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An engine head of a common rail direct injection engine with three in line cylinders for Light Transportation Vehicle (LTV) applications has been analyzed and optimized by means of uncoupled CFD and FEM simulations in order to assess the strength of the components. This paper deals with a structural stress analysis of the cylinder head considering the thermal loads computed through an CFD simulation and a detailed FV heat-transfer analysis. The FE model of the cylinder head includes the contact interaction between the main parts of the cylinder head assembly and it is subjected to the gas pressure, thermal loads and the effects of bolts tightening and valve springs. The results, in term of temperature field, are validated by comparing with those obtained by means of experimental analyses. Then a fatigue assessment of the cylinder head has been performed using a multi-axial fatigue criterion.

An engine head for microcar applications has been analysed and optimized by means of uncoupled CFD and FEM simulations in order to assess the strength of the component. This paper deals with a structural stress analysis of the cylinder head considering the thermal loads computed through an uncoupled CFD simulations of cylinder combustion and in cooling flow passages. The FE model includes the contact interaction between the main parts of the cylinder head assembly and it also considers the effects of bolts tightening and valve springs. Temperature dependent non-linear material properties are considered. The results, in term of temperature field, are validated by comparing with those obtained by means of experimental analyses; the engine has been instrumented with thermocouples on crank case and on cylinder head.