Application of Aluminum Cylinder

The cylinder head of a diesel engine is a multi-functional entity, deciding the performance and emission parameters of the engine. It also acts as a structural and sealing member. It accommodates ports for the gas exchange process; injectors for the combustion process, cooling passages optimized for heat transfer, valve train mechanism, and lubrication circuits and in addition in our case integrated common rail fuel injection pump drive and systems. Aluminum is lightweight with benefits. Combustion is direct injection subject to higher thermal and mechanical loads, it must be robust enough to withstand the high operating temperature and peak firing pressure. The design and development of effective Intake and Exhaust Ports remain critical to improving volumetric efficiency.

Compactness not only helps in packaging by having optimum LBH but also in making it light. To start with design considerations are Bore pitch of the cylinder block which is the center of each cylinder position, Block-head positioning dowels, cylinder head bolt receiving locations, etc. to be considered while laying-out. Next, it is desirable to start with a combustion layout which accommodates Valves, glow plug, injector, ports, head bolt locations, etc. Considering modularity cylinder head height has been designed for accommodating camshaft and other necessities.

With shrinking emission limits, the management of Blow-by Gases and Intake port swirl provides priorities. However, the diesel head design is primary, we can consider it while designing to accommodate a spark plug which will make the engine multi-fuel capability. This paper discusses the options that were considered in designing a compact cylinder. Head for a penta-fuel application operating in a complex environment. The aluminum alloy selection plays a pivotal role in the design and manufacturability of the intricate internal shape of the cylinder head with almost zero rejections after machining. With both linear and non-Linear Design variables, a frugal approach is used for engineering an efficient 2-Valve cylinder head for a 1.5-liter engine used in LCV application.

In layout design, uniqueness is not only to get maximum valve sizes or to get package spark plug or injector in optimum position but also to make an effective valve bridge.

All-aluminum cylinder heads have been adopted on a large scale in automobile engines long ago. The weight of the cylinder head is not large, so automakers like it not because it is light, but because it has better heat dissipation performance. With the development of engine technology, the four-valve structure has become the mainstream design trend of engines. Compared with the same two-valve engine, the cylinder head with four valves per cylinder generates more heat than the cylinder head with two valves per cylinder. The use of all-aluminum cylinder heads is the best solution.

For cost considerations, the cylinder block adopts an all-aluminum design much later than the cylinder head. The cylinder block is the heaviest part of the engine, so the use of aluminum alloy material can reduce the weight of the engine, so as to achieve the purpose of reducing the weight of the entire vehicle. This is especially valuable for front-drive models. Of course, on the other hand, due to the difference in material prices and processing techniques, the use of aluminum alloy cylinder blocks will increase the cost of the engine.

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