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ABSTRACT−Valve seats press-fitted in the cylinder head function to hold exhaust gas inside the ignition chamber and to
transfer heat to the coolant moving in the water jacket of the head. The press-fitting of the valve seats to the head at ambient
temperature has been widely spread out due to its many advantages over pressing with frozen valve seats or with a heated
head. The benefits include lower equipment costs, lower running costs, and fewer installation faults during the press-fitting.
Nevertheless, a systematic approach for pressing at ambient temperature (ATP; ambient temperature press-fitting) has not been
studied and analyzed to date. A technique to check the reliability of the press-fitting by measuring hoop strain inside the valve
seat and the FEM procedure to simulate ATP is developed in this study. The FEM procedure of ATP developed here exhibits
a concurrence with experimental results. Utilizing the DOE (Design of Experiments) technique, we determined the effects of
various geometric parameters and the optimal shapes of the valve seat and cylinder head. The optimal shapes have been
successfully applied in an actual engine and varified in a running-engine test.
KEY WORDS : Valve seat, Head, Interference, Press-fitting, FEM (Finite Element Method)
687
688 K. W. LEE and D. J. YEOM
fitting reliability is developed by measuring the level of the separation hoop stain. Therefore, the compressive
hoop strain inside the valve seat and utilizing the FEM circumferential hoop strain εθ signifies a reasonable criterion
procedure to simulate ATP process. The optimal designs of for the press-fitting reliability.
the valve seat and cylinder head are obtained with the help of
both the DOE (Design of Experiment) method and the FEM. 2.2. Measurement of the Circumferential Hoop Strain of
The results are verified using actual running-engine tests. the Valve Seat
The HMC (Hyundai Motor Company) has successfully
2. CRITERION FOR PRESS-FITTING used the frozen valve seats in the engine production line,
RELIABILITY thus, guaranteeing the press-fitting reliability of freeze
pressing. Therefore, the level of hoop strain via the freeze
2.1. Theoretical Relationship Between Hoop Strain and pressing method can be treated as a guideline range and it
Press-fitting is expected that there will be no problems when the level of
When the criterion for the press-fitting reliability is hoop strain using ATP is within that range. The value of the
developed, the failure of the valve seat can be anticipated hoop strain via the freezing press method is measured and
and prevented. The direct evaluation is surely the it is set for the criterion for the press-fitting reliability.
experimental measurement of the separation force of the The hoop strains of the valve seat specimens at different
valve seat from the cylinder head. The separation force can interferences are measured by attaching strain gages on the
be measured by the push of the valve bonded with the valve press-fitted valve seat, as seen in Figure 3. Two gages
seat. Unfortunately, this cannot be a standard method since it respectively are attached to each intake and exhaust valve
seldom proves success and the data scattering is too large seat, with the resultant number of 32 gages for the head of
(Kim, 2006). a 4-cylinder engine. The gages are positioned in the intake-
To obtain stable measurement data, an indirect intake and intake-exhaust bridge, as shown in Figure 3(a).
measurement is tried in this study, which uses the level of After the head in the vicinity of the valve seat is removed
compressive circumferential strain of the press-fitted valve and the valve seat is released, as seen in Figure 3(b), the
seat. To date, this method has not been attempted. As shown hoop strain inside the valve seat is measured by the gage.
in Figure 2, when two cylindrical, dissimilar materials are Next, the measurement results of freeze pressing and ATP
assembled, each with a radial interference δ, the hoop strain are compared.
εθ is given as equation (1) on the inner surface of the inner
cylinder (Ugural and Fenster, 1981; Kim et al., 2009).
2b2 -
εθ = ------------- P (1)
a 2 – b2
The radial pressure P on the contact surface between two
materials is given as equation (2).
bδ
P = --------------------------------------------------------------------------------------------------------------------- (2)
⎧ [ ( 1 – vA )b2 + ( 1 + vA )a2 ] [( 1 – vB )b2 + ( 1 + vB)c2 ] ⎫
⎨ ----------------------------------------------------- + ---------------------------------------------------- ⎬
⎩ EA ( b 2 – a2 ) EB ( c 2 – b 2 ) ⎭
Table 1. Material properties of the cylinder head and the be used as a guideline.
valve seat.
Cylinder head Valve seat 3. FINITE ELEMENT ANALYSIS
ITEM
(Aluminum alloy) (Powder metal)
3.1. Behavior of Press-fitting Process
Young’s modulus 72.4 GPa 94.7 GPa The graph in Figure 6 shows the press force during the
Poisson’s ratio 0.33 0.30 process, which is recorded with the load-cell of press
equipment. The typical behavior of a press-fitting process
with interference is shown (Choi et al., 2011; Gervásio et
2.3. Evaluation of Press-fitting Reliability al., 2010). In the beginning stage the peak press force by
The hoop strains for the intake valve seats are measured for ATP is 32% higher than the force by freeze pressing. The
two types of engines. In Figure 4, the measurements are resistance during the press using ATP is much higher than
compared with the theoretical equation (1) and the that with freeze pressing under the same condition;
simulations (to be explained in section 3). The material however, there is no change in the interference or the
properties are listed in Table 1. shapes of the valve seat or head. The reason is that the
The stress-strain curves of the cylinder head and the interference of ATP is larger at the instance of the
valve seat for the simulation are plotted in Figure 5. beginning.
In Figure 4, despite the large data scattering, the An ATP process can be divided into 3 stages: beginning,
theoretical solutions (the blue and black lines) qualitatively ongoing, and ending stages. At the beginning stage, the
agree with the experimental results of the hoop strains by press force increases due to the contact between valve seat
freeze pressing (blue triangles) and by ATP (gray and white and head. The plastic deformations and energy losses are
circles and orange diamonds) in similar positions. It is developed by this contact and they determine the value of
concluded that when there is no severe damage incurred maximum press force. And in the ongoing stage, the
during the press, the hoop strain is the same regardless of friction effect between valve seat and head is the primary
the press method. Although the tendencies for two engines factor and additional plastic deformation does not occur if
vary slightly due to the different interferences, the range of the interference is not too large. Hence, the force decreases
the hoop strains is almost identical. It is shown that a after the maximum value and remains at a steady level in
realistic level of hoop strain assures the reliability of the general. Finally, the force increases dramatically when the
press-fitting in a certain range and the measured level can bottom of the valve seat touches the bottom of the head.
Table 3. Friction coefficients between the cylinder head Figure 11. Press force and S/N results of the DOE.
and the valve seat.
Roughness
Friction coefficient
Cylinder head Valve seat
1.6 Ra 3.2 Rt 0.004
1.6 Ra 6.4 Rt 0.036
1.6 Ra 12.5 Rt 0.048
6.4 Ra 3.2 Rt 0.020
6.4 Ra 6.4 Rt 0.040 Figure 12. Comparison of experimental results.
6.4 Ra 12.5 Rt 0.058
12.5 Ra 3.2 Rt 0.024 angle) and G (seat roughness). The optimal design obtained
12.5 Ra 6.4 Rt 0.052 from the DOE is then made into a real product. Using the
12.5 Ra 12.5 Rt 0.073 same method explained in the previous sections, the hoop
strain and the press force are measured and compared with
the initial design to various interferences (Figure 12). As
expected, the hoop strain and the press force show linear
relations with the interferences. The hoop strain of optimal
design satisfies the guideline measured in section 2.3. The
maximum press force has been reduced approximately
13% below at the maximum interference condition,
averaging approximately 5% below. The design was
verified in the real engine dynamo-test and conclusively
passed without any problems.
5. CONCLUSION
ACKNOWLEDGEMENTS−The authors are thankful to Mr. J. design study of ambient assembly of head valve seat.
W. Yi and Mr. C. U. Kim of Hyundai Motor Company for Fall Conf. Proc., Korean Society of Automotive
valuable discussions and the technical assistance. Engineers, KSAE06-F0005, 29−35.
Kim, T. J., Kim, H. Y., Hwang, B. C., Kang, H. J. and Kim, C.
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