Thermal Performance Analysis of Engine Cylinder Fins: Design and Simulation Study

Effective engine cooling is essential for maintaining the performance and durability of internal combustion engines. The present study examines the thermal efficiency of engine cylinder fins by design, modeling, and simulation. Multiple fin configurations—fillet corners and drafted edges—were examined through Solidworks simulation, concentrating on two materials, Aluminum 6061 alloy and grey cast iron, with differing thicknesses (2.5 mm and 4 mm). The simulation assessed heat dissipation, temperature distribution, and overall thermal efficiency in natural convection settings. It is found that grey cast iron has enhanced thermal retention, but Aluminum 6061 alloy presents benefits in terms of weight and manufacturability. The present study highlights the importance of fin geometry, indicating that drafted edges provide more uniform heat distribution than fillet corners. Thus, the optimization of engine cooling system design was performed by integrating performance with material expenses.