Project Title: Thermal and Structural Analysis of Cylinder Head Gasket Using ANSYS
 
Project Description:
 
Cylinder head gaskets are critical components in internal combustion engines (ICE) as they provide an effective seal between the engine block and cylinder head, preventing leakage of combustion gases, coolant, and oil.
This project focuses on enhancing the sealing efficiency, heat resistance, and durability of gaskets using Finite Element Analysis (FEA) through ANSYS.
The simulation analyzes thermal and mechanical stresses to identify potential failure-prone areas, helping to recommend material improvements and geometric optimizations for improved engine performance and gasket longevity.
 
Tools & Software Used:
PROE / Creo: CAD modeling of the gasket geometry
ANSYS Workbench (Thermal + Structural Modules): Simulation of thermal and mechanical loads
Material Database: Steel, composite gasket materials with heat resistance properties
 
Simulation Procedure:
3D CAD Modeling:
Design gasket geometry in PROE / Creo as per cylinder head specifications.
Material Assignment:
Assign suitable heat-resistant materials (e.g., stainless steel, composite layers).
Boundary Conditions:
Apply combustion chamber temperatures and internal pressure loads.
Define fixed supports and contact conditions representing the engine assembly.
FEA in ANSYS:
Perform thermal analysis for heat flow and temperature distribution.
Conduct structural analysis for stress, deformation, and sealing integrity.
Result Evaluation:
Identify regions of maximum stress concentration and potential failure.
Recommend material changes or design modifications for improved performance.
 
Ideal For:
Final-year mechanical/automotive engineering students
Projects focused on thermal management and IC engine components
Research in automotive sealing technologies
 
Learning Outcomes:
Understand thermal-structural interactions in automotive components
Gain expertise in ANSYS thermal and mechanical simulations
Learn about gasket materials and design requirements in engines
Identify methods for increasing component lifespan and reliability
 
Components & Functions:
Gasket Geometry: Provides sealing under high pressure and temperature
ANSYS / PROE: CAD modeling and thermal-structural simulation tools
Thermal Input: Simulates realistic heat loads from combustion
 
Applications:
Internal combustion engines (cars, bikes, trucks)
Marine engines operating under heavy load
High-performance or racing engines with extreme conditions
 
Advantages:
Prevents gas and coolant leakage
Improves engine efficiency and reliability
Enhances gasket lifespan under harsh conditions
Validates gasket design prior to manufacturing
 
Disadvantages:
Requires precise and high-fidelity modeling
Sensitive to mounting conditions and torque application in real-world use
Time-consuming simulations for detailed analyses
 
Conclusion:
Thermal FEA identifies failure-prone zones and guides better material and design choices.
Enhanced gasket designs lead to better sealing performance, increased efficiency, and extended service life in engines.
Critical in ensuring engine safety and longevity, especially in high-performance applications.