Sumit Dwivedi

Dr. M. D. Mahajan

Abstract

With current era of the Automobile industry, every component of the engine should be built for improved strength, lighter weight, reliability and reduced cost. The early models of rocker cover were made up of either stamped steel, iron or casted aluminum. But nowadays the automobile companies are trying to save the material by reducing weight and cost of manufacturing for the development of components through the lightweight construction which helps in increasing fuel efficiency. Thus the plastics can be a good replacement of metals and are increasingly being used in internal combustion engines. This paper deals with the finite element analysis of a new rocker cover (or valve cover) for existing 1.8L engine in order to get stress distribution over the geometry, reduce the weight and cost of manufacturing. The existing CAD geometry is made for manufacturing, not for analysis, so we need to modify its geometry by using Creo Parametric 2.0. In this study, Hyper Mesh is used as the Pre-processing tool for Steady State Thermal and Modal analysis. Radioss and Optistruct are used as Solver and Post-processing has been done in HyperView

Keywords- Rocker cover, Thermal Analysis, Modal Analysis, Weight Reduction, Cost Optimization