Design of customized modular cylinder head for SI-engine

This paper proposed the design of modular cylinder head for a 150 cc racing motorcycle engine which provides the flexibility to change the internal architecture and use different components in the cylinder head to achieve the desired engine performance. Unconventional production method using CNC machining is the preferred approach because of lower per unit cost. The objective was to design a light weight cylinder head suitable for low-medium volume production using CNC machining and also prevent localized overheating of hotspots on the cylinder head. This was achieved by varying the local thickness of the cylinder head and directing more coolant by providing channels to the hotspots. In addition the heat transfer from the exhaust gas is minimized by shortening the exhaust manifold. By managing cylinder head cooling, it is possible to minimize the weight of the cylinder head and the size of the cooling system to reduce the overall engine weight. The cylinder head is divided into three parts consisting of the cylinder head cover, the valvetrain housing and the combustion chamber housing. The detailed design was then done and finalized. The computational work of stress and thermal analysis was done on ANSYS.