Optimization of two-wheeler Bike engine among three different designs using design of experiments

Area of Science:

• Mechanical Engineering
• Thermodynamics
• Materials Science

Background:

• Motorcycle engines generate significant heat, necessitating efficient cooling systems.
• External body temperature impacts engine performance and component longevity.
• Air-cooled fin design is crucial for managing heat transfer in engines.

Purpose of the Study:

• To investigate fin heat transfer in three distinct motorcycle engine models.
• To identify the optimal engine design that maximizes heat transfer rate and minimizes external temperature.
• To achieve a balance between outer boundary temperature and air-cooled fin efficiency.

Main Methods:

• Comparative analysis of three engine models (A, B, C) using simulation.
• Evaluation of heat transfer coefficient based on wind velocity and Nusselt Number.
• Design of Experiments (DOE) applied to fin thickness, size, and shape on the optimal model.
• Material selection: Aluminum alloy 6061 (thermal conductivity 200 W/mK).

Main Results:

• Design B was identified as the optimal design through simulation, exhibiting lower temperature gain, deformation, and normal stress.
• Heat transfer coefficient reached approximately 77.28 W/m²K at a wind velocity of 40 Km/h.
• DOE analysis provided further optimization insights for the selected fin parameters.

Conclusions:

• The optimized fin design (Design B) effectively manages heat transfer and reduces external temperature.
• The study demonstrates the importance of fin geometry and material properties in engine thermal management.
• The findings contribute to developing more efficient and durable air-cooled motorcycle engines.