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Design Modification in Engine Exhaust

Article  in  International Journal of Scientific and Engineering Research · January 2012

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International Journal of Scientific & Engineering Research Volume 2, Issue 12, December-2011 1
ISSN 2229-5518

Design Modification in Engine Exhaust

Ram M S
Abstract— The system aims at modifying the position and diameter of the exhaust valve in order to reduce the probability of knocking (both in SI and
in CI) and lessen the dilution of charge because of the small size of exhaust valve when compared to the size of inlet valve.
The size of the exhaust valve is smaller when compared to the size of inlet valve. It is done so because the region closer to the exhaust valve is at a
higher temperature compared to that of the temperature surrounding the inlet valve. Now if the exhaust valve size is increased there will be higher pos-
sibility of knocking because the charge coming inside the combustion chamber has a higher probability of combusting at exhaust valve’s surface (due to
large surface area). On the other hand if the size is too small then, there will be greater possibility of dilution in the intake charge because there is no
enough space for the burnt gas to leave the chamber.
To reduce these problems, modifications in the engine is proposed. In general inlet and exhaust valves are positioned vertically along the axis of the
combustion chamber. Now if the exhaust valve is placed along the horizontal axis (i.e. perpendicular to the cylinder axis) and if the size of the valve is
increased then there will be less possibility for the dilution. But the probability of knocking increases. Since the exhaust valve is placed along the horizon-
tal axis, the outer surface of the exhaust valve will be in contact with the water cooling system of the combustion chamber (outside the chamber). Thus
this cooling system or the coolant will be able to release the heat at the outer surface of the exhaust valve and transfer heat from the seat surface of the
exhaust valve (commonly in tappet valves). The rate of Heat Transfer will be high because the surface area perpendicular to heat flow direction is large
thereby enhancing heat transfer. The possibility of the dilution is reduced because, during the piston movement from BDC (Bottom Dead Center) to the
TDC (Top Dead Center) the piston pushes the burnt gases outside through the exhaust valve since the size of the exhaust valve is increased, it is easier
for the burnt gases to escape due to low density with higher temperature inside the combustion chamber. And the charge from the inlet will also push the
gas outside due to the concept of scavenging. But the inlet charge won’t escape through the exhaust because of the valve opening timing is so small
and also the density of the charge is high.
The rate of heat transfer can also be increased by changing the type of material used in valve seat. For material with high heat transfer rate, the density
increases, but it won’t affect the performance of the engine because the increase in weight is negligible. Since the size of the exhaust is increased, the
rate of exhaust air moving per stroke also increases and hence this high exhaust velocity can be used in turbochargers which increase the overall effi-
ciency when compared to the efficiency obtained before.
Index Terms— Internal Combustion Engine, Exhaust Valve, Dirichlet’s Boundary Condition, Conduction Heat Transfer, Convection Heat
Transfer, Turbo Chargers, Al-Mg-Si and Chrome Steel, Valve Actuation.

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1 INTRODUCTION

T HE internal combustion engine is generally a heat engine

which works on the principle of combustion for produc-
ing power. The term Combustion is saved for the reac-
bustion chamber causing serious damages to the engine. To
avoid the following issues the exhaust valve is made smaller
than the inlet valve.
tions which take place very rapidly with large conversion of
chemical energy to sensible heat. The burnt gases after expan-
Exaust Passage
sion should be pushed out from the chamber. The purpose is
for reducing the dilution rate of the intake charge. At present
all IC engines are operated by valves for opening and closing
of intake and exhaust fluids. The inlet and exhaust valves,
generally operated by cam shaft for opening and closing are of
various types. Few of the popular types of valves are sleeve
valve, rotary valve and tappet valve. The valves are designed
with various considerations for reducing the knocking possi-
bilities inside the cylinder. Te exhaust valve is made smaller in
size than the inlet valve. The exhaust valve is made smaller
because the exhaust valve is generally positioned in a high
heat region i.e. the region with more possibility of hot spot
and its possibility increases more with the its surface area (seat Inlet Passage
portion of the valve). As the seat area increases, the high tem-
perature region inside the combustion chamber increases
which results in increased possibility of knocking. Knocking is Fig.1: Valve Pas-
a phenomenon caused inside the engine which results in ab- sage in Engine
normal increase of pressure and temperature inside the com- Head
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International Journal of Scientific & Engineering Research Volume 2, Issue 12, December-2011 2
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2 DISADVANTAGES OF SMALL SIZED EXHAUST VALVES steel (7689 kg/m³). The conductive and convective heat trans-
fer studies for the material are as follows.
The opening of the exhaust valve is made smaller in size when
compared to the inlet valve as discussed earlier. By using
small sized exhaust valve the knocking is reduced but due to 5 HEAT TRANSFER STUDIES
small opening on the cylinder head the exhaust gases com- The rate of heat transfer mainly depends on the cross sectional
pletely won’t escape through the manifold during exhaust area on which the heat transfer is taking place and the thermal
stroke. This result in occurrence of exhaust gases inside the conductivity of the material. Aluminum has more thermal
combustion chamber. During intake stroke, when the fresh conductivity when compared to chrome steel and in addition
fuel mixes with the exhaust gas, the charge gets diluted and the large surface area increases the heat transfer. The heat
this results in unburnt charges left inside the chamber after transfer rate on a material by conduction can be given by
expansion. These unburnt charges give out hydrocarbon emis- Fourier’s law of heat conduction equation.
sions. The unburnt mixtures also results in increased fuel con- Q= [-kA (TH-TL)]/L
sumption of the engine. The performance of the engine is af- Where,
fected. Q= Heat Transfer Rate
The smaller size of the valve permits only controlled k= Thermal Conductivity of the Material
amount of gas to escape through the exhaust manifold which A= Cross Sectional Area (Area perpendicular to Heat Flow)
gives only less turbine efficiency in turbo chargers. TH= High Temperature Region
TL= Low Temperature Region
3 PURPOSE FOR MODIFICATION OF EXHAUST L= Length
For two different materials with same dimensional data and
 To reduce the dilution of charge inside the combus-
similar boundary conditions, the thermal conductivity alone
tion chamber thereby reducing the emission and uti-
varies. Thermal analysis for different cases with same boun-
lizing the fuel completely.
dary condition is undergone.
 To reduce the rapid pressure rise inside the combus-
Assumptions:
tion chamber (knocking)
 Boundary Condition: Dirichlet’s Boundary Condition
 To increase the turbine efficiency in turbo chargers.
(1st Kind)
 Highest Temperature (Valve Seat Portion): 1273K
4 MODIFICATION ON THE EXHAUST VALVE  Lowest Temperature: 303K
The main purpose to modify the exhaust valve is to control the  Element Type: Solid 87
emission from the engine and also to improve the fuel  Meshing Parameters: Free Mesh- Division 6- Tetra
cy. The modification is to be made to reduce the dilution of the
charge. The dilution of the charge is reduced by increasing the
exhaust valve opening which permits large amount of gas to
escape through the exhaust manifold. The modification results
in increased possibility of pressure rise (knocking) due to high
surface high temperature region on the seat of the exhaust
valve.
The possibility of knock is reduced by changing the
material used in exhaust
valve. The material with
high thermal conductivity is
selected to increase the heat
transfer rate from the cham- Fig.2: Temperature Distribution in Aluminium Alloy
ber. The exhaust valves are
generally made of high resis-
tance material like chrome
steel whose thermal conduc-
tivity is 72.7W/mK. Alumi-
nium alloy (Al-Mg-Si) is se-
lected as an alternative for
the material. Al-Mg-Si has
high thermal conductivity
when compared to chrome
steel (177.0W/mK). The den-
sity of this material is also
less (2707 kg/m³) when Fig.3: Temperature Distribution in Chrome Steel
compared to the chrome
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International Journal of Scientific & Engineering Research Volume 2, Issue 12, December-2011 3
ISSN 2229-5518

The measurements of the exhaust valve of Herohonda

CD100 are taken and the modifications are made. Exhaust Seat
Diameter is 2 centimeters and the length of the stem is 66 cen-
timeters. The diameter is modified to 2.35 centimeters (inlet
valve’s diameter of the same vehicle) and length is same. Due
to the increase in cross sectional area and increase in thermal
conductivity, the rate of heat transfer is increased which in
turn reduced the hot spot- high temperature region on the
valve seat there by reducing knocking possibilities. Thermal
analyses are made for the modified valves with same assump-
tions made above.

Fig.6: Heat Flux Variation in large sized exhaust valves

Fig.4: Free Tetra meshing for the large sized exhaust Valve
(2.3 cm)

Fig.7: Free Tetra meshing for small sized exhaust valve (2 cm)

Fig.5: Nodal Analysis for the large sized exhaust valve

Fig.8: Nodal Analysis for the smaller exhaust valve

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International Journal of Scientific & Engineering Research Volume 2, Issue 12, December-2011 4
ISSN 2229-5518

ion is shown below.

Fig.9: Heat flux variation in small sized exhaust valve

The position of the valves is also varied in addition to the
dimensional variation and change of material. The valve is
positioned along the horizontal axis on the cylinder block in-
stead of the cylinder head. The purpose is to further increase
the rate of heat transfer. The heat from the valve is transferred
to the face of the manifold pipe by the process of convection.
In this stage, this generally acts like a fin increasing the rate of
heat transfer.
Assumptions:
 Cylinder temperature during expansion: 588K
 Exhaust Gas Temperature: 578 K
 Room Temperature: 298 K
 Coolant Temperature: 303 K
 Exhaust manifold material: Stainless steel (cr 15%, Ni
10%)
 Thermal conductivity of the material: 19.1 W/mK
 Specific Heat: 461 J/Kg K
 Density of the Material: 7865kg/m3

Fig.11: Position of the exhaust valve in horizontal position.

Fig.10: Convection Heat Transfer

The change in position of the valve in horizontal position
affects the clearance volume of the engine affecting its volume- Fig.12: Pictorial Representation of the horizontal posi-
tric efficiency. The positioning of the valve in horizontal post- tioned exhaust valve in an inline engine.
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International Journal of Scientific & Engineering Research Volume 2, Issue 12, December-2011 5
ISSN 2229-5518

Fig.13: Exhaust valve’s position in an inline engine

Fig.16: Nodal Analysis of Curved Exhaust Valve

Fig.14: Exhaust valve’s position in V- Engine

Operating the opening and closing of the valve in horizon-
tal position can be achieved by double rack double pinion me-
chanism. The effect of reduction in volumetric efficiency be-
cause of the change in clearance volume can be reduced by
designing the valve in a curved manner with respect to the
circumferencial diameter of the cylinder bore such that the
valve closes completely when the piston approaches the valve
when it moves from bottom dead centre to the top dead centre
during exhaust stroke. The valve timing and profile of the cam
has to be designed such that the piston won’t hit the valve
during exhaust stroke. The conduction heat transfer studies .
for the exhaust valve with curved seat portion are done.
Fig.17: Heat flux variation in curved exhaust valves

Fig.15: Free Tetra meshing for curved exhaust valve Fig.18: Exhaust valve of Herohonda CD100
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 International Journal of Scientific & Engineering Research Volume 2, Issue 12, December-2011 6
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4 CONCLUSION
The modification in the exhaust valve by varying its position
size and shape and with particular thermal and structural con-
siderations helps in increasing the rate of heat transfer from
the seat portion of the exhaust valve thereby reducing the pos-
sibility of knocking. In addition, the increased size of the ex-
haust valve pushes large amount of exhaust gas outside
through the manifold which reduces the dilution inside the
engine’s combustion chamber. The reduced dilution reduces
the amount of unburnt mixture/charge inside the chamber
which reduces the hydrocarbon emissions coming out of the
engine. The reduced emissions help in development of the
emission standards. Reduction in unburnt fuel inside the
chamber results in increased power with less consumption of
fuel thereby increasing its fuel efficiency. Large amount of gas
escapes due to larger size of the exhaust valve and hence the
heat energy coming out will be more which can be completely
utilized for turbochargers thereby increasing its turbine effe-
ciency. These advantages can be achieved by using large ex-
haust valve by doing few modifications discussed before for
good and smooth running of the engine.

REFERENCES
[1] John B Heywood, “Internal Combustion Engines Fundamentals”, McGraw Hill
Book Company.
[2] Gary L.Borman & Kenneth W. Ragland, “Combustion Engineering”,
McGraw Hill International Editions- Mechanical Series.
[3] Frank P Incropera, “Fundamentals of Heat and Mass Transfer”, Wiley
India Edition.
[4] Ramalingam K K, “Internal Combustion Engines”, Scitech.
[5] Rajput R K, ”Thermal Engineering”, Laxmi Publications
[6] Other sources on web

————————————————
 Ram M S is currently pursuing bachelore degree program in mechanical
engineering in SASTRA University, India, PH-+91-99400-96287. E-mail:
[email protected]. Website: http://theautocom.co.cc
Paper ID: I069641

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