CAE-BASED THERMAL ANALYSIS OF ENGINE CYLINDER FINS USING VARIOUS GEOMETRIC PROFILES AND MATERIALS

Abstract

Engine cylinder fins play a crucial role in enhancing heat dissipation from air-cooled internal combustion engines, thereby maintaining optimal operating temperatures and improving engine efficiency. The thermal performance of cylinder fins is significantly influenced by their geometry and material properties. This study presents a Computer-Aided Engineering (CAE)- based thermal analysis of engine cylinder fins using various geometric profiles and materials to identify configurations that provide superior heat transfer characteristics. Three different fin geometries, including rectangular, circular, and tapered profiles, were modeled using CAD software and analyzed under identical operating conditions. In addition, commonly used engineering materials such as Aluminum Alloy, Cast Iron, and Copper were evaluated to determine their influence on heat dissipation performance. Finite Element Analysis (FEA) was performed using CAE tools to investigate temperature distribution, heat flux, and thermal gradients across the fin structures. The simulation results revealed that fin geometry and material selection have a substantial impact on thermal behavior. Among the materials considered, Copper exhibited the highest heat transfer capability due to its superior thermal conductivity, while Aluminum Alloy provided an effective balance between thermal performance and weight reduction. The tapered fin geometry demonstrated improved heat dissipation and more uniform temperature distribution compared to conventional fin designs. Comparative analysis showed significant reductions in maximum operating temperature for optimized fin configurations. The findings of this study demonstrate that the integration of CAE techniques in fin design enables efficient evaluation and optimization of thermal performance before prototype fabrication. The proposed approach contributes to the development of lightweight, cost-effective, and thermally efficient engine cooling systems. The results can assist designers and manufacturers in selecting appropriate fin geometries and materials for enhanced engine reliability and performance.