ANALYSIS OF CRACK IN ENGINE CYLINDER

HEAD

PROJECT REPORT
Submitted by

K.RAJESH KUMAR

Register No: 081120100021

In partial fulfillment for the award of the degree

of

MASTER OF ENGINEERING
in
ENGINEERING DESIGN

DEPARTMENT OF MECHANICAL ENGINEERING

ANNA UNIVERSITY COIMBATORE
COIMBATORE- 641 047
June 2010

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 ANNA UNIVERSITY COIMBATORE
COIMBATORE – 641 047
Department of Mechanical Engineering

PROJECT WORK

PHASE II

June 2010

This is to certify that the project entitled

ANALYSIS OF CRACK IN ENGINE CYLINDER
HEAD
is the bonafide record of project work done by
K.RAJESH KUMAR
Register No: 081120100021
of M.E.(Engineering Design) During the year 2008-2010.

----------------------------- ------------------------
Project Guide Head of the Department
Mr. D.DHANSEKARAN M.E., Dr. M.SAKTHIVEL Ph.D.,

Submitted for the Project Viva-Voice examination held on ------------------------

------------------------ ------------------------
Internal Examiner External Examiner

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 DECLARATION

I affirm that the project work titled Analysis of crack in Engine

Cylinder Head being submitted in partial fulfillment for the award of M.E-
Engineering Design is the original work carried out by me. It has not formed
the part of any other project work submitted for award of any degree or
diploma, either in this or any other University.

K.RAJESH KUMAR

081120100021

I certify that the declaration made above by the candidate is true

Mr. D.DHANSEKARAN M.E., Lecturer

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 ACKNOWLEDEMENT

It is privilege to be the student of ENGINEERING DESIGN in Anna

University, Coimbatore. I express my heart full thanks to our beloved Vice
Chancellor Dr. K.KARUNAKARAN who helped me for bring out this
project in good manner.
I extend my sincere thanks to our HEAD OFTHE DEPARTMENT
Dr.M.SAKHTIVEL, for his kind co-operation to complete this project well.
It’s my duty to extend my heart full gratitude to our beloved guide
Mr. D.DHANSEKARAN M.E., for his excellent guidance, encouragement
and for the facilities extended throughout the course of this project.
It’s my duty to extend my sincere thanks to management and
employees of S.K Engine Works and DPL Aluminum Welding works,
Coimbatore for giving me permission to do the project in their concern,
excellent guidance to complete the project successfully.
I whole heartedly thank to all Staff members of Mechanical
Department of this great institution for their support in my PG degree and
project work.

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 TABLE OF CONTENTS

CHAPTER NO. TITLE PAGE NO

ABSTRACT viii
LIST OF TABLES ix
LIST OF FIGURES x
LIST OF SYMBOLS xi
1. INTRODUCTION 2
1.1 Introduction-engine cylinder head 2
1.2 Importance of reliability in
automotive parts 3
2. PROJECT OVERVIEW 5
2.1 Research Overview 5
2.2 Objectives of the project 7
2.3 Scope of the project 7
3. LITERATURE REVIEW 9
3.1 Boundary element analysis of
thermally stressed interface cracks 9
3.2 A long circular cylinder with
a circumferential edge crack subjected
to a uniform shearing stress 10
3.3 Stress intensity factors in a finite length
cylinder with a circumferential crack 10
3.4 Spontaneous crack propagation
in functionally graded materials 11

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 3.5 Wear of diesel engine inlet valves and
Seat inserts 14
3.6 Modelling of fatigue damage in aluminum
cylinder heads 15
4 CRACK BEHAVIOUR 18
4.1 Reasons for crack 18
4.2 Crack terminologies 19
4.2.1 What is fracture mechanics? 20
4.3 Classification of fracture mechanics 21
4.3.1 Linear Elastic Fracture Mechanics 21
4.3.1. I Stress Intensity Factor 22
4.3.1. II Fracture Toughness 22
4.3.1 III Strain Energy Release Rate 23
4.3.2 Elastic Plastic Fracture Mechanics 24
4.3.2 I Crack Tip Opening Displacement 25
4.3.2. II J – Integral 26
4.3.2. III R – Curve analysis 27
5 MODES OF FRACTURE 29
5.1 Mode I 30
5.2 Mode II 31
5.3 Mode III 32
6 ENGINE CYLINDER HEAD CRACK STUDY 35
6.1 Methodology of analysis of crack 35
6.2 Boundary condition for analysis 38
6.3 Results & Discussion 43
7 WELDING PROCESS 46
7.1 Welding process 46

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 8 REINVESTMENT COST 53
9 CONCLUSION 55
9.1 Conclusion 55
9.2 Further Scope 55
10 REFERENCES 57

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ABSTRACT

The reliability of the component is the important criteria in

performance of any system. In this thesis, automobile engine cylinder head
subjected to crack is analyzed for improving its reliability. The deformation
of the crack is analyzed from its initial shape. Based on the results, suitable
re-engineering process is incorporated in the component for improving its
reliability by stopping the crack growth further. The project enables the
elimination of replacement cost of the engine cylinder head. Further the
process of analysis of crack, its deformation and incorporation of welding
process is presented in this thesis. The work will give an approach for
improving the reliability of the product and the performance of the system.

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 LIST OF TABLES

Table 1. Temperature for Cylinder Head 38

Table 2. Mechanical properties for Cylinder Head 43
Table 3. Welding parameters 46
Table 4. Cost Comparison of Re-engineering vs Replacement 53

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 LIST OF FIGURES

Fig 1. Engine cylinder Head 2

Fig 2 Crack (A) in cylinder Head 6
Fig 4.1 Crack tip opening displacement 26
Fig.4.2 Integration path about the crack tip 27
Fig 5.1 Different Modes of failure 29
Fig 5.2 Stress Field near the crack tip 33
Fig 6.1 CAD Model 36
Fig 6.2 Single Engine cylinder Head 37
Fig 6.3 Single Engine cylinder crack 39
Fig 6.4 Crack between Valve seats 40
Fig 6.5 Mesh Generation 40
Fig 6.6 Boundary condition 41
Fig 6.7 Crack Deformation plot 42
Fig 7.1 Cylinder head with crack 48
Fig 7.2 Cylinder head welded at crack regions 49
Fig 7.3 Cylinder head machined after welding 50
Fig 7.4 Crack elimination after machining-a closer view 51

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 LIST OF SYMBOLS, ABBREVIATIONS AND NOMENCLATURE
OF CRACK

The standard symbol nomenclature & definition of the crack are

σ Applied normal stress

A crack length

β Parameter that depends on the geometry of specimen

R = dW/da crack resistance

u, v and w displacements in the x, y and z directions

ν Poisson’s ratio

G shear modulus of elasticity

Un normal (opening) displacement of the crack face.

E Young’s modulus (N/mm2)

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