IC ENGINE exhaust valve design and analysis using finite element analyis

Abstract: Intake and exhaust valves are very important engine components that are used to
control the flow of intake and exhaust Gases in internal combustion engines. They are used to
seal the working space inside the cylinder against the manifolds; and are opened and closed by
means of what is known as the valve train mechanism.. These valves are loaded by spring forces
and subjected to thermal loading due to high temperature and pressure inside the cylinder. The
present study is forced on different failure modes of internal combustion engine exhaust valve.
Failures due to fatigue, high temperature effects, and Failures due to impact load that depends
on load and time. For the study of fatigue life, a combined S-N (max. stress v/s number of cycles)
curve is prepared. Such a curve helps in comparing the fatigue failure for different materials at
different high temperatures and may also assist the researchers in developing the valve materials
with a prolonged life.For achieving above sad goals couple field, fatigue and transient analysis
will be done on valves to determine structural and thermal behavior in working condition.
Keywords: Failure, Internal Combustion Engine Valves, High Temperature, Fatigue, Wear.
 INTRODUCTION
Exhaust valve of an Internal Combustion engine is one of the most crucial parts. It
is the main cause of most problems like pre- ignition, burned valves etc. Design of
the valve depends on many parameters like behavior of material at high
temperature, fluid dynamics of exhaust gas, oxidization characteristics of valve
material and exhaust gas, fatigue strength of valve material, configuration of the
cylinder head, coolant flow and the shape of the exhaust port. The most important
factor affecting the performance of a valve is its operating temperature. This
project deals with the stress induced in a valve due to high thermal gradient and
high pressure inside the combustion chamber. To analyze the valve ANSYS is used
as the tool. Thermal and structural analyses are performed on the valve. In the first
stage of analysis the temperature distribution across the valve is determined. In the
second stage this temperature distribution is transferred on to another element and
pressure load will be applied to the valve to determine the displacement
distribution in the valve. The above said process is repeated for the different valve
materials and finally the best material is suggested for the valve based on its
strength and thermal properties.
LITERATURE REVIEW
Naresh Kr. Raghuwanshi & et al [1] kept focus on
various failure modes of IC engine inlet & exhaust valves.
The failure mainly due to fatigue at high temperature, high
operating temperature effects on mechanical properties of
valve materials like hardness and yield strength. Wear
failure which is due to impact loading, and wear rate that
depends on load and time. This is helpful for researchers to
develop the valve materials to achieve a prolonged life.
Yuvraj K Lavhale et al. [2] proposed the Overview of
Failure Trend of Inlet & Exhaust Valve. In this workDifferent
modes of failure of valves, Methods of fracture analysis were
used for valve failure analysis.
 J. M. Cherrie [3] there was a dramatic decrease in the
carbon content of the material of the failed valve. It was
found between 0.28 and 0.34% although the normal value
of carbon content is 0.40- 0.45%. The causes of
considerable decrease of the carbon content in valve
material likely owing to decarburization which was occurred
in whole structure. Angular titanium phases were found in
microstructure of the material of the failed valve. The
angular phases had caused crack initiation in the material
structure. Vanadium was found on the surfaces of the failed
valve. The fuel-born vanadium has caused the corrosion on
the valve. Chromium carbide was detected on the surface,
which is due to high ambient temperature. Since fatigue
striations and beach marks did not appear on the fracture
surfaces, the fatigue was not a possible cause of failure in
the valve and the valve was broken down before its
expected service life.
 T.N. Charyulu [4] Static structural analysis of the exhaust
valve for different materials such as 21 4N, Nimonic 80Aand
Nimonic105A is carried out. The properties of different
exhaust valve materials such as thermal expansion, youngs
modulus are given as input for the structural analysis.
Bo Wong et al. [5] studied the thermal deformation field
of exhaust valve used in steam booster pump based on
ANSYS. Simulation results show that the thermal
deformation value of the new type of exhaust valve is less
than the traditional exhaust valve.
Naresh Kr. Raghuwanshi et.al [6] had given a review on
the failure analysis of IC engine valves. From the study, it is
quite evident that a common cause of valve fracture is
fatigue.
OBJECTIVES
Study the valve mechanism basics and failure modes in
exhaust valve.
b) Design the valve as per the specification and model it in
CATIA and analyze it in ANSYS software.
b) Find the cause of failure in existing valve.
d) Take composite materials in design and modify it in order
to eliminate the cause of failure.
c) Study the different valve materials and recommend the
best alternative material for valve with stress and weight as
a selection criterion
 Proposed Methodology

REVIEW OF LITERATURES

DESIGNING OF ENGINE ECHAUST VALVE

FINITE ELEMENT ANALYSIS AND OBSERVATION

MATERIAL SELECTION

ANALYSIS OF RESULTS

COCLUSION
Expected outcomes
The following outcomes are expected from this research work:-

1. Fatigue failure prediction.

2. Reduction in weight of the valve.
3. Temperature reduction on exhaust valve
4. Pressure reduction on valve
 REFERENCES:-
1. Wang, Y.S., Narasimhan, S., Larson, J.M., Schaefer, S.K. Wear and wear mechanism
simulation of heavy-duty engine intake valve and seat inserts, Journal of Materials
Engineering and Performance, 7(1): 53-65 (1998).
2. Naresh Kr. Raghuwanshi, Ajay Pandey, R. K. Mandloi, Failure Analysis of Internal
Combustion Engine Valves: A Review, International Journal of Innovative Research
in Science, Engineering and Technology, Vol. 1, Issue 2, December 2012.
3. .J. M. Cherrie, Factors Influencing Valve Temperatures in Passenger Car Engines, SAE
Paper 650484, 1965.
4. Pradeep Kumar A.R., Annamalai K., Prabhakar S., Banugopan V.N., Premkartikkumar
S.R., Heat transfer analysis in a low heat rejection diesel engine, National Journal on
Advances in Building Sciences and Mechanics, Vol. 1, No.2, October 2010
5. SingaiahGali, T.N. Charyulu, Diesel Engine Exhaust Valve Design, Analysis and
Manufacturing Processes, Indian Stream Research Journal, Vol.2, Issue 7, Aug. 2012,
ISSN 2230-7850
6. .Thermo physical properties of the ni-based alloy nimonic 80a up to 2400 k, iii b.
wilthan1, k. preis1, r. tanzer2, w. schtzenhfer2, g. pottlacher11 institute of
experimental physics, graz university of technology, petersgasse 16, 8010 graz, Austria
2 bhleredelstahlgmbh, mariazellerstrasse 25, 8605 kapfenberg, Austria