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Term Paper Report: Submitted in Partial Fulfillment of The Requirements For The Degree of

This document summarizes a study that used finite element modeling to optimize valve-train components for durability analysis using titanium alloy materials. The study analyzed thermal and mechanical stresses on intake and exhaust valves made of titanium alloy and steel alloys. Results showed that titanium alloy valves had higher design safety factors compared to steel alloy valves, indicating titanium is a better material choice. The study aimed to enhance engine performance and reliability by reducing stresses on valves through optimizing component design and using lightweight titanium alloy materials.

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nanda kumar
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26 views

Term Paper Report: Submitted in Partial Fulfillment of The Requirements For The Degree of

This document summarizes a study that used finite element modeling to optimize valve-train components for durability analysis using titanium alloy materials. The study analyzed thermal and mechanical stresses on intake and exhaust valves made of titanium alloy and steel alloys. Results showed that titanium alloy valves had higher design safety factors compared to steel alloy valves, indicating titanium is a better material choice. The study aimed to enhance engine performance and reliability by reducing stresses on valves through optimizing component design and using lightweight titanium alloy materials.

Uploaded by

nanda kumar
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Term Paper Report

On

OPTIMIZATION OF VALVE-TRAIN COMPONENTS


FOR DURABILITY ANALYSIS USING FEM

Submitted in Partial Fulfillment of the Requirements for the Degree

Of

Master of Technology
In
Machine Design

By

Veralla Nanda Kumar Yadav

Under the supervision of

Dr. SUBHANKAR BHOWMICK


Assistant Professor

National Institute Of Technology, Raipur


ABSTRACT

The valve-train components must be designed in concern with the reliability criteria,
environmental requirements, shorter valve response time, and lightweight design solution for
improved engine performance. The stress concentration’s get accumulated on the valve due
to the partial contact in the valve-train system, which further aids for failure of the valve.
Because of the thermal distortion the partial contact between the valve, insert and guide
becomes uneven. This paper proposes a case study of the automotive engine valve-train
system using lightweight titanium for intake and exhaust valves using the finite element
process. To obtain a thermo-mechanical loading effect on the valve-train system, the full
structural virtual simulation assessment, the 3D linear heat transfer and stress-strain method
are used. Simultaneously comparison of test results will be made between current steel grade
material with proposed titanium material.
1. INTRODUCTION

The automotive engine's valve-train components are a system for regulating the valve of the
engine. Sealing the gas in the cylinder is the main feature of the valve. It is closely related to
the efficiency of the flow and engine output. The need for greater longevity and reliability of
the engine valve (a vital component of the IC engine), is increasingly demanded by the
automotive industry. In addition, the emphasis on higher environmental and pollution control
requirements leads us to use titanium as a solution to the need for high-performance
durability. During the operation of the engine, due to valve closing speed, the valves are
subjected to varying loads of combustion forces, spring force, thermal loads, and impact
force. The different combined loads and repetitive cycling induce stresses that contribute to
fracture of cylinders. When the cumulative fatigue damage to the valve is above the fatigue
strength of the valve material, the valve failure occurs. The engine loses its work and stops in
the event that the valve breaks. Therefore, it is important for the reliability of the valve to be
tested in advance.

The design of a valve and its application to the engine are as important as the selection of the
alloys. Most common materials are:

Titanium grade 5 (Ti6Al4V)

 Lightness and superior high-temperature strength.


 Achieves better sealing, flexibility, and uniform stress distribution.

There are two distinct types of material grade steels, used for the manufacture of valves,
martensitic alloys and austenitic alloys. Austenitic stainless steel can withstand high
temperatures, but at lower temperatures, the steel is softer than martensitic steel and loses
hardness and strength above 1000 °C. Austenitic exhaust valve operating temperatures are as
hot as around 850 °C. The present study presents a general discussion on stress, strain and
heat transfer FEA, fatigue safety factor and safety design with its governing equations
assisted by practical tests carried out on steel material for intake valve design EN-52 and 21-
4N exhaust valve design with titanium valves for material modeling.
2. FINITE ELEMENT MODELING

Fig 1 Valve-train design and analysis

3. ANALYSIS AND RESULTS

The analysis of a 3D linear steady-state thermal analysis gives the results of thermal stress on
the valve. The working temperature of the intake valves reaches up to 500 °C -600 °C during
the combustion process, and the exhaust valves are about 700 °C -850 °C, and thermal
analysis is performed at this temperature. Between the master surface guides or insert and
slave surface valve, the surface-surface interactions are given. The load affects a face and
guide with uniform distribution and the guide and insert with 350 magnitudes. The coefficient
of friction is 0.05 for the titanium valve and 0.15 for the steel valve.

Thermo-Mechanical Stress Analysis Results: The combustion pressure of 200 Mpa was
applied to the face of the valve holding seat and the guide for static structural study, restricted
in all directions and rotation. The Lancaster have been held fixed. In between the valve insert
and valve guide, tie constraints are applied.

Fig 2 Thermo-mechanical max working stresses of Titanium exhaust, intake, 21-4N exhaust & EN-52 intake
valve-train components respectively

Fatigue Assessment and Design Safety Factors:

It is important to provide a valve fatigue life assessment model for engine valve
manufacturers, which can be used further in future product design to ensure a high durability.
A detailed stress analysis job by finite element was performed under mechanical loads before
modeling on valve fatigue. The fatigue life typically varies between 105 cycles and 107
cycles. For an application, the design factor is specified and is not an actual calculation; the
safety factor is the ratio of maximum strength to the intended load for the object. A structure
with a FOS of exactly 1 can only accommodate the design load and no more, by this
definition.

Stress-Life Approach: In the stress-life approach, the equivalent value of fully reversed
cycling in Soderberg curve is used to find the valve fatigue life and design of safety factor.
The equivalent Soderberg’s equation:

YS
N fs =
σ mean+ σ r k f ( YSσ )
e

σ max −σ min
σ a=
2

σ max + σ min
σ m=
2

Conclusions

Following conclusions are drawn from the results obtained:

 By using the SN method, valve fatigue life can be evaluated fairly.


 In comparison with steel alloy (En-52 & 21-4N) valves, the design safety factor of
titanium for both exhaust and inlet valves is high. Therefore, in comparison to 21-4 N
and EN-52 steel alloy, it is also shown that the titanium alloy has ample potential as
an ideal better material for the engine valve to enhance engine performance.
 Owing to the thermal deformation of the seat and the deterioration of material
strength due to high temperature and static load as the valve moves, the performance
of the valve neck is found to be subject to different factors (such as partial contact).
Thereby compromising valve life.

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