THERMAL STRESS & FATIGUE LIFE ANALYSIS OF ENGINE CYLINDER HEAD

Abstract

The engine cylinder head is exposed to severe thermal and mechanical conditions during operation, making it highly susceptible to thermal stress and fatigue failure. This project investigates the thermal behavior and fatigue life of an engine cylinder head using numerical simulation techniques. A three-dimensional model of the cylinder head is developed in CATIA and analyzed using ANSYS. A steady-state thermal analysis is performed to determine temperature distribution under combustion and cooling conditions. The resulting temperature field is then used to evaluate thermal stresses and deformation through structural analysis. Fatigue analysis is conducted by applying cyclic thermal loads to estimate the life of the component using material S–N curves. The results indicate that maximum thermal stresses occur near critical regions such as the combustion chamber, valve seats, and bolt holes. These areas are identified as potential sites for crack initiation due to repeated thermal cycling. The study highlights the importance of effective cooling design, material selection, and stress reduction techniques to enhance the durability and performance of the cylinder head. This work provides valuable insights into improving engine reliability and serves as a foundation for further optimization and advanced thermal fatigue studies.