ISSN 2319-8885
Vol.03,Issue.21
September-2014,
Pages:4283-4289
www.semargroup.org,
www.ijsetr.com
Thermal Analysis of Copper Coated 2 Stroke Spark Ignition Engine
KHALDOON FAWZI MUKHLIF1, DR. E. RAMJEE2
1
PG Scholar, Dept of Mechanical Engineering, JNTUH College of Engineering, Hyderabad, India, E-mail: [email protected].
2
Professor, Dept of Mechanical Engineering, JNTUH College of Engineering, Hyderabad, India, E-mail: [email protected].
Abstract: Piston temperature has considerable influence on efficiency, emission and performance of the SI engine. Piston and
liner are the contributors of heat transfer to the coolant through which heat is rejected, the use of a thermal barrier in the piston
and liner has become attractive. Though the copper coatings have proved to be a promising technique, In the present work the
Piston and cylinder Models are done by using PRO-Engineer, then analyzed for structural, thermal with and without copper
coated using ANSYS software 14.5, which is a powerful Finite Element analysis In the process to get stresses, the temperature
distribution in the piston and combustion chamber has been evaluated using this soft. The copper coated on piston head and
inside of the combustion chamber of the engine. In the present thesis, work has been taken up on the following aspects.
Temperature distribution and heat flow through the piston and combustion chamber of SI engine with and without copper coated.
Temperature distribution, Thermal gradient vector sum and heat flux vector sum vector sum through the piston, liner and
cylinder head of the conventional SI engines with and without copper coated using ANSYS 14.5. FEA analysis of 2 stroke SI
engine to measure the temperature at points where it is not possible to find out practically and to observe the heat flow inside the
piston. Structural analysis to find von misses stress and displacement vector sum with and without copper coated using ANSYS.
From the thermal analysis, the temperature distribution through the piston and cylinder with copper coated more than the
temperature distribution through the piston and cylinder without copper coated and from the structural analysis, the von misses
stress and displacement vector sum with copper coated more than the von misses stress and displacement vector sum without
copper coated.
Keywords: FEA Analysis, Copper, SI Engine, Thermal Gradient Vector.
I. INTRODUCTION
I.C. engine converts the reciprocating motion of piston
into rotary motion of the crankshaft by means of a
connecting rod. The piston which reciprocating in the
cylinder is very close fit in the cylinder. Rings are inserted
in the circumferential grooves of the piston to prevent
leakage of gases from sides of the piston. Usually a
cylinder is bored in a cylinder block and a gasket, made of
copper sheet or asbestos is inserted between the cylinder
and the cylinder head to avoid ant leakage. The combustion
space is provided at the top of the cylinder head where
combustion takes place. The connecting rod connects the
piston and the crankshaft. The end of the connecting rod
connecting the piston is called small end. A pin called
gudgeon pin or wrist pin is provided for connecting the
piston and the connecting rod at the small end. . The other
end of the connecting rod connecting the crank shaft is
called big end. When piston is moved up and down, the
motion is transmitted to the crank shaft by the connecting
rod and the crank shaft makes rotary motion. The
crankshaft rotates in main bearings which are fitted the
crankcase. A flywheel is provided at one end of the
crankshaft for smoothing the uneven torque produced by
the engine. There is an oil sump at the bottom of the engine
which contains lubricating oil for lubricating different parts
of the engine [1].
II. WORKING PRINCIPLE OF I.C. ENGINE/ FOUR
STROKE CYCLE ENGINE
A mixture of fuel with correct amount of air is exploded
in an engine cylinder which is closed at one end. As a
result of this explosion, heat is released and this heat
causes the pressure of the burning gases to increase. This
pressure forces a close fitting piston to move down the
cylinder. The movement of piston is transmitted to a
crankshaft by a connecting rod so that the crankshaft
rotates and turns a flywheel connected to it. Power is taken
from the rotating crank shaft to do mechanical work. To
obtain continuous rotation of the crankshaft the explosion
has to be repeated continuously. Before the explosion to
take place, the used gases are expelled from the cylinder,
fresh charge of fuel and air are admitted in to the cylinder
and the piston moved back to its starting position. The
sequences of events taking place in an engine are called the
working cycle of the engine. The sequence of events taking
place inside the engine are as follows 1.Admission of air or
air-fuel mixture inside the engine cylinder (suction), 2.
Compression of the air or air fuel mixture inside the engine
(compression) 3. Injection of fuel in compressed air for
Copyright @ 2014 SEMAR GROUPS TECHNICAL SOCIETY. All rights reserved.
KHALDOON FAWZI MUKHLIF, DR. E. RAMJEE
ignition of the fuel or ignition of air-fuel mixture by an
 As there is a working stroke in every revolution, a more
electric spark using a spark plug to produce thermal power
uniform turning moment is obtained on the Crankshaft
inside the cylinder (power ) 4. Removal of all the burnt
and therefore, a lighter flywheel is required.
gases from the cylinder to receive fresh charge (exhaust)
Note: Charge means admitting fresh air in to the cylinder in
Disadvantages of Two-Stroke Engines
the case of compression ignition engines (diesel engines) or
 High speed two-stroke engines are less efficient owing to
admitting a mixture of air and fuel in to the cylinder in the
the reduced volumetric efficiency.
case of spark ignition engines [2].
 With engines working on Otto cycle, a part of the fresh
mixture is lost as it escapes through the exhaust port
III. TWO STROKE CYCLE ENGINE (PETROL
during scavenging. This increases the fuel consumption
ENGINE)
and reduces the thermal efficiency.
In two stroke cycle engines, the whole sequence of
 Part of the piston stroke is lost with the provision of the
events i.e., suction, compression, power and exhaust are
ports thus the effective compression is less in case of
completed in two strokes of the piston i.e. one revolution of
two-stroke engines.
the crankshaft. There is no valve in this type of engine. Gas
movement takes place through holes called ports in the
cylinder. The crankcase of the engine is air tight in which
the crankshaft rotates.
A. Two stroke cycle: Upward stroke of the piston
(Suction + Compression)
When the piston moves upward it covers two of the
ports, the exhaust port and transfer port, which are normally
almost opposite to each other. This traps the charge of airfuel mixture drawn already in to the cylinder. Further
upward movement of the piston compresses the charge and
also uncovers the suction port. Now fresh mixture is drawn
through this port into the crankcase. Just before the end of
this stroke, the mixture in the cylinder is ignited by a spark
plug Thus, during this stroke both suction and compression
events are completed.
B. Downward stroke (Power + Exhaust)
Burning of the fuel rises the temperature and pressure of
the gases which forces the piston to move down the
cylinder. When the piston moves down, it closes the suction
port, trapping the fresh charge drawn into the crankcase
during the previous upward stroke. Further downward
movement of the piston uncovers first the exhaust port and
then the transfer port. Now fresh charge in the crankcase
moves in to the cylinder through the transfer port driving out
the burnt gases through the exhaust port. Special shaped
piston crown deflect the incoming mixture up around the
cylinder so that it can help in driving out the exhaust gases.
During the downward stroke of the piston power and
exhaust events are completed [1].
C. Advantages and Disadvantages Of Two Stroke
Engines
Two-stroke engines have certain advantages as well as
disadvantages compared to four-stroke engines. In the
following sections the main advantages and disadvantages
are discussed briefly.
Advantages of Two-stroke Engines
 As there is a working stroke for each revolution, the
power developed will be nearly twice that of a Fourstroke engine of the same dimensions and operating at
the same speed.
 The work required to overcome the friction of the
exhaust and suction strokes is saved.
Fig.1. Two stroke cycle engine.
IV. INTRODUCTION TO COPPER
Copper is a chemical element with the symbol Cu (from
Latin: cuprum) and atomic number 29. It is a ductile metal
with very high thermal and electrical conductivity. Pure
copper is soft and malleable; a freshly exposed surface has a
reddish-orange color. It is used as a conductor of heat and
electricity, a building material, and a constituent of various
metal alloys.
A. Applications
The major applications of copper are in electrical wires
(60%), roofing and plumbing (20%) and industrial
machinery (15%). Copper is mostly used as a pure metal,
but when a higher hardness is required it is combined with
other elements to make an alloy (5% of total use) such as
brass and bronze. A small part of copper supply is used in
production of compounds for nutritional supplements and
fungicides in agriculture. Machining of copper is possible,
although it is usually necessary to use an alloy for intricate
parts to get good machinability characteristics.
B. Project Objective
There are three main objectives that must be achieved:
1. To develop the geometry of the piston using
PRO/ENGINEEEING software.
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.21, September-2014, Pages: 4283-4289
Thermal Analysis of Copper Coated 2 Stroke Spark Ignition Engine
2. To investigate Temperature distribution, Thermal
3. Specifications of engine
gradient vector sum and heat flux vector sum vector
Engine type: 2-stroke spark ignition engine
sum through the piston, liner and cylinder head of the
Bore
conventional SI engines. with and without copper
Displacement = 145.5CC
coated using ANSYS.
3. Structural analysis to find von misses stress and
C. FEA Software – Ansys
displacement vector sum with and without copper
1. Introduction
coated using ANSYS.
ANSYS is general-purpose finite element analysis
(FEA) software package. Finite Element Analysis is a
V. METHODOLOGY
numerical method of deconstructing a complex system
A. General
into very small pieces (of user-designated size) called
Basically in this Project Solid Model of a Piston and
elements. The software implements equations that govern
cylinder are developed in Pro-E and is further imported
the behaviour of these elements and solves them all;
into the Ansys Package for Analysis Phase. So here the
creating a comprehensive explanation of how the system
two Software„s used are.
acts as a whole. These results then can be presented in
1- Pro-E
tabulated, or graphical forms. This type of analysis is
2- Ansys
typically used for the design and optimization of a system
far too complex to analyze by hand. Systems that may fit
B. Pro-E
into this category are too complex due to their geometry,
1. Introduction to Pro/Engineer
scale, or governing equations.
Pro/ENGINEER is a computer graphics system for
modeling various mechanical designs and for
D. Procedure for Ansys Analysis
performing related design and manufacturing
The procedure for ANSYS analysis consists of three
operations. The system uses a 3D solid modeling
main steps:
system as the core, and applies the feature-based,
1. Build the model.
parametric modeling method. In short, Pro/Engineer is
2. Obtain the solution.
a feature-based, parametric solid modeling system with
3. Review the results.
many extended design and manufacturing applications
[3].
1. Build the model
In this step, we specify job name and analysis title and
2. Objectives [4]
then define the element types, element real constants,
material properties and the model geometry element types Create a feature using an Extruded protrusion.
both linear and non-linear structural elements are allowed.
 Understand Setup and Environment settings.
The ANSYS element library contains over 80 different
 Define and set a Material type.
element types. A unique number and prefix identify each
 Create and use Datum features.
element type. E.g.: PLANE-71, SOLID-96, BEAM-94 and
 Sketch protrusion and cut feature geometry using
PIPE-16. Material properties: Young„s modulus [Ex] must
the Sketcher.
be defined for static analysis. If we have to apply inertia
 Understand the feature Dashboard
loads [such as gravity], we define mass properties such as
 Copy a feature
density [DENS]. Similarly if we apply thermal loads
 Save and Delete Old Versions of an object
[temperatures], we define coefficients of thermal expansion
[ALPX].
2. Obtain the solution:
In this step we define the analysis type and options, apply
loads and initiate the finite element solution. This involves
three phases:
i. Pre-Processor phase
ii. Solution Phase
iii. Post-Processor phase
Fig2. Assembly with copper liner.
i. Pre-Processor: Pre-Processor has been developed so that
the same program is available on micro, mini, super-mini
and mainframe computer system. This allows easy transfer
of models from one system to the other. Pre-Processor is an
interactive model builder to prepare the finite element model
and input data. The solution phase utilizes the input data
developed by the pre-processor, and does the solution
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.21, September-2014, Pages: 4283-4289
KHALDOON FAWZI MUKHLIF, DR. E. RAMJEE
according to the problem definition. It creates input files to
advances in computer technology and CAD systems,
the visualization of results on the graphics screen. It displays
complex problems can be modeled with relative ease.
the displacements, stresses, temperatures, etc. on the screen
Several alternate configurations can be tried out on a
in the form of contours.
computer before the first prototype is built. The basics in
engineering field are must to idealize the given structure for
the required behavior. In the Finite Element Method, the
ii. Solution
The solution phase deals with the solution of the problem
solution region is considered as many small, interconnected
according to the problem definitions. All the tedious work of
sub regions called Finite elements [5].
formulating and assembling of matrices are done by the
B. Elements and Its Types
computer and finally displacements and stresses are given as
In general, the finite elements are classified.
output.
1. Based on dimension as
 One dimensional element – Line element
iii. Post Processor
 Two dimensional element – Triangular and quadrilateral
The post-processing phase of the ANSYS program follows
elements.
the preprocessing and solution phases. With this portion of
 Three dimensional elements Tetrahedral and hexahedral
the program, the user may easily obtain and operate on the
elements.
results calculated in the solution phase through a very
2. Based on material properties
complete set of user-friendly post-processing features. These
 Linear element
results may include displacements, temperatures, strains and
 Non-linear element
stresses, velocities and heat flows. The output from the post3. Based on degree of freedom
processing phase of the program is in display and/or tabular
 Translational – one, two or three degrees of freedom
report form. Because the post-processing phase is fully
 Rotational – one, two or three degrees of freedom
integrated with the ANSYS preprocessing and solution
phases, the user can examine results immediately. It is a
VII. ANALYSIS USING ANSYS
powerful user-friendly post-processing program. Using
A. Thermal Analysis of Cylinder, Piston with Copper
interactive color graphics, it has extensive plotting features
Lining Assembly
for displaying results obtained from FEM. One picture of
analysis results can often reveal in seconds what would take
engineer hours to assess from numerical printout. The
engineer may also see important aspect of the results that
could be easily missed in stock of printout. Employing state
of the art image enhancement techniques, it facilities
viewing of contours of stresses, displacements, temperatures
etc.
Table 1: Steps followed in Ansys Software
Fig3.Imported Model from Pro/Engineer with copper
lining.
VI. FINITE ELEMENT METHOD
A. Introduction To Finite Element Method
The Finite Element Method has been a powerful tool for
the numerical solution of a wide range of engineering
problems. Applications range from deformation and stress
analysis of automotive, aircraft, building, defense, and
missile and bridge structures to the field of analysis of
dynamics, stability, fracture mechanics, heat flux, fluid flow,
magnetic flux, seepage, and other flow problems. The basic
idea in the Finite Element Method is to find the solution of
complicated problems with relatively easy way .with the
Fig4. Meshed Model with copper lining.
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.21, September-2014, Pages: 4283-4289
Thermal Analysis of Copper Coated 2 Stroke Spark Ignition Engine
B. Structural Analysis Of Cylinder, Piston with Copper Lining
Assembly
Fig5.Nodal temperature with copper lining(k)
Fig8. Displacement vector sum with copper lining (mm).
Fig6.Thermal gradient vector sum with copper lining
(k/mm).
Fig9.Von misses stress with copper lining(mpa).
Fig7. Heat flux vector sum with copper lining (w/mm2).
Fig.9. Von misses total strain with copper lining.
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.21, September-2014, Pages: 4283-4289
KHALDOON FAWZI MUKHLIF, DR. E. RAMJEE
VIII. RESULTS AND DISCUSSIONS
 By using Ansys software analysis (Structural, Thermal)
of the two stroke spark ignition engine has been carried
out successfully. By using the Analysis obtained from the
Structural Analysis of copper coated, The value of
Maximum
Displacement vector sum is found to be
0.014119. Von Misses Stress is found to be 28.451MPa.
 By using the Analysis obtained from the Structural
Analysis without copper coated, the value of Maximum
Displacement vector sum is found to be 0.013471. and
the value of Maximum Von Misses Stress is found to be
22.076MPa.
Table.3. Structural analysis without copper lining
 By using copper coated in the engine lead to increase the
Von misses stress, the copper coated engine has higher
Von Misses Stress from without copper engine. so we
concluded that the copper coated was the best.
 From the thermal analysis of tow stroke engine, the
temperature distribution with copper coated engine
higher than the temperature distribution without copper
coated engine.
 Maximum elongations and temperature are observed at
the piston head and cylinder head section and minimum
Table.4.Thermal analysis with copper lining
elongation and temperature variation at the root of the
engine.
 The copper coated has small effect in the displacement
vector sum, so the engine with copper coated better than
the engine without copper coated.
Table.2. Structural analysis with copper lining
Table.5.Thermal analysis without copper lining
Table.6.Thermal analysis with copper lining
IX. CONCLUSION
 The copper coated has a significant effect on the overall
stresses and temperature.
 By using Ansys software analysis (Structural, Thermal)
of the two stroke spark ignition engine has been carried
out successfully. By using the Analysis obtained from
the Structural Analysis of copper coated, The value of
Maximum Displacement vector sum is found to be
0.014119. The value of Minimum Displacement vector
sum is found to be 0 and the value of Maximum Von
Misses Stress is found to be 28.451MPa. The value of
Minimum Von Misses Stress is found to be 0.180E-04
Map.
 By using the Analysis obtained from the Structural
Analysis without copper coated, the value of Maximum
Displacement vector sum is found to be 0.013471. The
value of Minimum Displacement vector sum is found to
be .0 and the value of Maximum Von Misses Stress is
found to be 22.076MPa. The value of Minimum Von
Misses Stress is found to be 0.270E-04 Map.
 The temperature distribution in the piston and the
cylinder with copper coated higher than the temperature
distribution in the piston and the cylinder without
copper coated because in copper coated engine the,
copper has high thermal conductivity this lead to more
dissipated of the heat through the engine.
 If the thermal conductivity is increased, the amount of
the heat flow will be high. Therefore the material type
with high thermal conductivity is considered better than
the material type of low thermal conductivity. This
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.21, September-2014, Pages: 4283-4289
Thermal Analysis of Copper Coated 2 Stroke Spark Ignition Engine
means that the engine with copper coated better than the
engine without copper coated due to high thermal
conductivity of copper.
 ANSYS program in which finite element mesh
generated employing node elements predicted isotherms
well for copper coated piston, liner, copper coated
cylinder head, conventional piston, liner, and
conventional cylinder head for the copper coated and
conventional engines.
 From the above discussions it is clear that the increase
in the temperature is high in the copper coated engine
compared to conventional engine.
X. REFERENCES
[1] B. Heywood John, Internal Combustion Engine
Fundamentals,McGraw-Hill, New York.
[2] V. Ganesan., “Internal combustion engines”, Tata Mc
Graw- Hill Publications.
[3] Roger Toogood ,Pro/Engineer Wildfire 4.0: Tutorial And
Multimedia CD, ISBN: 978-1-58503-415-4.
[4] Louis Gray Lamit, Introduction to Pro/ENGINEER
Wildfire 2, 2004.
[5] Gantla Shashidhar Reddy and N. Amara Nageswara Rao,
Modeling and Analysis Of Diesel Engine Piston,
International Journal of Mathematics and Engineering, 206
(2013) 1994 – 2027, ISSN 0976 – 1411.
Author's Profile:
Khaldoon fawzi mukhlif, Received his
Bachelor Degree in Mechanical
Engineering & Education from
University of Anbar, IRAQ. Presently
he finished his Master of Technology
(Thermal Engineering) in Jawaharlal
Nehru Technological
University,
Hyderabad, INDIA. His research
interest.
Dr.E.
Ramjee
Professor
of
Examination, Mechanical Engg..
Areas of Interest IC. Engines, Fuels,
Combustion and
Environment,
Thermal Engineering.
International Journal of Scientific Engineering and Technology Research
Volume.03, IssueNo.21, September-2014, Pages: 4283-4289