Batch 12 Final Report

STATIC STRUCTURAL AND THERMAL
ANALYSIS OF POPPET VALVE IN IC

ENGINE
ME8811- A PROJECT REPORT
Submitted by
SUGANTHAN A 813818114107
SARAN R 813818114096
VIGNESH S 813818114311
RAHUL R 813818114087
in partial fulfilment for the award of the degree

of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING
SARANATHAN COLLEGE OF ENGINEERING

TIRUCHIRAPPALLI - 620 012
ANNA UNIVERSITY: CHENNAI 600 025

JUNE 2022
I
ANNA UNIVERSITY: CHENNAI-600 025
BONAFIDE CERTIFICATE
Certified that this project report “STATIC STRUCTURAL AND

THERMAL ANALYSIS OF POPPET VALVE IN IC ENGINE by
“SUGANTHAN A (813818114107), SARAN R (813818114096),
VIGNESH S (813818114311), RAHUL R (813818114087)” who carried
out the project work under my supervision.
SIGNATURE SIGNATURE
Dr.G.Jayaprakash, ME.,Ph.D Dr.A.MercyVasan,M.E., Ph.D.,
HEAD OF THE DEPARTMENT SUPERVISOR
PROFESSOR ASSOCIATE PROFESSOR
Department of Mechanical Engineering Department of Mechanical Engineering
Saranathan College Of Engineering, Saranathan College of Engineering,
Tiruchirappalli – 620102 Tiruchirappalli – 620102
II
CERTIFICATE OF EVALUATION
COLLGECODE :8138
COLLEGE NAME :SARANATHAN COLLEGE OFENGINEERING
BRANCH :MECHANICAL ENGINEERING
SEMESTER :VIII
NAME OF
S. NAME OF THE TITLE OF THE
THE
No STUDENTS PROJECT
SUPERVISOR
1 SUGANTHAN A Static structural
2 SARAN R and Thermal Dr.A.Mercy
3 VIGNESH S Analysis of Poppet Vasan
4 RAHUL R valve in IC Engine
The thesis of the project work submitted by the above students in partial
fulfillment for the award of the Bachelor of Mechanical Engineering of Anna
University, Chennai was confirmed to be the work done by the above students and
then evaluated on ______________.
INTERNAL EXAMINER EXTERNALEXAMINER
III
ABSTRACT
Poppet valve is a precision engine component which blocks gas flow

ports and controls the exchange of gases in internal combustion engines.
Intake and exhaust valves are known as "poppet" valves. Poppet valves have
a round head that blocks a Hole (the "port") the "stem" attached to the back
of this "valve head" pushes the valve up and away from the port, allowing
air/fuel to flow through the gap between the valve head and valve seat and
into the combustion chamber. Poppet valves work well in engines because
the pressure inside the combustion chamber pushes the valve against the
seat, sealing the chamber and preventing leaks during this cycle poppet
valves are exposed to high temperature and pressure which will affect the
life and performance of the engine. The aim of the project is to design and
analysis of poppet valve with different alloy materials like Steel, Aluminium
Silicon carbide and Aluminium magnesium alloy using Finite element
Method. 3D model is done in CATIA and Analysis is done in ANSYS.
Keywords: Poppet Valve, Valve Head, Ic Engine
IV
ACKNOWLEDGEMENT
The success and final outcome of this project required a lot of guidance
and assistance from many people and we extremely privileged to have got this all
along the completion of our project. All that we have done is only due to such
supervision and assistance and we would not forget to thank them.
We sincerely thank Shri. S. Ravindran, Secretary, Saranathan College
of Engineering, for giving us platform to realize our project.
We express our sincere thanks to Dr. D. Valavan, Principal, Saranathan
College of Engineering, for giving us an opportunity and immense cooperation
for the successful completion of the project.
We are obliged to thank Dr. G. Jayaprakash, Professor & Head,
Department of Mechanical Engineering for his valuable suggestions and
encouragement to our project.
We express our heartfelt thanks to our Project Overall Coordinators Dr.
M.R. Anantha Padmanaban, Associate Professors, Mr. P. Jothi Palavesam,
Assistant Professor, we also express our sincere thanks to Dr. M. Ganesan,
Associate Professor, Mr. S. Sathyanarayanan, Assistant Professor and Dr.
G. Mahesh, Associate Professor, Department of Mechanical Engineering for
assisting us with their inspiring ideas.
We express our sincere thanks to Dr.A.MERCYVASAN, Associate
Professor for their guidance and continuous support on our research, we also
thank them for their patience, motivation, and immense knowledge.
We also thank all the staff members and our parents for their support to
complete the project successfully.
V
CHAPTER TITLE PAGE
NO NO
ABSTRACT iv
LIST OF TABLES xi
LIST OF FIGURES xii
1 INTRODUCTION 1
1.1 POPPET VALVE 2
2 LITERATURE SURVEY 4
2.1 INTRODUCTION 4
2.2 LITERATURE REVIEW 4
2.3 OBJECTIVES 12
2.4 NEED FOR PRESENT WORK 13
3 PROBLEM IDENTIFICATION 14
3.1 OBJECTIVES 14
1
3.2 METHODOLOGY 15
4 POPPET VALVE 16
4.1 ABOUT POPPET VALVE 16
4.2 MATERIALS USED FOR COMPARISON 17
5 MATERIAL SELECTION 18
5.1 ABOUT STEEL 18
5.1.1 History 18
5.1.2 Production 18
5.1.3 Carbon Steels 19
5.1.4 Alloy Steels 20
5.1.5 Stainless Steels 20
5.1.6 Manufacturing Process of Steel 22
5.1.7 Properties 23
5.1.8 Applications 24
2
5.1.9 Disadvantages of Existing Material 25
5.2 ABOUT MAGNESIUM 25
5.2.1 About Magnesium 25
5.2.2 General Magnesium Information 26
5.2.3 Historic Facts About Magnesium 26
5.2.4 Magnesium’s Chemical Composition 27
And Related Properties
5.2.5 Magnesium as A Metal 28
5.2.6 Properties 28
5.2.7 Characteristics 28
5.2.8 History 29
5.2.9 Production 29
5.2.10 Applications 30
5.2.11 Environmental Effects of Magnesium 31
3
5.2.12 Pure Magnesium 32
5.2.13 More About Magnesium 32
5.2.14 Magnesium Alloys 32
5.2.15 Automotive Applications 33
5.2.16 Aerospace Applications 35
5.2.17 Medical Applications 36
5.2.18 Electronic Applications 37
5.2.19 Sports Applications 37
5.2.20 Other Applications 37
5.3 ABOUT SILICON CARBIDE 39
5.3.1 Silicon’s Multitude of Uses 40
5.3.2 Physical Properties 41
5.3.3 Chemical Properties 41
5.3.4 Occurrance In Nature 41
4
5.3.5 Isotopes 42
5.3.6 Extraction 43
5.3.7 Uses 43
5.3.8 Compounds 44
5.3.9 Health Effects 45
5.3.10 Silicon Carbide 46
5.4 ABOUT GREY CAST IRON 47
5.4.1 Composition of Grey Cast Iron 49
5.4.2 Microstructure of Grey Cast Iron 50
5.4.3 Classification of Grey Cast Iron Classes 50
5.4.5 Mechanical Properties 52
5.4.6 Thermal Properties 52
5.4.7 Electrical Properties 53
5
5.5 ABOUT TITANIUM 53
6 ABOUT CATIA 54
6.1 INTRODUCTION TO CAD/CAM/CAE 54
6.1.1 Need for CAD, CAM, CAE 55
6.1.2 Advantages 55
6.1.3 Drawbacks 56
6.2 INTRODUCTION OF CATIA 56
6.2.1 What Is Catia 56
6.2.2 Feature Based 56
6.2.3 Features Can Be Classified as Sketched- 57
Based or Dress-Up
6.2.4 Solid Modelling 57
6.2.5 Fully Associate 57
6.2.6 Constraints 57
6
6.3 CATIA USER INTERFACE 58
6.4 WORKBENCHES 58
6.5 IN SKETCHER MODE 62
6.6 2D DESIGN IMAGES 63
7 ANSYS 65
7.1 ABOUT ANSYS 65
7.2 STATIC STRUCTURAL RESULTS OF 69
STEEL POPPET VALVE
ALUMINIUM SIC POPPET VALVE
ALUMINIUM MAGNESIUM POPPET
VALVE
GREY CAST IRON POPPET VALVE
TITANIUM POPPET VALVE
7
POPPET VALVE
8 THERMAL ANALYSIS 86
8.1 THERMAL ANALYSIS RESULTS OF 86
POPPET VALVE
POPPET VALVE USING STEEL
ALUMINIUM POPPET VALVE
POPPET VALVE USING MAGNESIUM
ALLOY
8.5 THERMAL ANALYSIS OF POPPET 90
VALVE USING GREY CAST IRON
8.6 THERMAL ANALYSIS OF POPPET 91
VALVE USING TITANIUM
8.7 COMPARISON RESULTS OF THERMAL 92
ANALYSIS OF POPPET VALVE
8
9 CONCLUSION 93
9.1 SUMMARY 93
9.2 REFERENCES 94
9
LIST OF TABLE
S NO TITLE PAGE
NO
5.1 Properties of steel for poppet valve analysis 24
5.2 Properties of aluminium magnesium alloy 38
5.3 Properties of aluminium silicon carbide 46
5.4 Properties of grey cast iron 50
7.1 Result comparison 85
8.1 Result comparison 92
10
LIST OF FIGURES
S. NO TITLES PAGE
NO
1.1 Poppet valve 3
4.1 Poppet valve 17
5.1 Structural steel 19
5.2 Structure of magnesium 26
5.3 Grey cast iron magnified to show the flakes of graphite 47
5.5 Alloy composition 52
6.1 Generally, all CAD models are generated in the same 58
passion
6.2 2D design of poppet valve 63
6.3 3D design using Catia V5 R20 64
7.1 Work bench 65
7.2 Imported in ANSYS workbench 18.1 68
11
7.3 Meshing of poppet valve 68
7.4 Force applied in poppet valve 68
7.5 Static structural results of steel poppet valve 69
7.6 Total deformation of steel poppet valve 69
7.8 Maximum principal stress of steel poppet valve 70
7.9 Equivalent stress of aluminium SIC poppet valve 72
7.10 Total deformation of aluminium SIC poppet valve 73
7.11 Maximum principal stress of aluminium SIC poppet 74
valve
7.12 Equivalent stress of aluminium SIC poppet valve 74
7.13 Total deformation of aluminium magnesium poppet 76
valve
7.14 Maximum principal stress of aluminium magnesium 77
poppet valve
7.15 Equivalent stress of aluminium magnesium poppet 78
12
valve
7.16 Total deformation of grey cast iron poppet valve 79
7.17 Maximum principal stress of grey cast iron poppet valve 80
7.18 Equivalent stress of grey cast iron poppet valve 81
7.19 Total deformation of titanium alloy poppet valve 82
7.20 Maximum principal stress of titanium alloy poppet 83
valve
7.21 Equivalent stress of titanium alloy poppet valve 84
8.1 Temperature and convection applied 86
8.2 Temperature distribution of steel poppet valve 87
8.3 Total heat flux of steel poppet valve 87
8.4 Directional heat flux of steel poppet valve 87
8.5 Temperature distribution of AL poppet valve 88
8.6 Total heat flux of AL poppet valve 88
13
8.7 Directional heat flux of AL poppet valve 88
8.8 Temperature distribution of magnesium poppet valve 89
8.9 Total heat flux of magnesium poppet valve 89
8.10 Directional heat flux of magnesium poppet valve 89
8.11 Temperature distribution of grey cast iron poppet valve 90
8.12 Total heat flux of grey cast iron poppet valve 90
8.13 Directional heat flux of grey cast iron poppet valve 90
8.14 Temperature distribution of titanium alloy poppet valve 91
8.15 Total heat flux of titanium alloy poppet valve 91
8.16 Directional heat flux of titanium alloy poppet valve 91
14
CHAPTER 1
INTRODUCTION
Intake and exhaust valves are very important engine components that
are used to control the flow and exchange of gases in internal combustion
engines. They are used to seal the working space inside the cylinder against
the manifolds and are opened and closed by means of what is known as the
valve train mechanism. Internal combustion engine valves are precision
engine components. They open and close as and when needed. The fresh
charge (air - fuel mixture in Spark Ignition Engines and air alone in
Compression Ignition Engines) is induced through inlet valves and the
products of combustion get discharged to atmosphere through exhaust
valves. There are different types of valves used by the manufactures; some
common types of valves being poppet valves, slide valves, rotary valves and
sleeve valve. Any type of valve failure affects the engine performance thus
making it mandatory to give due importance to temperature and stress
analysis of IC valves. Valve mechanism is the arrangement of different
components which controls the intake and exhaust process.
Exhaust and inlet valve are vital components of an IC engine and
which are controlling the flow of fresh air and burnt gases in and out of
engine cylinders.
In the operation thermal and mechanical stresses are imposed on inlet
and exhaust valve because of high temperature and pressure in the cylinder.
Safety valves, which are usually of the poppet type, open at a
predetermined pressure. The movable element may be kept on its seat by a
weighted lever or a spring strong enough to hold the valve closed until the
pressure is reached at which safe operation requires opening. On gasoline
engines, poppet valves are used to control the admission and rejection of the
15
intake and exhaust gases to the cylinders. The valve, which consists of a disk
with a tapered edge attached to a shank, is held against the tapered seat by a
compressed spring. The valve is raised from its seat by the action of a
rotating cam that pushes on the bottom of the shank, permitting gas flow
between a region, which leads to the intake or exhaust pipes, and to region,
which leads to the cylinder.
The word poppet shares etymology with "puppet": it is from the Middle
English poppet ("youth" or "doll"), from Middle French poupette, which is
a diminutive of poupe. The use of the word poppet to describe a valve comes
from the same word applied to marionettes, which – like the poppet valve –
move bodily in response to remote motion transmitted linearly. In the past,
"puppet valve" was a synonym for poppet valve; however, this usage of
"puppet" is now obsolete.
1.1 POPPET VALVE
A poppet valve is a type of check valve often associated with kill and
choke lines or pressure control equipment. A poppet valve is a directional
control valve and is typically characterized as being a high flow, fast acting
design due to the large flow paths through the main body of the valve.
Usually, the poppet valve can be opened relatively quickly. The inlet valves
are made from plain nickel, nickel chrome or chrome molybdenum. Whereas
exhaust valves are made from nickel chrome, silicon chrome steel, high
speed steel, stainless steel, high nickel chrome, tungsten steel and cobalt
chrome steel. With the help of these parts, valve performs its operation very
accurately in internal combustion engine. The valve spring, keeps the valve
pressed against its seat and ensure a leakage proof operation and also bring
back the valve very quickly during its closing. When the engine is started, it
gets heated up gradually thereby causing the valve stem to expand.
16
The clearance provided in exhaust valve is slightly more than that of
inlet valve. This is due to slightly more expansion in exhaust valve because
of higher temperature of hot exhaust gases produced during combustion.
Valves are the most important part of every engine, So due care must be
taken in selection and maintenance of valve. Engines, So due care must be
taken in selection and maintenance of valve.
FIGURE 1.1 POPPET VALVE
17
CHAPTER 2
LITERATURE SURVEY
2.1 INTRODUCTION
Poppet manufacturing industries are selected the materials based on

their properties and the recommendation of the manufacturer. But the
materials they are using have many drawbacks. So, the selection of new
materials is difficult. The new material should have high chemical and
thermal properties. So, many researches have worked in this area with
different concepts and the research findings are discussed below.
2.2 LITERATURE REVIEW
Matthew T. Muller et al addressed that “Design and Analysis of a

Two-Stage Poppet Valve For Flow Control” This paper explores dynamic
modelling and design of a typical two stage metering poppet valve system.
In particular, nonlinear and linear models of a spring force feedback
configuration are developed and parameters tuned through the use of root
locus techniques. Typical steady state conditions as well as extreme high
and low pressure drops are simulated in attempts to uncover instabilities
and other possible undesirable performance characteristics of the valve.
Finally the nonlinear model is used to produce Bode magnitude plots at
various pressure drops in order to estimate the system bandwidth. Results
indicate that increasing the size of the orifice at the inlet of the pilot stage
of the valve increases performance in terms of rise time at the cost of a
more oscillatory response. High pressure differences between the inlet and
outlet of the valve were found to cause performance to increase
significantly as well as move poles into a region indicated less damping. A
scheme for controlling the inlet orifice area to the pilot stage is presented
18
and shown to improve performance capability (bandwidth) of the valve
while maintain a damped response.
Ivan Gomez et al addressed that“Analysis of the Design of a Poppet

Valve by Transitory Simulation” This article contains the results and
analysis of the dynamic behavior of a poppet valve through CFD
simulation. A computational model based on the finite volume method was
developed to characterize the flow at the interior of the valve while it is
moving. The model was validated using published data from the valve
manufacturer. This data was in accordance with the experimental model.
The model was used to predict the behavior of the device as it is operated
at high frequencies. Non-dimensional parameters for generalizing and
analyzing the effects of the properties of the fluid were used. It was found
that it is possible to enhance the dynamic behavior of the valve by altering
the viscosity of the working fluid. Finally, using the generated model, the
influence of the angle of the poppet was analyzed. It was found that angle
has a minimal effect on pressure. However, flow forces increase as angle
decreases. Therefore, reducing poppet angle is undesirable because it
increases power requirements for valve actuation.
Yalla M Surya Chandra Rao et al addressed that “structural and

thermal analysis of poppet valve made of different composite materials”
Intake and exhaust valves are known as "poppet" valves. Poppet valves have
a round head that blocks a Hole (the "port") the "stem" attached to the back
of this "valve head" pushes the valve up and away from the port, allowing
air/fuel to flow through the gap between the valve head and valve seat and
into the combustion chamber. Poppet valves work well in engines because
19
the pressure inside the combustion chamber pushes the valve against the
seat, sealing the chamber and preventing leaks during this cycle poppet
valves are exposed to high temperature and pressure which will affect the
life and performance of the engine. The aim of the project is to design an
exhaust valve with a suitable material for a four wheeler diesel engine using
Finite element analysis. 2D drawings are drafted from the calculations and
3D model is done in CATIA and Analysis is done in ANSYS.
J. Kastner, M.A., M.Sc et al addressed that;” POPPET INLET

VALVE CHARACTERISTICS AND THEIR INFLUENCE ON THE
INDUCTION PROCESS” In view of the wide use made of the poppet valve
in internal combustion engines it seems strange that, comparatively, so little
has been published on its flow characteristics since these are so important in
determining the breathing capacity of an engine. Indeed, the main sources
of detailed information on inlet valves are still the papers of Tanaka (I)§ and
of Dennison, Kuchler, and Smith (2), both of which represent work done a
considerable time ago. It is perhaps more remarkable, if the published
information is taken as a guide, that so-called 'static' tests, in which the air
flow through a stationary valve is measured, seem very rarely, if ever, to
have been supplemented by experiments in which the kinetics ofthe valve
motion and ofthe air column have been taken into account. In the present
investigation, a series of static tests was followed by a series in which the
valve was reciprocated whilst the overall pressure drop across valve and port
was kept constant. The apparatus used permitted high rates of reciprocation,
similar to those which would occur in high-speed engines, and enabled the
flow characteristics at various rates of reciprocation, and with different
cams, to be measured. As a third stage in the investigation, more elaborate
equipment enabled valves which had previously been tested in the 'static'
and 'kinetic' rigs to be used in conjunction with a piston and cylinder
20
apparatus of a special type. This allowed valve-and-port performance to be
evaluated under conditions closely similar to those which apply in a real
engine, and measurements to be made of the effects of alterations in the inlet
arrangements on the volumetric efficiency ofthe cylinder. An analytical
technique was developed for calculating pressure-time and temperature-time
variations in the cylinder during the induction process. The rather complex
calculations were carried out with the help of a digital computer and in those
instances where the results could be compared with values obtained
experimentally, a fair agreement was achieved
M Kamili Zahidi1et al addressed that;” The two-stroke poppet valve

engine. Part 1: Intake and exhaust ports flow experimental assessments” A
two-stroke poppet valve engine is developed to overcome the common
problems in conventional two-stroke engine designs. However, replacing
piston control port with poppet valve will resulted different flow
behaviour. This paper is looking at experimental assessment on a two-
stroke poppet valve engine configuration to investigate the port flow
performance. The aims are to evaluate the intake and exhaust coefficient of
discharge and assess the twostroke capability of the cylinder head. The
results has shown comparable coefficient of discharge values as production
engine for the intake while the exhaust has higher values which is
favourable for the two-stroke cycle operation.
Kuldeep Shakya#1 et al addressed that;” Steady-State Thermal

Analysis of I.C. Engine Poppet Valve Using ANSYS “ Design of the
poppet valve based on variousfactors like performance of material at peak
temperature, vibrations, fluid dynamics of burnt gases, oxidization features
of valve metal and burnt gas, fatigue behavior of valve material, structure
of the cylinder head, coolant movement and the form of the port. This
project deals with the analysis of thermal stress developed in a valve due to
21
high pressure within the combustion chamber at high temperature
situations. For modelling Solidwork is to be utilized and to optimized the
Poppet valve ANSYS will be utilized as the tool. Steady State thermal
analyses are to be performed on the valve based on fillet radius at 3 mm, 6
mm and 10 mm and Chamfer at 2 mm, 4 mm and 6 mm at 45 0 angle.
Maximum thermal stresses found 24.783 MPa at 6 mm chamfer at 45 0
angle. Hence it is clear that 6 mm fillet radius of poppet valve is best and
safe for designing of I.C. Engine inlet and outlet valve.
Awanish Kumar Singh1et al addressed that ; “Design and Analysis

of Poppet Valve Using Composite Materials”Poppet valve is a precision
engine component which blocks gas flow ports and controls the exchange
of gases in internal combustion engines. Intake and exhaust valves are
known as "poppet" valves. Poppet valves have a round head that blocks a
Hole (the "port") the "stem" attached to the back of this "valve head"
pushes the valve up and away from the port, allowing air/fuel to flow
through the gap between the valve head and valve seat and into the
combustion chamber. Poppet valves work well in engines because the
pressure inside the combustion chamber pushes the valve against the seat,
sealing the chamber and preventing leaks during this cycle poppet valves
are exposed to high temperature and pressure which will affect the life and
performance of the engine. The aim of the project is to design and analysis
of poppet valve with a suitable material using Finite element Method. 3D
model is done in CATIA and Analysis is done in ANSYS. Thermal and
structural analysis is to be done on the poppet valve when valve is closed.
Shaik Arifulla1 et al addressed that; “Design and Thermal Analysis

of IC Engine Valves using ANSYS” In order to develop an exhaust valve
with highthermal strength, experimental investigations are often costly and
time consuming, affecting manufacturing time as well as time-to- market.
22
An alternative approach is to utilizecomputational methods such as Finite
Element Analysis, which provides greater insights on temperature
distribution across the valve geometry as well as possible deformation due
to thermal stresses. Thermal analysis is evaluating the thermal equilibrium
of a system in which the temperature remains constant over time. In other
words, thermal analysis involves assessing the equilibrium state of a
system subject to constant heat loads and environmental conditions. This
method significantly shortens the design cycle by reducing the numberof
physical tests required. Utilizing the computational capability, this research
aims to identify possible design optimization of the exhaust valve for
material and weight reduction, without affecting the thermal and
strength.In this project we are using single metallic and bi-metallic valves
in design and analysis of engine valves. Thermal and Total heat flux is
determined in this analysis of different cases used for design of
enginevalves.
J.SUMATHI1et al addressed that; “Thermal Analysis of an Exhaust

Valve of an IC Engine using Different Materials” Exhaust valve of an
Internal Combustion engine is one of the most crucial parts in the Engine
head. It is the main cause of most problems like pre ignition etc. Both the
inlet and exhaust valves are subjected to high temperatures during the
power stroke, therefore, it is necessary to take care about the materials of
the valves such that it should withstand those higher temperatures. Design
of the valve depends on so many different parameters like fluid dynamics
of exhaust gas, behavior of material at high temperature, oxidization
characteristics of valve material and exhausts gas, fatigue strength of valve
material, coolant flow and the shape of the exhaust port etc. The most
important factor affecting the performance of a valve is its operating
temperature i.e. temperature at the inlet valve is less compared to exhaust
23
valve. This project deals with the stress induced in a valve due to high
thermal gradient and high pressure inside the combustion chamber. In first
stage 3D model of the exhaust valve is modeled using CATIA and the
analysis of this exhaust valve is done using ANSYS. Thermal and
structural analysis is performed on the valve. In the first stage of analysis
the pressure load will be applied to the valve to determine the structural
stress and strain distribution. In the second stage the exhaust valve is
provided with the temperature for the thermal analysis. The above process
of thermal analysis is carried out with two different materials i.e. 21-4N
super alloy and Nimonic 80A and finally the best material is suggested for
the valve based on its strength and thermal properties.
Ganesh N. Kokane1et al addressed that “INVESTIGATION OF

EXHAUST VALVE OF C.I. ENGINE FOR PERFORMANCE AND ITS
ANALYSIS” In I.C engines valves are essential components for better
working of engine. The Intake and exhaust valves are used to control the
flow and exchange of gases. These valves seal the working space inside the
cylinder against the manifolds and are opened and closed with the valve train
mechanism. These valves are loaded by spring forces and subjected to
pressure inside the cylinder and thermal loading due to high temperature.
Due to these different conditions faced by the valves the premature failure
of valve takes place. In this paper, design of exhaust valve was done based
on given specifications with study of valves and Suitable valve radius was
selected. To analyze the valve ANSYS is used. Transient structural and
modal analysis of valve was done and optimization of valve radius along
with recommendation of better material for life improvement of exhaust
valve and further experimentation was done on universal testing machine
2.3 OBJECTIVES
24
To vary the dimensions of the existing poppet valve and analyse the its
strength using static structural analysis and thermal analysis in ANSYS
workbench 18.1 To analyse
• Total deformation
• Equivalent stress
• Maximum principal stress
• Shear stress
• Temperature
• Total heat flux
• Directional heat flux.
2.4 NEED FOR PRESENT WORK
Because past research and experiences had indicated that during the
operation of the internal combustion engine, the axial stresses are produced
in exhaust valve due to cylinder gas pressure (compressive only) and the
inertia force arising in account of valve spring action. At the same time it is
subjected to overheating due to a very high temperature It results into the
development of maximum stresses at the fillet section of the exhaust valve.
Hence the problem statement is “To design the poppet valve with
modelling & structural analysis. So, that it can withstand to given operating
conditions. Further material selection is to be done based on analysis
25
CHAPTER 3
PROBLEM IDENTIFICATION
Because past research and experiences had indicated that

during the operation of the internal combustion engine, the axial
stresses are produced in exhaust valve due to cylinder gas pressure
(compressive only) and the inertia force arising in account of valve
spring action. At the same time it is subjected to overheating due
to a very high temperature It results into the development of
maximum stresses at the fillet section of the exhaust valve.
Hence the problem statement is “To design the poppet valve

with modeling & structural analysis. So, that it can withstand to
given operating conditions. Further material selection is to be done
based on analysis
3.1 OBJECTIVE
26
To vary the dimensions of the existing poppet valve and
analyze the its strength using static structural analysis and thermal
analysis in ANSYS workbench 18.1 To analyze
• Total deformation
• Equivalent stress
• Maximum principal stress
• Shear stress
• Temperature
• Total heat flux
• Directional heat flux.
3.2 METHODOLOGY
27
CHAPTER 4
POPPET VALVE
4.1 ABOUT POPPET VALVE
28
A poppet valve is a type of check valve often associated with kill and
choke lines or pressure control equipment. A poppet valve is a directional
control valve and is typically characterized as being a high flow, fast acting
design due to the large flow paths through the main body of the valve.
Usually, the poppet valve can be opened relatively quickly. The inlet valves
are made from plain nickel, nickel chrome or chrome molybdenum. Whereas
exhaust valves are made from nickel chrome, silicon chrome steel, high
speed steel, stainless steel, high nickel chrome, tungsten steel and cobalt
chrome steel. With the help of these parts, valve performs its operation very
accurately in internal combustion engine. The valve spring, keeps the valve
pressed against its seat and ensure a leakage proof operation and also bring
back the valve very quickly during its closing. When the engine is started, it
gets heated up gradually thereby causing the valve stem to expand.
FIGURE 4.1 POPPET VALVE

The clearance provided in exhaust valve is slightly more than that of
inlet valve. This is due to slightly more expansion in exhaust valve because
of higher temperature of hot exhaust gases produced during combustion.
29
Valves are the most important part of every engines, So due care must be
taken in selection and maintenance of valve, engines. So due care must be
taken in selection and maintenance of valve.
4.2 MATERIALS USED FOR COMPARISON

 Steel
 Aluminium Magnesium (5%)
 Aluminium silicon carbide (5%)
 Grey cast iron
 Titanium alloy
30
CHAPTER 5
MATERIAL SELECTION
5.1 ABOUT STEEL
5.1.1 History
The advent of commercial steel production in the late 19th century

was a result of Sir Henry Bessemer's creation of an efficient way to lower
the carbon content in cast iron. By lowering the amount of carbon in iron to
about 2%, the harder and more malleable steel is produced.
It is not known who produced the first steel. Since 200 BC, many
cultures have produced steel in one form or another. A British inventor,
Henry Bessemer, is generally credited with the invention of the first
technique to mass produce steel in the mid1850s. Steel is still produced
using technology based on the Bessemer Process of blowing air through
molten pig iron to oxidise the material and separate impurities.
5.1.2 Production
Today, most steel is produced by basic oxygen methods (also known

as basic oxygen steelmaking or BOS). BOS is so-named because it requires
oxygen to be blown into large vessels containing molten iron and scrap steel.
Although BOS accounts for the largest share of global steel

production, the use of electric arc furnaces (EAF) has been growing since
the early 20th century and now accounts for about one-third of all steel
production.
31
FIGURE 5.1 STRUCTURAL STEEL
for their application, and various grading systems are used to distinguish
steels based on these Different types of steel are produced according to the
properties required properties. According to the American Iron and Steel
Institute (AISI), steel can be broadly categorized into four groups based on
their chemical compositions:
 Carbon Steels
 Alloy Steels
 Stainless Steels
 Tool Steels
5.1.3 Carbon Steel
Carbon steels contain trace amounts of alloying elements and account

for 90% of total steel production. Carbon steels can be further categorized
into three groups depending on their carbon content:
Low Carbon Steels/Mild Steels contain up to 0.3% carbon
Medium Carbon Steels contain 0.3 – 0.6% carbon
High Carbon Steels contain more than 0.6% carbon
32
5.1.4 Alloy Steels
Alloy steels contain alloying elements (e.g. manganese, silicon,

nickel, titanium, copper, chromium, and aluminum) in varying proportions
in order to manipulate the steel's properties, such as its hardenability,
corrosion resistance, strength, formability, weldability or ductility.
Applications for alloys steel include pipelines, auto parts,

transformers, power generators and electric motors.
5.1.5 Stainless Steels
Stainless steels generally contain between 10-20% chromium as the

main alloying element and are valued for high corrosion resistance. With
over 11% chromium, steel is about 200 times more resistant to corrosion
than mild steel. These steels can be divided into three groups based on their
crystalline structure:
Austenitic: Austenitic steels are non-magnetic and non heat-

treatable, and generally contain 18% chromium, 8% nickel and less than
0.8% carbon. Austenitic steels form the largest portion of the global stainless
steel market and are often used in food processing equipment, kitchen
utensils, and piping.
Ferritic: Ferritic steels contain trace amounts of nickel, 12-17%

chromium, less than 0.1% carbon, along with other alloying elements, such
as molybdenum, aluminum or titanium. These magnetic steels cannot be
hardened by heat treatment but can be strengthened by cold working.
Martensitic: Martensitic steels contain 11-17% chromium, less than

0.4% nickel, and up to 1.2% carbon. These magnetic and heat-treatable
33
steels are used in knives, cutting tools, as well as dental and surgical
equipment.
Tool Steels
Tool steels contain tungsten, molybdenum, cobalt and vanadium in

varying quantities to increase heat resistance and durability, making them
ideal for cutting and drilling equipment.
Steel products can also be divided by their shapes and related

applications:
Long/Tubular Products include bars and rods, rails, wires,

angles, pipes, and shapes and sections. These products are commonly used
in the automotive and construction sectors.
Flat Products include plates, sheets, coils, and strips. These materials
are mainly used in automotive parts, appliances, packaging, shipbuilding,
and construction.
Other Products include valves, fittings, and flanges and are mainly
used as piping materials.
Steel has a wide range of alloy compositions, which allow it to have

diverse mechanical properties. Steel is not a single product. There are more
than 3,500 different grades of steel with many different physical, chemical,
and environmental properties. Approximately 75% of modern steels have
been developed in the past 20 years. If the Eiffel Tower were to be rebuilt
today, the engineers would only need one-third of the steel that was
originally used. Modern cars are built with new steels that are stronger but
up to 35% lighter than in the past.
34
5.1.6 MANUFACTURING PROCESS OF STEEL
Globally, steel is produced via two main routes: the blast furnace-
basic oxygen furnace (BF-BOF) route and electric arc furnace (EAF) route.
Variations and combinations of production routes also exist. The key
difference between the routes is the type of raw materials they consume. For
the BF-BOF route these are predominantly iron ore, coal, and recycled steel,
while the EAF route produces steel using mainly recycled steel and
electricity. Depending on the plant configuration and availability of recycled
steel, other sources of metallic iron such as direct-reduced iron (DRI) or hot
metal can also be used in the EAF route. About 75% of steel is produced
using the BF-BOF route. First, iron ores are reduced to iron, also called hot
metal or pig iron. Then the iron is converted to steel in the BOF. After
casting and rolling, the steel is delivered as coil, plate, sections or bars. Steel
made in an EAF uses electricity to melt recycled steel. Additives, such as
alloys, are used to adjust to the desired chemical composition. Electrical
energy can be supplemented with oxygen injected into the EAF.
Downstream process stages, such as casting, reheating and rolling, are
similar to those found in the BF-BOF route. About 25% of steel is produced
via the EAF route. Another steelmaking technology, the open hearth furnace
(OHF), makes up about 0.4% of global steel production. The OHF process
is very energy intensive and is in decline owing to its environmental and
economic disadvantages. Check out our publication World Steel in Figures
for a detailed split.
Most steel products remain in use for decades before they can be
recycled. Therefore, there is not enough recycled steel to meet growing
demand using the EAF steelmaking method alone. Demand is met through
a combined use of the BF-BOF and EAF production methods. All of these
35
production methods can use recycled steel scrap as an input. Most new steel
contains recycled steel.
5.1.7 Properties
Different types of steel are produced according to the properties

required for their application, and various grading systems are used to
distinguish steels based on these properties. The following table lists the
properties of steels at room temperature (25°C).
An alloy composed primarily of iron, steel is one of the defining

materials of the last two centuries. Traditionally, steels were combinations
of iron and carbon, but there are now many classes of steel that now alloy
iron with other materials and exclude carbon. The key attributes of a steel
are that it be iron-based and formable into permanent shapes.
Steel is typically measured by a number of qualities, including its

hardness, machinability, and resistance to wear. Various alloys provide
different advantages and are therefore used for certain applications where
those qualities are useful. For instance, stainless steel, an alloy containing at
least 10.5 % chromium and usually nickel, is corrosion resistant, and suits a
wide range of medical applications. The alloy 300M, a low alloy steel, is
used in situations where high-strength steel is necessary. Steels with high
levels of chromium and no nickel are perfect for many blades, especially in
household use. Other ratings include the Rockwell B & C scales, which rank
harder metals with higher numbers. A Rockwell B scale ranking of
approximately 96 corresponds to a rank of 20 on the Rockwell C scale.
Steel can be shaped in an endless assortment of forms. However, most

steel is produced for machining in bars, rods, sheets, balls and tubes. Other
shapes are available, but these are the most common tubes, in fact, are
36
generally produced from sheet stock. Steel can be made from either
recycled, re-melted steel or from raw materials, which normally include iron
ore, limestone and coke. More than 1 billion metric tons of steel are
produced each year, and there are more than 3,500 different grades of steel
available to consumers. Its considerable use can be attributed to its role in
automotives, construction and heavy industry, as well as the different
capabilities of its many alloys.
5.1.8 Applications
From stainless and high-temperature steels to flat carbon products,

steel's various forms and alloys offer different properties to meet a wide
range of applications. For these reasons, as well as the metal's combination
of high strength and a relatively low production cost, steel is now used in
countless products.
TABLE 5.1 PROPERTIES OF STEEL FOR POPPET VALVE

ANALYSIS
5.1.9 DISADVANTAGES OF EXISTING MATERIAL

A major drawback in using steel as a material for engine components
is their higher density which results in increase in weight.
37
Thus it increases the overall vehicle load and consumes more fuel
for large amount of load.
Also steel is less resistance to corrosion. Thus the life of the steel
also decreases.
5.2 ABOUT MAGNESIUM
5.2.1 ABOUT MAGNESIUM
Magnesium is a common metal that, in the body, activates hundreds

of cellular, biochemical reactions. In the nervous system, it functions as a
dampener. Magnesium is the ninth most abundant element in the universe 1,
and the eighth most abundant element in the Earth’s crust. 2
Below you’ll find over two dozen interesting facts about magnesium
— including the history of magnesium, chemical composition, and health
info. on magnesium.
5.2.2 General Magnesium Information
FIGURE 5.2 STRUCTURE OF MAGNESIUM
38
Unstable in its pure state, magnesium typically forms a white coating
of magnesium oxide. In nature, most of its compounds appear as white
crystals. Approximately 320,000 tons of magnesium are extracted annually
for commercial use. 3 Magnesium is commonly extracted from seawater,
where it is the third most common component.
5.2.3 Historic Facts About Magnesium
Magnesium was first discovered outside of the Greek city of

Magnesia.In 1808, Sire Humphrey Davy first isolated several of the alkaline
earth metals, naming them after their oxides as barium, strontium, calcium,
and magnium. Davy derived the term “magnium” from the common name
for magnesium oxide: magnesia. Eventually the term magnesium replaced
the term magnium in general usage.Magnesium was used as a curative as
early as ancient times, in the form of laxatives and Epsom salts.
In the 1600’s, water from the famous Epson spring discovered in

England was a popular curative, used as an internal remedy and purifier of
the blood. In 1695, magnesium sulphate as a salt was isolated from the
Epsom spring water by Nehemia Grew. Marie de Medici, of the famous and
powerful Italian family, described the healing properties of Epsom spring
water as, used by “a great store of citizens” especially by “persons of
quality”.
Richard Willstatter won the Nobel prize in 1915 for describing the
nature of the structure of chlorophyll in plants, noting magnesium as the
central element. Magnesium is regularly used in the acute treatment of
eclampsia during pregnancy and acute myocardial infarction.
39
5.2.4 Magnesium’s Chemical Composition and Related Properties
Magnesium has the atomic number 12 with 12 protons and

approximately 12 neutrons inside its shell, surrounded by 12 electrons
orbiting in three shells, with two valence electrons. The atomic weight of
magnesium is 24.3050. Magnesium’s outer shell has only two electrons out
of the ordinary eight, making it highly reactive. It cannot be found in nature
as an independent compound. In seawater, for example, it is found as the
salt Magnesium Chloride, comprised of one magnesium cation and two
chloride anions.
On the periodic table, magnesium is known as an alkaline earth metal.

Other alkaline earth metals include calcium, beryllium, barium, strontium,
and radium. Strontium and radium are radioactive metals, particularly
dangerous to the body because their similarity to calcium and magnesium
can lead to their uptake and absorption.
5.2.5 Magensium as a metal
Magnesium is the lightest of all the metal elements and is primarily

used in structural alloys due to its light weight, strength, and resistance
to corrosion. There are over 60 different minerals known to have a
magnesium content of 20% or greater, making it the eighth most abundant
element in the earth's crust. But when water bodies are accounted for,
magnesium becomes the most abundant element on the surface of the earth.
That is because of the significant magnesium content in salt water,

which averages about 1290 parts per million (ppm). Yet, despite its
abundance, global magnesium production is only about 757,000 tons per
year.
40
5.2.6 Properties
 Atomic Symbol: Mg
 Atomic Number: 12
 Element Category: Alkaline metal
 Density: 1.738 g/cm3 (20°C)
 Melting Point: 1202 °F (650 °C)
 Boiling Point: 1994 °F (1090 °C)
 Moh's Hardness: 2.5
5.2.7Characteristics
Magnesium's characteristics are similar to its sister metal, aluminum.

It not only has the lowest density of all the metal elements, making it the
lightest, but it is also very strong, highly resistant to corrosion and easily
machinable.
5.2.8 History
Magnesium was discovered as a unique element in 1808 by Sir

Humphrey Davy but not produced by in a metallic form until 1831 when
Antoine Busy made magnesium during an experiment with dehydrated
magnesium chloride. Commercial production of electrolytic magnesium
began in Germany in 1886. The country remained the only producer until
1916 when military demand for magnesium (for flares and tracer bullets) led
to production in the US, Great Britain, France, Canada, and Russia. World
magnesium production dropped off between the wars, although German
production continued in support of Nazi military expansion.
Germany's production increased to 20,000 tons by 1938, accounting

for 60% of global production. In order to catch-up, the US supported 15 new
41
magnesium production facilities, and by 1943, had a capacity of over
265,000 tons of magnesium. After World War II, magnesium production fell
again, as producers struggled to find economical methods to extract the
metal in order to make its price competitive with the cost of aluminum.
5.2.9 Production
Depending upon the location and type of resource being used, a wide
variety of production methods can be used to refine magnesium metal.This
is due to both the fact that magnesium is so abundant, making production in
many locations possible, and that the minor metal's end-use applications are
so price sensitive, so as to encourage buyers to constantly be seeking the
lowest possible cost source.
Traditionally magnesium is produced

from dolomite and magnesite ore, as well as magnesium chloride containing
salt brines (naturally occurring salt deposits).
5.2.10 Applications
Because of its similarities with aluminum, magnesium can be used as

a substitute for many, if not most, aluminum applications. Magnesium is
still, however, limited by its extraction’s costs, which make the metal about
20% more expensive than aluminum. Due to import tariffs on Chinese-
produced magnesium, US magnesium prices can be almost double that of
aluminum.
Over half of all magnesium is used in alloys with aluminum, which

are valued for their strength, lightness, and resistance to sparking, and are
widely used in automobile parts. In fact, various car manufacturers use cast
magnesium-aluminum (Mg-Al) alloys to produce steering wheels, steering
42
columns, support brackets, instrument panels, pedals and inlet manifold
housings, among numerous other parts. Mg-Al die castings are further used
to make transmission and clutch housings.
High strength and corrosion resistance are critical to aerospace alloys,

as well as helicopter and race car gearboxes, many of which rely on
magnesium alloys. Beer and drink cans don't have the same requirements as
aerospace alloys, yet a small amount of magnesium is used in the aluminum
alloy that forms these cans. Despite using only, a small amount of
magnesium per can, this industry is still the largest consumer of the metal.
Magnesium alloys are also used in other industries where light weight
is crucial, such as in chainsaws and machinery parts, and in sporting goods
like baseball bats and fishing reels. Alone, magnesium metal can be used as
a desulphurize in iron and steel production, as a deoxidizer in the thermal
reduction of titanium, zirconium, and hafnium, and as a modularize in the
production of nodular cast iron. Other uses for magnesium are as an anode
for cathodic protection in chemical storage tanks, pipelines, and ships, and
in the production of flare bombs, incendiary bombs, and fireworks.
5.2.11 Environmental effects of magnesium
There is very little information available on the environmental effects

of magnesium oxide fume. If other mammals inhale magnesium oxide fume,
they may suffer similar effects as do humans.
On an environmental spectrum of 0 - 3 Magnesium oxide fume

registers 0.8. A score of 3 represents a very high hazard to the environment
and 0 a negligible hazard. Factors that are taken into account to obtain this
ranking include the extent of the material's toxic or poisonous nature and/or
its lack of toxicity, and the measure of its ability to remain active in the
43
environment and whether it accumulates in living organisms. It does not take
into exposure to the substance.
Magnesium powder is not suspected of being highly harmful to the

environment. As magnesium oxide an aquatic toxicity rating of tlm 1000
ppm has been established. "Water Quality Characteristics of Hazardous
Materials", Hann & Jensen, Enviro. End. Div., Texas A&M, vol. 3 (1974).
5.2.12 Pure magnesium

Burning magnesium produces white light. This makes it ideal for
firework sparklers, flares and flash photography. It also functions as an agent
to produce uranium out of salt. The element’s ions are necessary for every
living organism. That is why magnesium salt is included in fertilizers and
food. In many cases, magnesium bromide is utilized as a sedative.
Magnesium is also used to remove sulfur from iron and steel.
5.2.13 More about compounds
This element has numerous compounds. The most vital commercially
are sulfates, carbonates, chlorides, hydroxides and oxides. These are used in
textile processing, leather tanning, insulation, fertilizers, cosmetics and
ceramics. The citrates of magnesia and magnesium hydroxide are used in
medication. The element can interact with organic halides.
5.2.14 Magnesium alloys
Magnesium alloys are in use around the world in a variety of different
applications. They are a preferred material when looking for weight
reduction without compromising overall strength. The vibration damping
capacity is also beneficial in applications in which the internal forces of
high-speed components must be reduced.
The most common applications are:
 Aircraft and missile components
 Aircraft engine mounts, control hinges, fuel tanks, wings
44
 Automotive wheels, housings, transmission cases, engine blocks
 Bicycles and other sporting equipment
 Equipment for material handling
 Ladders
 Laptops, televisions, cell phones
 Luggage
 Portable power tools, chainsaws, hedge clippers, weed whackers
 Printing and textile machinery
 Steering wheels and columns, seat frames
 Magnesium alloys have also been used as a replacement for some
engineering plastics due to their higher stiffness, high recycling
capabilities and lower cost of production.
5.2.15 Automotive applications

Today's interest in magnesium alloys for automotive applications is
based on the combination of high strength properties and low density. In
automotive applications weight reduction will improve the performance of
a vehicle by reducing the rolling resistance and energy is used in
acceleration, thus reducing fuel consumption and, moreover, a reduction in
the greenhouse gas CO2 can be achieved.
In the 1920s magnesium began to make an appearance in the
automotive industry. The light weight metal began to be used in racing car
adding to their competitive edge. About a decade later, magnesium began to
be used in commercial vehicles such as the Volkswagen Beetle which
contained about 20kg (44.09lbs) of the material. Interest in using magnesium
in automotive applications has increased over the past decade in response to
45
the increasing environmental and legislative influences. Fuel efficiency,
increased performance and sustainability are top-of-mind issues.
The use of magnesium in vehicles can, and does, lower overall weight
and improves each of these conditions. Many large automotive companies
have already replaced steel and aluminum with magnesium in various parts
of their products. Audi, DaimlerChrysler (Mercedes-Benz), Ford, Jaguar,
Fiat and Kia Motors Corporation are just a few of these companies.
Magnesium is currently being used in gearboxes, steering columns and
driver’s air bag housings as well as in steering wheels, seat frames and fuel
tank covers.
The use of magnesium in automotive applications can provide more
than just weight savings. For many years, the desire to identify challenges,
solutions, and opportunities regarding the use of magnesium in vehicles has
been growing. Magnesium usage on the front end of a vehicle provides not
just a lower overall mass for the car, but also allows for the shifting of the
center of gravity towards the rear improving the car’s handling and turning
capabilities. In addition, frequencies that reduce vibration and overall noise
can be achieved through the tuning of magnesium parts. Steel components
in vehicles can be replaced by a single cast piece of magnesium adding to
the strength of the material and allowing for housings to be cast into place.
This castability also requires less tooling and fewer gauges, which lowers
manufacturing costs.
According to the United States Automotive Materials Partnership
(USAMP), it is estimated that by 2020, 350 lbs of magnesium will replace
500 lbs of steel and 130lbs of aluminum per vehicle, an overall weight
reduction of 15%. In turn, this weight saving would lead to fuel savings of
9% to12% without any drastic changes in design. Considering the large
number of vehicles produced worldwide, these weight savings could lead to
a significant drop in the carbon dioxide released into the atmosphere,
46
reducing its harmful impact on global warming. It is for this reason that
magnesium is known as the green metal of the 21st century.
Currently, multiple automobile parts can be made from magnesium
alloys such as engine block, wheels, steering columns, seats, front consoles,
and hoods .
5.2.16 Aerospace applications
Cars, vans and trucks are not the only vehicles that have incorporated
magnesium in their designs. The aerospace industry has a long history of
using the metal in many applications both civil and military. It is critical to
lower the weight of air and space craft, as well as projectiles, if we are to
achieve decreases in emissions and greater fuel efficiency. These changes
will result in lower operational costs as well. Magnesium is an ideal material
for use in these applications, due to limited continuing improvements on
aluminum weight reduction, the high cost of fiber metal laminates, and the
poor impact and damage properties of low density plastics when subjected
to extreme temperatures. Magnesium can be found in the thrust reversers for
the Boeing 737, 747, 757, and 767, as well as in engines and aircraft and
helicopter transmission casings.
Spacecraft and missiles also contain magnesium and its alloys. Lift-
off weight reduction is of high importance in their design and a material is
needed that can withstand the extreme conditions faced during their
operation. Magnesium is capable of withstanding the extreme elevated
temperatures, exposure to ozone and the impact of high energy particles and
matter. It is also used in large quantity in intercontinental ballistic missiles
such as Titan, Atlas and Agena.
5.2.17 Medical Application s

In the 1st half of last century, magnesium was first introduced in the
medical industry as an orthopedic biomaterial. There are many
47
characteristics and properties that make magnesium a very attractive option
for use in implants and similar applications. Other common implant
materials have densities that range from 3.1-9.2g/cm3, whereas the density
of natural bone is 1.8-2.1g/cm3 (112.37-131.10lb/ft3). Magnesium alloys
are much more comparable, at a density of 1.74-2.0g/cm3 (108.62-lb/ft3).
Magnesium is also much more akin to natural bone than other materials in
regards to fracture toughness, elastic modulus and compressive yield
strength. Not only does magnesium provide the mechanical and physical
properties desirable in these applications, it also exhibits some special
characteristics.
Magnesium is found naturally as an ion in the human body equating
to about one mole in a 155lb (70kg) person, half of which is stored within
bone tissue. Magnesium within the body assists in metabolic reactions, has
good biocompatibility, and is nontoxic. In addition, uncoated magnesium
implants can be biodegradable in bodily fluids through corrosion, which
eliminates the need for a further surgery to remove implants. Application of
protective coatings can prevent corrosion issues in situations where a more
permanent solution is needed. Research and testing of different alloys and
formulas for protective finishes is currently in progress with the aim of
increasing the array of ways in which magnesium can be used in medical
applications.
5.2.18 Electronic applications
In the current market, small and portable electronics are trending
upward. The demand for compact devices that can be easily transported is
booming and magnesium is often a key component in meeting this demand.
Many magnesium alloys being used to replace plastics are just as light, but
they are much stronger and more durable. Magnesium is also better in
regards to heat transfer and dissipation as well as its ability to shield
electromagnetic and radio frequency interference. Many electronics require
48
parts or casings with complex shapes which are possible with magnesium.
Cameras, cell phones, laptops and portable media device housings are all
common applications in addition to the arms of hard drives.
5.2.19 Sports applications
Similar to its applications in other industries, magnesium is prized for
use in sports equipment due to its light weight and impact resistance.
Magnesium also has the ability to be formed into intricate shapes, which is
ideal for use in golf clubs, tennis rackets and the handles of archery bows.
The damping effects of the alloys also make it a good candidate for bicycle
frames and the chassis of in-line skates, since the magnesium can absorb
shock and vibration. This absorption allows cyclists to exert less energy and
enjoy a smoother, more comfortable ride. Magnesium vaulting poles have
also come into production as they have minimal twisting due to their high
torsional strain resistance.
5.2.20 Other applications
Magnesium is utilized in optical and hand-held tool design. Wearers
of spectacles often desire an aesthetically pleasing frame that is not felt
during day-to-day wear but is sturdy enough to handle being removed and
replaced throughout the day. Rifle scopes and binoculars must be stable in
order to be effective and a light weight is also beneficial in their
marketability. Magnesium allows for these design criteria to be met.
Hand-held work tools and devices such chain saws, hand shears, hand
drills, pneumatic nail guns and weed whackers are all perfect candidates for
magnesium applications. The low density, comparative strength and
vibration damping capabilities are all desirable characteristics in creation of
handheld tools such as these.
Magnesium has also found its way into small household appliances
such as vacuums. By utilizing this material for a vacuum head, it will be
49
light enough to easily move around as well as being dent resistant in normal
use when coming in contact with furniture and other obstacles.
As the inherent benefits of magnesium applications are further
realized, the ways in which it can and will be used become numerous.
Demand for sustainable, lightweight and recyclable materials is ever
increasing with the push towards environmentally-conscious products,
which can only be beneficial for the magnesium industry.
TABLE 5.2 PROPERTIES OF ALUMINIUM MAGNESIUM ALLOY
By analyzing the above given results for a better mixture composition we

have chosen 5 % Mg for using in poppet valve.
5.3 ABOUT SILICON CARBIDE
Silicon carbide (SiO2) in the form of sharp flints were among the first
tools made by humans. The ancient civilizations used other forms of Silicon
carbide such as rock crystal, and knew how to turn sand into glass.
Considering silicon’s abundance, it is somewhat surprising that it aroused
little curiosity among early chemists.
Attempts to reduce Silicon carbide to its components by electrolysis
had failed. In 1811, Joseph Gay Loussac and Louis Jacques Thenar reacted
silicon tetrachloride with potassium metal and produced some very impure
form of silicon. The credit for discovering silicon really goes to the Swedish
chemist Jöns Jacob Berzelius of Stockholm who, in 1824, obtained silicon
50
by heating potassium fluor Silicon carbide with potassium. The product was
contaminated with potassium silicide, but he removed this by stirring it with
water, with which it reacts, and thereby obtained relatively pure silicon
powder.
Silicon conducts electricity to an extent that depends on the extent to
which impurities are added. The addition of impurities to silicon, or to any
semiconductor material, is called doping. Some impurities produce N-type
silicon, in which the majority charge carriers are negatively
charged electron s. Other impurities result in the production of P-type
silicon, in which the majority charge carriers are positively charged wholes.
Most silicon devices contain both N-type and P-type material.
5.3.1 Silicon's Multitude of Uses
One of the most important properties of silicon is that it's

a semiconductor, meaning its ability to conduct electricity is better than an
insulator (like sulfur) but not as good as a conductor (like copper). When
pure silicon is infused with other elements (called impurities) such as boron
or phosphorous, the number of available electrons in the mix changes. This
process is called doping.
Through the use of doping and the creation of junctions between

differently doped silicon regions, nearly any electronic circuit component
can be produced from silicon on an integrated circuit (or IC) chip. This
includes diodes, transistors, resistors, capacitors, insulators, and even highly
conducting paths that can replace expensive metals such as gold. IC chips
are produced on a round wafer of silicon
SYMBOL Si
ATOMIC NUMBER 14
ATOMIC MASS 28.0855

51
FAMILY Group 14 (IVA) Carbon
5.3.2 Physical properties
Silicon is a metalloid, an element with properties of both metals and

non-metals. Silicon exists in two allotropic forms. Allotropes are forms of
an element with different physical and chemical properties. One allotrope is
in the form of shiny, grayish-black, needle-like crystals, or flat plates. The
second allotrope has no crystal structure and usually occurs as a brown
powder.
The melting point of silicon is 1,410°C (2,570°F) and the boiling point
is 2,355°F (4,270°F). Its density is 2.33 grams per cubic centimeter. Silicon
has a hardness of about 7 on the Mohs scale. The Mohs scale is a way of
expressing the hardness of a material. It runs from 0 (for talc) to 10 (for
diamond).
Silicon is a semiconductor. A semiconductor is a substance that

conducts an electric current better than a non-conductor—like glass or
rubber—but not as well as a conductor—
like copper or aluminum. Semiconductors have important applications in
the electronics industry.
5.3.3 Chemical properties
Silicon is a relatively inactive element at room temperature. It does

not combine with oxygen or most other elements. Water, steam, and most
acids have very little affect on the element. At higher temperatures, however,
silicon becomes much more reactive. In the molten (melted) state, for
example, it combines with oxygen, nitrogen, sulfur, phosphorus, and
52
other elements. It also forms a number of alloys very easily in the molten
state.
5.3.4 Occurrence in nature
Silicon is the second must abundant element in the Earth's crust. Its
abundance is estimated to be about 27.6 percent of the crust. It ranks second
only to oxygen. Some authorities believe that more than 97 percent of the
crust is made of rocks that contain compounds of silicon and oxygen.
Silicon has been detected in the Sun and stars. It also occurs in certain
types of meteorites known as aerolites or "stony meteorites." Meteorites are
rock-like chunks that fall to the Earth's surface from outside the Earth's
atmosphere.
Silicon never occurs as a free element in nature. It always occurs as a

compound with oxygen, magnesium, calcium, phosphorus, or other
elements. The most common minerals are those that contain silicon
dioxide in one form or another. These are known as Silicon carbidetes.
Silicon has been detected in the Sun and stars. It also occurs in certain
types of meteorites.
5.3.5 Isotopes
There are three naturally occurring isotopes of silicon: silicon-28,

silicon-29, and silicon-30. Isotopes are two or more forms of an element.
Isotopes differ from each other according to their mass number. The number
written to the right of the element's name is the mass number. The mass
number represents the number of protons plus neutrons in the nucleus of an
atom of the element. The number of protons determines the element, but the
53
number of neutrons in the atom of any one element can vary. Each variation
is an isotope.
Five radioactive isotopes of silicon are known also. A radioactive

isotope is one that breaks apart and gives off some form of radiation.
Radioactive isotopes are produced when very small particles are fired at
atoms. These particles stick in the atoms and make them radioactive.
None of the radioactive isotopes of silicon has any commercial use.
5.3.6 Extraction
Silicon is prepared by heating silicon dioxide with carbon. Carbon

replaces the silicon in the compound. The silicon formed is 96 to 98 percent
pure.
Many applications of silicon require a very pure product. Methods

have been developed to produce silicon that is at least 99.97 percent pure
silicon. This form of silicon is called hyper-pure silicon.
5.3.7 Uses
Perhaps the best known use of silicon is in electronic devices.

Hyperpure silicon is used in transistors and other components of electronic
devices. It is also used to make photovoltaic (solar) cells, rectifiers, and parts
for computer circuits. A photovoltaic cell is a device that converts sunlight
into electrical energy. A rectifier is an electrical device for changing one
kind of electric current (alternating current, or AC) into another kind of
electric current (direct current, or DC). Almost without exception, all glass
contains silicon dioxide.
The largest single use of silicon, however, is in making alloys. The

most important silicon alloys are those made with iron and steel, aluminum,
and copper. When silicon is produced, in fact, scrap iron and metal is
54
sometimes added to the furnace. As soon as the silicon is produced, it reacts
with iron and steel to form ferrosilicon. Ferrosilicon is an alloy of iron or
steel and silicon. It is used for two major purposes. First, it can be added to
steel to improve the strength and toughness of the steel. Second, it can be
added during the steel-making process to remove impurities from the steel
that is being made.
The aluminum industry uses large amounts of silicon in alloys. These

alloys are used to make molds and in the process of welding. Welding is a
process by which two metals are joined to each other. Alloys of silicon,
aluminum, and magnesium are very resistant to corrosion (rusting). They are
often used in the construction of large buildings, bridges, and transportation
vehicles such as ships and trains.
5.3.8 Compounds
A number of silicon compounds have important uses. Silicon dioxide

(sand) is used in the manufacture of glass, ceramics, abrasives, as a food
additive, in water filtration systems, as an insulating material, in cosmetics
and Pharmaceuticals (drugs), and in the manufacture of paper, rubber, and
insecticides. Each of these applications could be the subject of a very long
discussion in and of itself. For example, humans have made glass for
thousands of years. Today, dozens of different kinds of glass are produced,
each with special properties and uses. But almost without exception, they all
contain silicon dioxide.
Another important compound is silicon carbide (SiC). Silicon carbide

is also known as carborundum. It is one of the hardest substances known,
with a hardness of about 9.5 on the Mohs scale. Carborundum is widely used
as an abrasive, a powdery material used to grind or polish other materials.
Carborundum also has refractory properties. A refractory material can
55
withstand very high temperatures by reflecting heat. Refractory materials
are used to line the inside of ovens used to maintain very high temperatures.
Another important silicon group is the silicones. The silicones have

an amazing range of uses. These include toys (Silly Putty and Superballs),
lubricants, weatherproof!ng materials, adhesives (glues), foaming agents,
brake fluids, cosmetics, polishing agents, electrical insulation, materials to
reduce vibration, shields for sensitive equipment, surgical implants, and
parts for automobile engines.
5.3.9 Health effects
Information on the health effects of silicon is limited. Some studies

show that silicon may be needed in very small amounts by plants and some
animals. One study showed, for example, that chickens that did not receive
silicon in their diet developed minor health problems. Overall, silicon
probably has no positive or negative effects on human health.
However, a serious health problem called silicosis is associated with

silicon dioxide (SiO 2 ). Silicon dioxide occurs in many forms in the earth.
Ordinary sand is nearly pure silicon dioxide.
In some industries, sand is ground up into a very fine powder that gets
into the air. As workers inhale the dust, it travels through their mouths, down
their throats, and into their lungs. Silicon dioxide powder can block the tiny
air passages in the lungs through which oxygen and carbon dioxide pass.
When this happens, silicosis results.
Silicosis is similar to pneumonia. The person finds it difficult to

breathe. The longer one is exposed to silicon dioxide dust, the worst the
problem gets. In the worst cases, silicosis results in death because of the
inability to breathe properly.
56
5.3.10SiliconCarbide
The silicon carbide has the advantages of stable chemical property,
high thermal conductivity, small coefficient of thermal expansion and good
abrasionresistance.
Made of advanced refractory materials, heat shock, small size, light
weight and high strength, energy saving effect.
Low grade silicon carbide (containing about 85% SiC) is an excellent
deoxidizer, which can speed up the steelmaking process, and facilitate the
control of chemical composition, improve the quality of steel.
TABLE 5.3 PROPERTIES OF ALUMINIUM SILICON CARBIDE
PURPOSE OF USING ALUMINIUM ALLOY (SILICON CARBIDE)
The current generation focus mainly on composite materials by

replacing existing high dense materials like steel, cast iron, wrought iron etc.
These alloy materials are creating greater impact in material science.
5.4 ABOUT GREY CAST IRON
57
Grey cast iron (a.k.a. gray iron castings) is a type of iron found in
castings known for its grey color and appearance caused by graphite
fractures in the material. Specifically, what makes grey iron “grey iron,” is
the graphite flake structure that is created during the cooling process from
the carbon that is in the component.
Grey iron is a result of both the materials used and the process used
to cast a part. In other words, the properties of the grey iron will change
depending on what materials are melted together to pour into the mold as
well as the process that is used for casting (it is primarily the cooling part of
the process that defines the characteristics of the cast part versus other parts
of the process.).
FIGURE 5.3 Grey Iron Magnified to Show the Flakes of

Graphite
If you use a powerful microscope you can see the graphitic

microstructure that makes grey iron so easily identifiable. In a grey iron
casting, you can see little black flakes of graphite. These flakes cause
fractures and cause the material to have a grey appearance. The mechanical
properties of grey iron are controlled by the size and shape of the graphite
flakes present in the microstructure and can be characterized according to
the guidelines given by the ASTM.
58
There are more pounds of grey iron castings produced every year
throughout the world than any other type of casting. Just about every
manhole cover is from grey iron and the disc brakes on your car are most
likely grey iron as well. Other common uses for grey iron include:
 Gears
 Hydraulic components
 Automotive suspension components
 Plow shares
 Pumps
 Linkages
 Stove parts
 Steering knuckles
 Tractor parts
 Valves
 Truck suspension components
 Other truck parts
 Wind turbine housings.
 Weights and counter-weights
 Machinery bases
The popularity of grey cast iron components (gray iron castings) is
because grey iron is one of the cheapest types of iron castings to produce. It
has acceptable ductility, tensile strength, yield strength, and impact
resistance for most applications. Grey Iron is also excellent in its ability to
dampen vibrations making it ideal for machinery bases and as well as many
housing applications. Grey iron has high thermal conductivity meaning it
moves heat more easily through the metal.
A final benefit of grey iron castings is its ability to withstand thermal

cycling well. Thermal cycling is where the component goes back and forth
59
between warmer and colder temperatures. While thermal cycling can create
stress and premature failure in some types of metal castings, grey iron has
proven to endure the strain of thermal cycling quite well and not stress as
easily.
While grey cast iron has less tensile strength and shock resistance than
most other castings or even steal, it has compressive strength that is
comparable to low- and medium-carbon steel. These mechanical properties
are controlled by the size and shape of the graphite flakes present in the
microstructure.
5.4.1 Composition of Gray Cast Iron

Just like all cast iron parts, the primary component of Grey Iron is
going to be the iron (no surprise there, right?). Just like most other cast
irons, it also has 2.5–4.0% carbon and 1–3% silicon. If you look at Chart 2
you will notice that the composition of the iron is very close to other
common cast parts, but with a little more phosphorus.
60
TABLE 5.4 PROPERTIES OF GRAY CAST IRON
Iron Family Gray Ductile CGI Malleable White
Carbon 2.5-4.2 3.0-4.0 2.5-4.0 2.2-2.8 1.8-3.6
Silicon 1.0-3.0 1.8-3.0 1.5-3.0 1.2-1.9 0.5-2.0
Manganese 0.15-1.0 0.1-1.0 0.10-1.0 0.15-1.2 0.15-0.8
Sulfur 0.02-0.25 0.01-0.03 0.01-0.03 0.02-0.2 0.02-0.2
Phosphorus 0.02-1.0 0.01-0.1 0.01-0.1 0.02-0.2 0.02-0.2
5.4.2 Microstructure of Grey Cast Iron

Grey iron has graphite flakes entwined with the rest of the structure.
Unhardened grey iron is “fragile” compared to other cast metals. The
graphite flakes create areas of weakness in the metal where fractures can
begin that will split the metal. This propensity to fracture is why grey iron
has low tensile and impact strength. Yet the graphite flakes are what create
great wear resistance because as friction occurs the graphite acts as a
lubricant. The graphite structure also has great vibration dampening
properties because the structure created by the graphite flakes helps cancel
out vibrations.
5.4.3 Classification of Grey Iron Classes

In the United States, the classification for grey iron is usually set using
the ASTM International standard A48. ASTM A247 is also commonly used
to describe the graphite structure. Grey iron is grouped into classes which
correspond with its minimum tensile strength in thousands of pounds per
square inch (ksi); (i.e. class 20 grey iron has a minimum tensile strength of
61
20,000 psi (140 MPa)). Other ASTM standards that deal with gray iron
include ASTM A126, ASTM A278, and ASTM A319.
Class 20 grey iron has a ferrite matrix and a high carbon equivalent.
Higher strength gray irons, up to class 40, have lower carbon equivalents
and a pearlite matrix. To get grey iron above class 40 requires alloying to
provide solid solution strengthening. Grey iron can also be heat treated
which modifies the matrix giving the cast iron greater strength. Class 80 is
the highest class available for grey iron and it makes the iron have high
tensile strength but low impact resistance because class 80 parts are more
brittle.
5.4.4 G1800 CAST IRON AND CAST STEEL TO A 159 (2011)

G1800 - Specification & Application
A 159 (2011) - Automotive Gray Iron Castings
Used in the products of the automobile, truck, tractor, and allied

industries. Miscellaneous soft iron castings (as cast or annealed) in which
strength is not of primary consideration. Exhaust manifolds may be made of
this grade of iron, alloyed or unalloyed
FIGURE 5.5 ALLOY COMPOSITION
62
5.4.5 MECHANICAL PROPERTIES
Brinell Hardness -160
Elastic modulus – 180GPA
Poissons Ratio -0.29
Shear Modulus -69GPA
Ultimate Tensile Strength -140MPA
Yield Tensile strength – 94MPA
5.4.6 THERMAL PROPERTIES
Latent heat of fusion – 280 J/g
Melting completion -1380 c
Melting onset (solidus) -1340 c
Specific Heat Capacity – 490 J/kg K
Thermal Conductivity -43 W/m K
Thermal expansion -13 um/m K
5.4.7 ELECTRICAL PROPERTIES
Electrical Conductivity: Equal volume – 7.4 % IACS.
Electrical Conductivity: Equal Weight (Specific) -8.9 %IACS
5. 5 ABOUT TITANIUM
63
Titanium is a chemical element with the symbol Ti and atomic
number 22. Found in nature only as an oxide, it can be reduced to produce a
lustrous transition metal with a silver color, low density, and high strength,
resistant to corrosion in sea water, aqua regia, and chlorine. Titanium was
discovered in Cornwall, Great Britain, by William Gregor in 1791 and was
named by Martin Heinrich Klaproth after the Titans of Greek mythology.
The element occurs within a number of mineral deposits, principally rutile
and ilmenite, which are widely distributed in the Earth's crust and
lithosphere; it is found in almost all living things, as well as bodies of water,
rocks, and soils.[6] The metal is extracted from its principal mineral ores by
the Kroll[7] and Hunter processes. The most common compound, titanium
dioxide, is a popular photocatalyst and is used in the manufacture of white
pigments.[8] Other compounds include titanium tetrachloride (TiCl4), a
component of smoke screens and catalysts; and titanium trichloride (TiCl3),
which is used as a catalyst in the production of polypropylene.[6] Titanium
can be alloyed with iron, aluminium, vanadium, and molybdenum, among
other elements, to produce strong, lightweight alloys for aerospace (jet
engines, missiles, and spacecraft), military, industrial processes (chemicals
and petrochemicals, desalination plants, pulp, and paper), automotive,
agriculture (farming), medical prostheses, orthopedic implants, dental and
endodontic instruments and files, dental implants, sporting goods, jewelry,
mobile phones, and other applications.[6] The two most useful properties
of the metal are corrosion resistance and strength-to-density ratio, the
highest of any metallic element.[9] In its unalloyed condition, titanium is as
strong as some steels, but less dense.[10] There are two allotropic forms[11]
and five naturally occurring isotopes of this element, 46Ti through 50Ti,
with 48Ti being the most abundant (73.8%).
64
CHAPTER 6
ABOUT CATIA
6.1 INTRODUCTION TO CAD/CAM/CAE
The Modern world of design, development, manufacturing so on, in
which we have stepped can’t be imagined without interference of computer.
The usage of computer is such that, they have become an integral part of
these fields. In the world market now the competition in not only cost factor
but also quality, consistency, availability, packing, stocking, delivery etc. So
are the requirements forcing industries to adopt modern technique rather
than local forcing the industries to adapt better techniques like CAD / CAM
/ CAE, etc.
The Possible basic way to industries is to have high quality products
at low costs is by using the computer Aided Engineering (CAE), Computer
Aided Design (CAD) And Computer Aided Manufacturing (CAM) set up.
Further many tools is been introduced to simplify & serve the requirement
CATIA, PRO-E, UG are some among many.
This penetration of technique concern has helped the manufacturers to
a) Increase productivity
b) Shortening the lead-time
c) Minimizing the prototyping expenses
d) Improving Quality
e) Designing better products
CAD: Computer Aided Designing (Technology to create, Modify, Analyze

or Optimize the design using computer.
CAE: Computer Aided Engineering (Technology to analyze, Simulate or
Study behavior of the cad model generated using computer.
CAM: Computer Aided Manufacturing (Technology to Plan, manage or
65
control the operation in manufacturing using computer.
6.1.1 NEED FOR CAD, CAE & CAM

time with better quality and consistency . In general view, it has lead
to fast approach and creative thinking. The usage of CAD CAE & CAM
have changed the over look of the industries and developed healthy &
standard competition , as could achieve target in lean time and ultimately
the product reaches market in estimated
6.1.2 ADVANTAGES
Cut off of the designing time
Cut off of the editing time
Cut off of the manufacturing time
High & controlled quality
Reduction of process cost.
Maintenance of Universal accessing data
6.1.3 DRAWBACKS
 Requires skilled operators
 Initial setting & assumption consumes time o Setting cost is more
 Over heads are high and
 Applicable if production is high
6.2 INTRODUCTION TO CATIA
CATIA is a robust application that enables you to create rich and
complex designs. The goals of the CATIA course are to teach you how to
build parts and assemblies in CATIA, and how to make simple drawings
of those parts and assemblies. This course focuses on the fundamental
skills and concepts that enable you to create a solid foundation for your
designs
6.2.1 WHAT IS CATIA
CATIA is mechanical design software. It is a feature-based,
66
parametric solid modeling design tool that takes advantage of the easy-to-
learn Windows graphical user interface. You can create fully associative3D
solid models with or without constraints while utilizing automatic or user-
defined relations to capture design intent. To further clarify this definition,
the italic terms above will be further defined:
6.2.2 Feature-based
Like an assembly is made up of a number of individual parts, a
CATIA document is made up of individual elements. These elements are
called features.
When creating a document, you can add features such as pads,
pockets, holes, ribs, fillets, chamfers, and drafts. As the features are created,
they are applied directly to the work piece.
6.2.3 Features can be classified as sketched-based or dress-up
Sketched-based features are based on a 2D sketch. Generally, the
sketch is transformed into a 3D solid by extruding, rotating, sweeping, or
lofting.
Dress-up features are features that are created directly on the solid
model. Fillets and chamfers are examples of this type of feature.
6.2.4 Solid Modeling:-
A solid model is the most complete type of geometric model used in
CAD systems. It contains all the wireframe and surface geometry necessary
to fully describe the edges and faces of the model. In addition to geometric
information, solid models also convey their ―topology‖, which relates the
geometry together. For example, topology might include identifying which
faces (surfaces) meet at which edges (curves). This intelligence makes
adding features easier. For example, if a model requires a fillet, you simply
select an edge and specify a radius to create it.
6.2.5 Fully Associative:-
A CATIA model is fully associative with the drawings and parts or
67
assemblies that reference it. Changes to the model are automatically
reflected in the associated drawings, parts, and/or assemblies. Likewise,
changes in the context of the drawing or assembly are reflected back in the
model.
6.2.6 Constraints:-
Geometric constraints (such as parallel, perpendicular, horizontal,
vertical, concentric, and coincident) establish relationships between features
in your model by fixing their positions with respect to one another. In
addition, equations can be used to establish mathematical relationships
between parameters. By using constraints and equations, you can guarantee
that design concepts such as through holes and equal radii are captured and
maintained.
6.3 CATIA User Interface:
Below is the layout of the elements of the standard CATIA application.
A. Menu Commands
B. Specification Tree
C. Window of Active document
D. Filename and extension of current document
E. Icons to maximize/minimize and close window
F. Icon of the active workbench
G. Toolbars specific to the active workbench
H. Standard toolbar
I. Compass
J. Geometry area
Different types of engineering drawings, construction of solid models,
assemblies of solid parts can be done using inventor.
Different types of files used are:
1. Part files: .CATPart
2. Assembly files: .CATProduct
68
6.4 WORKBENCHES
Workbenches contain various tools that you may need to access
during your part creation shown in figure6.1 . You can switch between any
primary workbenches using the following two ways:
FIGURE 6.1
GENERALLY ALL CAD MODELS ARE GENERATED IN THE
SAME PASSION GIVEN BELOW
: Enter CAD environment by clicking, later into part

designing mode to construct model.
: Select plane as basic reference.
: Enter sketcher mode.
69
IN SKETCHER MODE
: Tool used to create 2-d basic structure of

part using line, circle etc
: Tool used for editing of created geometry

termed as operation
: Tool used for Dimensioning, referencing. This

helps creating parametric relation.
: Its external feature to view geometry

in & out
: Tool used to exit sketcher mode after creating geometry.
Sketch Based Feature :
Pad : On exit of sketcher mode the feature is to be padded .( adding

material)
Pocket: On creation of basic structure further pocket has to be

created (removing material )
Revolve: Around axis the material is revolved, the structure should

has same profile around axis.
Rib: sweeping uniform profile along trajectory (adding material)
Slot: sweeping uniform profile along trajectory (removing material)
70
Loft: Sweeping non-uniform/uniform profile on different plane along
linear/non-linear trajectory
: Its 3d creation of features creates chamfer,

radius, draft, shell etc,.
: Its tool used to move geometry, mirror, pattern,
scaling in 3d environment On creation of individual
parts in separate files,
Assembly environment: In assembly environment the parts are

recalled & constrained..
Product structure tool: To recall existing components already modeled.
: Assembling respective parts by mean of constraints
Update: updating the made constrains.

Additional features are: Exploded View, snap shots, clash analyzing
numbering, bill of material etc. Finally creating draft for individual parts &
assembly with possible details
The parts of the major assembly is treated as individual geometric
model , which is modeled individually in separate file .All the parts are
previously planned & generated feature by feature to construct full model
Generally all CAD models are generated in the same passion given
bellow :
: Enter CAD environment by clicking, later into part designing

mode to construct model.
: Select plane as basic reference.
71
: Enter sketcher mode.
6.5 IN SKETCHER MODE
for editing of created geometry termed as

operation
: Tool used for Dimensioning, referencing. This

helps creating parametric relation.
: Tool used to exit sketcher mode after creating geometry.

SKETCH BASED FEATURE
Pad: On exit of sketcher mode the feature is to be padded. (Adding

material)
Pocket: On creation of basic structure further pocket has to be created

(removing material)
Revolve: Around axis the material is revolved, the structure should

have same profile around axis.
Rib: sweeping uniform profile along trajectory (adding material)
Slot: sweeping uniform profile along trajectory (removing material)
Loft: Sweeping non-uniform/uniform profile on different plane along

linear/non-linear trajectory.
: Its 3d creation of features creates chamfer,

radius, draft, shell, thread.
: Its tool used to move geometry, mirror, pattern,

72
scaling in 3d environment.
6.6 2D DESIGN IMAGES
FIGURE 6.2 2D design of poppet valve
73
FIGURE 6.3 3D design using CATIA V5 R20
74
CHAPTER 7
7.1 ABOUT ANSYS
ANSYS is a general purpose software, used to simulate interactions
of all disciplines of physics, structural, vibration, fluid dynamics, heat
transfer and electromagnetic for engineers.
FIGURE 7.1 WORKBENCH

So ANSYS, which enables to simulate tests or working conditions,
enables to test in virtual environment before manufacturing prototypes of
products as shown in figure 7.1 . Furthermore, determining and improving
weak points, computing life and foreseeing probable problems are possible
by 3D simulations in virtual environment.
ANSYS software with its modular structure as seen in the table below
gives an opportunity for taking only needed features. ANSYS can work
integrated with other used engineering software on desktop by adding CAD
75
and FEA connection modules.
ANSYS can import CAD data and also enables to build a geometry
with its "preprocessing" abilities. Similarly in the same preprocessor, finite
element model (a.k.a. mesh) which is required for computation is generated.
After defining loadings and carrying out analyses, results can be viewed as
numerical and graphical.
ANSYS can carry out advanced engineering analyses quickly, safely

and practically by its variety of contact algorithms, time based loading
features and nonlinear material models.
In engineering applications, heat is generally transferred from one

location to another and between bodies. This transfer is driven by differences
in temperature (a temperature gradient) and goes from locations of high
temperature to those with low temperature.
These temperature differences, in turn, cause mechanical stresses

and strains in bodies due to their coefficient of thermal expansion, α
(sometimes abbreviated CTE in engineering literature)
The amount of heat transfer is directly proportional to the size of

the temperature gradient and the thermal resistance of the material(s)
involved
In engineering applications, there are three basic mechanisms:
1. Conduction
2. Convection
3. Radiation
ANSYS Workbench is a platform which integrate simulation

76
technologies and parametric CAD systems with unique automation and
performance as shown in figure a.. The power of ANSYS Workbench
comes from ANSYS solver algorithms with years of experience.
Furthermore, the object of ANSYS Workbench is verification and
improving of the product in virtual environment.
FIGURE A
ANSYS Workbench, which is written for high level compatibility with

especially PC, is more than an interface and anybody who has an ANSYS
license can work with ANSYS Workbench as shown in figure7.2. As same
as ANSYS interface, capacities of ANSYS Workbench are limited due to
possessed license as shown in figure 7.3.
77
FIGURE7.2 IMPORTED IN ANSYS WORKBENCH 18.1
FIGURE7.3 MESHING OF POPPET VALVE
TABLE 7.1
Nodes FIGURE7.2
Elements 535
78
FIGURE7.4 FORCE APPLIED IN POPPET VALVE
7.2 STATIC STRUCTURAL RESULTS OF STEEL POPPET
VALVE
79
FIGURE7.6 TOTAL DEFORMATION OF STEEL POPPET VALVE
80
FIGURE7.8 MAXIMUM PRINCIPAL STRESS OF STEEL
POPPETVALVE
81
FIGURE7.9. EQUIVALENT STRESS OF STEEL POPPET VALVE
82
7.3 STATIC STRUCTURAL RESULTS OF ALUMINIUM SIC
POPPET VALVE
FIGURE7.10 TOTAL DEFORMATION OF ALUMINIUM SIC

POPPET VALVE
83
FIGURE7.11. MAXIMUM PRINCIPAL STRESS OF ALUMINIUM
SIC POPPET VALVE
84
FIGURE7.12 EQUIVALENT STRESS OF ALUMINIUM SIC
POPPET VALVE
85
7.4 STATIC STRUCTURAL RESULTS OF ALUMINIUM
MAGNESIUM POPPET VALVE
FIGURE7.13 TOTAL DEFORMATION OF ALUMINIUM

86
FIGURE7.14 MAXIMUM PRINCIPAL STRESS OF MAGNESIUM
POPPET VALVE
87
FIGURE7.15 EQUIVALENT STRESS OF MAGNESIUM POPPET
VALVE
88
7.5 STAIC STRUCTURAL ANALYSIS OF POPPET VALVE USING
GREY CAST IRON
FIGURE7.16 TOTAL DEFORMATION OF GREY CAST IRON POPPET

VALVE
89
FIGURE7.17 MAX PRINCIPAL STRESS OF POPPET VALVE USING GREY
CAST IRON
90
FIGURE7.18 EQUIVALENT STRESS OF POPPET VALVE USING
GREY CAST IRON
91
7.6 STATIC STRUCTURAL ANALYSIS OF POPPET VALVE
USING TITANIUM ALLOY
FIGURE7.19 TOTAL DEFORMATION OF POPPET VALVE

USING TITANIUM ALLOY
92
MAXIMUM PRINCIPAL STRESS OF POPPET VALVE USING
TITANIUM ALLOY
FIGURE7.20 MAXIMUM PRINCIPAL STRESS OF POPPET

VALVE USING TITANIUM ALLOY
93
FIGURE7.21 EQUIVALENT STRESS OF POPPET VALVE USING
TITANIUM ALLOY
94
7.8 STATIC STRUCTURAL RESULTS OF POPPET VALVE
TABLE 7.1 RESULT COMPARISON
95
CHAPTER 8
THERMAL ANALYSIS
8.1 THERMAL ANALYSIS RESULTS OF POPPET VALVE
FIGURE 8.1 TEMPERATURE AND CONVESTION

APPLIED
96
8.2 THERMAL ANALYSIS OF POPPET VALVE USING STEEL
FIGURE 8.2 TEMPERATURE DISTRIBUTION OF STEEL

POPPET VALVE
FIGURE 8.3 TOTAL HEAT FLUX OF STEEL POPPET VALVE
FIGURE 8.4 DIRECTIONAL HEAT FLUX OF STEEL POPPET

VALVE
97
8.3 THERMAL ANALYSIS RESULTS OF ALUMINIUM POPPET
VALVE
FIGURE 8.5 TEMPERATURE DISTRIBUTION OF AL

POPPET VALVE
FIGURE 8.6 TOTAL HEAT FLUX OF STEEL AL POPPET

VALVE
FIGURE 8.7 DIRECTIONAL HEAT FLUX OF AL POPPET

VALVE
98
8.4 THERMAL ANALYSIS RESULTS OF MAGNESIUM POPPET
VALVE
FIGURE 8.8 TEMPERATURE DISTRIBUTION OF

FIGURE 8.9 TOTAL HEAT FLUX OF MAGNESIUM

POPPET VALVE
FIGURE 8.10 DIRECTIONAL HEAT FLUX OF MAGNESIUM

POPPET VALVE
99
8.5 THERMAL ANALYSIS OF POPPET VALVE USING GREY
CAST IRON
FIGURE 8.11 TEMPERATURE DISTRIBUTION OF GREY CAST

IRON POPPET VALVE
FIGURE 8.12 TOTAL HEAT FLUX OF GREY CAST IRON

POPPET VALVE
FIGURE 8.13 DIRECTIONAL HEAT FLUX OF GREY CAST

IRON POPPET VALVE
100
8.6 THERMAL ANALYSIS OF POPPET VALVE USING
TITANIUM
FIGURE 8.14 TEMPERATURE DISTRIBUTION OF

TITANIUM POPPET VALVE
FIGURE 8.15 TOTAL HEAT FLUX OF TITANIUM

POPPET VALVE
FIGURE 8.16 DIRECTIONAL HEAT FLUX OF TITANIUM

POPPET VALVE
101
8.7 COMPARISON RESULTS OF THERMAL ANALYSIS POPPET
VALVE
TABLE 8.1 RESULT COMPARISON
102
CHAPTER 9
CONCLUSION
9.1 SUMMARY
From the above table 8.1 comparison of poppet valve with different
material of structural steel , aluminum silicon carbide , magnesium ,grey cast
iron material, titanium alloy we analyze the static structural analysis and
thermal analysis so we shown in figure7.1- 8.17 conclude that the static
structural analysis of poppet valve that aluminum silicon carbide gives an
better results compared to other material in thermal analysis the titanium
alloy material gives an better results compared other material
103
9.2 REFERENCES
Transport, Vol.14, Lucjan Witek, ¯Failure and thermo-mechanical stress

analysis of the exhaust valve of diesel engine‖ .Engineering Failure Analysis
66 (2016) 154–165. [
S. M. Jafari, H.Mehdigholi, and M.Behzad ¯Valve Fault Diagnosis in

Internal Combustion Engines Using Acoustic Emission and Artificial
Neural Network‖Hindawi Publishing Corporation Shock and Vibration
Volume 2014, Article ID 823514, 9 pages
Kum-Chul, Oh et.al. ¯A Study of Durability Analysis Methodology for

Engine Valve Considering Head Thermal Deformation and Dynamic
Behaviour‖ Of R & D Center, Hyundai Motor Company, at 2014 SIMULIA
Community
Yuvraj K Lavhal & Prof. Jeevan SS Overview of Failure Trend of Inlet &
Exhaust Valve‖ at International Journal of Mechanical Engineering and
Technology (IJMET), ISSN 0976 – 6340(Print), ISSN 0976 – 6359(Online),
Volume 5, Issue 3, March (2014), pp. 104-113.
B.E.Gajbhiye, V.V.Bhoyar, S.B.Chawale, R.S.Ambade¯Vibration Testing

and Performance Analysis of IC Exhaust Valve Using Finite Element
Technique‖ at International Journal of Research in Advent Technology, E-
ISSN: 2321-9637Vol.2, No.2, February 2014.
Naresh Kr. Raghuwanshi et.al. ¯Failure Analysis of Internal Combustion

Engine Valves: A Review‖ by International Journal of Innovative Research
104
in Science, Engineering and Technology ISSN: 2319 – 8753 Vol. 1, Issue 2,
and December 2012.
Sanoj T. & S. Balamurugan ¯Thermo Mechanical Analysis of Engine Valve‖

at International Journal of Science and Research (IJSR) ISSN (Online):
2319-7064, Volume 3 Issue 5, May 2014.
A. S. More & S P. Deshmukh¯Analysis of Valve Mechanism – A Review‖

at International Journal IOSR Journal of Mechanical and Civil Engineering
(IOSR-JMCE) ISSN (e): 2278 1684, ISSN (p): 2320–334X, PP: 06-09.
H. J. C. Voorwalda, R. C. Coisse, M. O. H. Cioffi¯Fatigue Strength of

X45CrSi93 stainless steel applied as internal combustion engine valves‖
Procedia Engineering 10 (2011) 1256–1261.
P. Forsberg, S. Jacobson P. Hollman, ¯Wear mechanism study of exhaust

valve system in modern heavy duty combustion engines ¯Wear 271 (2011)
2477– 2484.
105
106

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STATIC STRUCTURAL AND THERMAL

ANALYSIS OF POPPET VALVE IN IC

ME8811- A PROJECT REPORT

in partial fulfilment for the award of the degree

SARANATHAN COLLEGE OF ENGINEERING

ANNA UNIVERSITY: CHENNAI 600 025

Certified that this project report “STATIC STRUCTURAL AND

INTERNAL EXAMINER EXTERNALEXAMINER

Poppet valve is a precision engine component which blocks gas flow

Keywords: Poppet Valve, Valve Head, Ic Engine

LIST OF FIGURES xii

1.1 POPPET VALVE 2

2.2 LITERATURE REVIEW 4

2.4 NEED FOR PRESENT WORK 13

4.1 ABOUT POPPET VALVE 16

4.2 MATERIALS USED FOR COMPARISON 17

5.1 ABOUT STEEL 18

5.1.3 Carbon Steels 19

5.1.4 Alloy Steels 20

5.1.5 Stainless Steels 20

5.1.6 Manufacturing Process of Steel 22

5.2 ABOUT MAGNESIUM 25

5.2.1 About Magnesium 25

5.2.2 General Magnesium Information 26

5.2.3 Historic Facts About Magnesium 26

5.2.4 Magnesium’s Chemical Composition 27

And Related Properties

5.2.5 Magnesium as A Metal 28

5.2.11 Environmental Effects of Magnesium 31

5.2.13 More About Magnesium 32

5.2.14 Magnesium Alloys 32

5.2.15 Automotive Applications 33

5.2.16 Aerospace Applications 35

5.2.17 Medical Applications 36

5.2.18 Electronic Applications 37

5.2.19 Sports Applications 37

5.2.20 Other Applications 37

5.3 ABOUT SILICON CARBIDE 39

5.3.1 Silicon’s Multitude of Uses 40

5.3.2 Physical Properties 41

5.3.3 Chemical Properties 41

5.3.4 Occurrance In Nature 41

5.3.9 Health Effects 45

5.3.10 Silicon Carbide 46

5.4 ABOUT GREY CAST IRON 47

5.4.1 Composition of Grey Cast Iron 49

5.4.2 Microstructure of Grey Cast Iron 50

5.4.3 Classification of Grey Cast Iron Classes 50

5.4.5 Mechanical Properties 52

5.4.6 Thermal Properties 52

5.4.7 Electrical Properties 53

6.1 INTRODUCTION TO CAD/CAM/CAE 54

6.1.1 Need for CAD, CAM, CAE 55

6.2 INTRODUCTION OF CATIA 56

6.2.1 What Is Catia 56

6.2.2 Feature Based 56

6.2.3 Features Can Be Classified as Sketched- 57

6.2.4 Solid Modelling 57

6.2.5 Fully Associate 57

6.5 IN SKETCHER MODE 62