELECTION
• The cylinder fin geometry is selected based on the research and experiments
conducted by various researchers as described as per the standards. Cylinder
model is created in CAD with straight fin profile.
• Various parameters are rightly taken for further simulation by ANSYS.
• Aluminium and Magnesium are selected as a fin material for further analysis
by ANSYS.
• Aluminium is a very light metal with a specific weight. The use of Al in
vehicle reduces dead weight and energy consumption while increasing load
capacity.
• Aluminium is a good reflector of visible light as well as heat. Aluminium
properties better corrosion resistance, thermal conductivity, reflectivity,
ductility, odourless, recyclability. Magnesium alloys are not only lighter but
have other benefits as well. They are shock resistant and have greater edge
over aluminium to damp noise and vibrations
 METHODOLOGY

• Used Transient Thermal Analysis model for analysis of imported geometry

• Imported finned cylinder geometry to ANSYS Design Modeler.
• Selected material (Aluminium alloy and Magnesium alloy).
• Generated mesh and tuning up analysis settings.
• Selected relevant faces in the geometry for heat flux and convection.
• Calculate the solution by gradually increasing the number of iterations in Ansys.
• Determining the results and coming to a conclusion.
 RESULTS
Analysis of Rectangular shaped fin design
Al Alloy Mg Alloy

  Maximum Temperature Minimum Temperature Maximum Heat Flux Minimum Heat Flux Mass

Al Alloy 6061 564.4 K 330.33 K 1.3359 (W/mm2) 0.0002082 (W/mm2) 0.84211 Kg

Mg Alloy 626.71 K 338.97 K 1.8099 (W/mm2) 0.00052723 (W/mm2) 0.7455 Kg

 Analysis of Circular shaped fin design

Al Alloy Mg Alloy

  Maximum Minimum Temperature Maximum Heat Flux Minimum Heat Flux Mass
Temperature

Al Alloy 6061 708.27 K 674.76 K 1.2775 (W/mm2) 0.001559(W/mm2) 1.0233Kg

Mg Alloy 797.48 K 757.97 K 1.407 (W/mm2) 0.002393(W/mm2) 0.988Kg

 Analysis of PROPOSED shaped fin design

Al Alloy Mg Alloy

  Maximum Minimum Temperature Maximum Heat Flux Minimum Heat Flux Mass
Temperature

Al Alloy 6061 766.05 K 388.16 K 3.9887 (W/mm2) 0.0001 (W/mm2) 1.03 Kg

Mg Alloy 860.41 K 433.89 K 3.5558 (W/mm2) 0.000266 (W/mm2) 0.972 Kg

 MODEL VALIDATION
Value of Thermal Flux
Thermal Flux G. Babu and Result by present work Result by the modification
(W/mm2) Lavakumar[2] in design Hence, the modifications done in the
model have led to a huge improvement in
  Al Alloy Mg Alloy Al Alloy Mg Alloy Al Alloy 6061 Mg Alloy Heat analysis.
6061 6061

Rectangular 0.571051 0.463962 0.523876 0.60347 1.3359 1.8099 Owing to similar modifications, the
Fin results of proposed design are extremely
efficient.
Thermal Normally G. Babu and Result by present work Result by the
Flux used Lavakumar [2] modification in
(W/mm ) 2
design

  Al Alloy 2024 Al Alloy Mg Alloy Al Alloy Mg Alloy Al Alloy Mg

6061 6061 6061 Alloy

Circular Fin 0.723258 0.738145 0.716357 0.63876 0.70347 1.2775 1.407

 Value of Maximum and Minimum Temperature

Maximum Minimum Maximum Heat Flux

Temperature Temperature
We can see, there is improvement in
Al Alloy 6061 766.05 K 388.16 K 3.9887 (W/mm2)
efficiency in Heat Transfer in the proposed
Mg Alloy 860.41 K 433.89 K 3.5558 (W/mm2) design.

Mass of G.Babu and LavaKumar Result by

cylinder fin (Kg) Present Work

  Al alloy 6061 Mg alloy Al alloy 6061 Mg Alloy

Rectangular fin 0.97395552 0.89459618 0.845 0.735

Circular fin 1.1423490 1.0492687 1.0233 0.988

Proposed fin     1.03 0.9172
 DISCUSSION
• The temperature change within the Rectangular fins of Aluminum
alloy was from 564.4 K to 330.33 K by the flowing of air over the
fin. The Total heat flux has a maximum value of 1.3359 W/mm2.
• The temperature change within the Rectangular fins of Magnesium
alloy was from 626.71 K to 338.97 K It was observed the Total heat
flux has a maximum value of 1.8099 W/mm2.
• The probable reason for increase in heat transfer rate in case of
magnesium alloy would be the high thermal conductivity k, as
effectiveness(performance) of fins depends directly on k.
• The cylinder wall area is exposed to the hot gases varies with the
piston position. In this project, it can be seen that in figure 4.2 and
figure 4.4, area exposed to flux is more, hence the heat transfer is
maximization.
• The proportion of the time for which an area remains in contact with
the hot gases in virtually independent of speed. Figure shows comparison between various fin model.
 CONCLUSION
• This project has compared the materials Aluminum alloy 6061 and Magnesium alloy ZC63A with varying shapes
of engine cylinder. The fin geometry is modeled using the SOLIDWORKS 2018 and then thermal analysis is
done on ANSYS workbench.
• By simply changing the shape of the fins and also by changing the material of fin; the fin performance is
increased as well as the weight is reduced.
• It was observed the Total heat flux has a maximum value of 3.9887 W/mm2 within the Proposed model of fin
Shape of Aluminum alloy from by the flowing of air over the fin.
• Also, it was observed the Total heat flux has a maximum value of 3.558 W/mm2 for the Proposed model of fin
shape of Magnesium alloy. This clearly conclude that heat transfer hence the cooling is improved.
• When analyzed on software, the modified cylinder 3(proposed model) has shown better results than other two, as
surface area is increased that leads to increased heat rate. But manufacturing of this type fins will not be
economical because of the complexity of the design.
• Hence, conclude that using magnesium alloy material is better and fins shape should be longitudinal.
THANKYOU