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INTERNATIONALJournal of Mechanical
JOURNALEngineering
OFandMECHANICAL
Technology (IJMET), ENGINEERING
ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
AND TECHNOLOGY (IJMET)
ABSTRACT
Diesel engine consists of number of vital components, which perform various functions and
are subjected to different forces, thermal loadings and stresses. Inlet & Exhaust valves are most
important components of the diesel engine. The function of Inlet valve is to provide path for desired
air flow to combustion chamber. Function of Exhaust valve is to provide opening, to pass burnt gases
through the cylinder. The opening and closing of inlet and exhaust valve is controlled by valve
mechanism during the engine operation. Valves are subjected to thermal loading because of high
temperature and pressure developed inside the cylinder. This paper focuses on failure trend of inlet
and exhaust valve. Failures take place of inlet and exhaust valve in different manners due to fatigue,
thermal loading, wear, corrosion and erosion which leads to loss of mechanical properties of material
and engine performance etc,.
Keywords: Exhausts Valve, Erosion, Fatigue, Inlet Valve, Thermal Loading, Scavenging, Stress.
1. INTRODUCTION
Valve mechanism is the arrangement of different components which controls the intake and
exhaust process. The operation of timely opening and closing the inlet and outlet valves in
accordance with the firing order of cylinders is performed through valve mechanism. In each cycle
of the operation, the intake and exhaust processes take place in a short span of time. Valve
mechanism components work at high and changing speed. Some components have to withstand high
temperature; therefore valve mechanism components have too much inertia and thermal stress. They
also have poor lubrication, which results in increased wear and influence the correct gas distribution.
Main requirements of the valve mechanism is accurate timing, a large enough area for gas flow,
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
minimum restricted path for flow of fresh air, less vibration, lower noise, reliable, long service life,
simple structure and easy maintenance.
Both exhaust and inlet valve are vital components of an IC engine and which are controlling
the flow of fresh air and burnt gases in and out of engine cylinders. In four stroke diesel engine
during suction stroke inlet valve remains in open condition which allows the flow of fresh air inside
the combustion chamber and exhaust valve is kept closed. In power stroke both valves remain
closed. At the end of power stroke exhaust valve gets opened to remove burnt gases from
combustion chamber. This entire operation is performed by valve mechanism. Valve mechanism
consists of components like valves, valve sheets, valve guide, valve seals, valve spring, retainers etc.
These components are properly installed in cylinder head body. Valve mechanism also consists of
rocker lever, push rod, crosshead, tappet, and camshaft. Fig.1 shows the construction of valve
mechanism.
In the operation thermal and mechanical stresses are imposed on inlet and exhaust valve
because of high temperature and pressure in the cylinder. These thermal and mechanical stresses are
prime sources of valve failures at sealing area. The movement of opening and closing also impart
sliding friction on valve and valve seat sealing area which leads to valve and valve seat wear. Impact
on valve closure may also cause plastic deformation of sealing faces and surrounding surface and
formation of series of circumferential ridges. During engine operation sealing is most important
factor to achieve perfect combustion of the injected fuel to get best performance and thermal
efficiency from the engine. Sealing pressure must be around 550 to 600 bar. Inlet valve failures
occurs due to reasons like wear, impurities in air in addition to this, exhaust valve are subjected to
different stresses than inlet valve.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
Exhaust valves are exposed to thermal stress more than intake valve because intake valve are
virtually cooled by fresh air. However burnt gases have very high temperature in the range of 800 to
10000C because of this frequency of failure of exhaust valve is higher than inlet valve. In turbo
charge engines the cooling of inlet and exhaust valve is taken care by scavenging operation. Clean
fresh air is cooled by intercooler and then pumped into the combustion chamber during the suction
stroke and during the scavenging operation. This process receives adequate cooling of valve and
valve seat surface and prevents from premature failure. Depositions building up on valve face and
valve seats leads to poor sealing and seat can have an insulating effect which causes poor cooling
and makes the valve run hot. If deposition is built up on valve face in the form of one spot, then poor
sealing appears. This poor sealing leads to leaking of the combustion and creates hot spot on valve
sealing face which in turn results in channeling effect.
The deposition on valve seat, valve face, valve stem, is from combined reaction of impure
contaminated fuel and lubricating oil. The chemicals like sulfur vanadium and sodium content in fuel
oxidizes during the combustion process to form sulfur dioxide, sulfur trioxide, sodium oxide and
vanadium pent oxide. These oxides act with each other and calcium contents in lubricating oil to
form low melting point salts. These salt particles get deposited on valve surfaces in their molten
state. These salt particles get cooled sufficiently to adhere to valve stem and valve spindle and do not
get carried away by the exhaust gases. As operating temperature is more than 6000C the deposited
salts change into molten state. This molten state salts flow along the grain boundaries depending on
valve material and dissolves the protective oxide on the grain boundaries. This phenomena is called
inter granular corrosion, which leads to burning of the valve sealing face.
There is another important type of valve failures i.e valve breakage. Valve failures due to
breakage are called fatigue failures. During engine operation valves are subjected to cyclic loading,
opening and closing causes loading and unloading of stresses on the valve. If this cyclic loading on
the valve is beyond the limit, then valve failure due to fatigue occurs at weakest surface point of the
valve. In stray cases valves also fail due to impact loading, when valve drops take place due to some
of the reasons like over speeding, valve lock loosening. Any kind of valve failure cannot be
neglected since it may cause sluggish performance or permanent stoppage of engine operation.
Failure of valve trends and modes can be summarized in categories like wear failure, valve
face recession, fatigue failures, thermal fatigue, erosion/corrosion of valve, overheating of valves,
carbon deposition of valves etc., The available research literatures regarding valve failure trends
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
indicate that valve design is a critical and complicated task since during operation, valve is subjected
to various loading patterns throughout working of diesel engine.
Diesel engine operates at different temperature level range, which depends on use of fuel,
application, RPM, torque, BHP etc.,
Naresh Kr. Raghuwanshi & et al [1] kept focus on various failure modes of IC engine inlet &
exhaust valves. The failure mainly due to fatigue at high temperature, high operating temperature
effects on mechanical properties of valve materials like hardness and yield strength. Wear failure
which is due to impact loading, and wear rate that depends on load and time. This is helpful for
researchers to develop the valve materials to achieve a prolonged life.
Nurten Vardar & et al[2] investigated the failure of Exhaust Valve Failure in Heavy duty
Diesel Engine. This was carried out by using several experimental tests methods like optical
emission spectroscopy, optical microscopy, scanning electron microscopy SEM and EDX. They
conclude that the valve was failed and broken down prior to its desired service life.
S. M. Jafari, & et al. [3] presented the potential of acoustic emission (AE) technique to detect
valve damage in internal combustion engines. The cylinder head of a spark-ignited engine was used
as the experimental setup. The effect of three types of valve damage (clearance, semi-crack, and
notch) on valve leakage was investigated.
R. V. Wanjari & et al [5] Failure analysis of Camshaft is done either by experimental or finite
element analysis. The result obtain by the finite element analysis is an approximate of the component
failure.
Dr. Ing. Holger & et al [6] Optimize service intervals as well as to perform the correct and
necessary work & to reduce the operating costs over a long period of service life by means of a high
quality service program.
Tomasz Lus & et al [7] presented Marine diesel engines new diagnostics method which can
be used on marine high speed diesel engines & presented method which is based on vibration signal
analyzing in crankshaft revolution angle domain. By using this method checking angle of fuel
injection or timing in valve gear mechanism without stopping the engine and dismantling it is
possible.
W. Tuckart [8] presented failure analysis of pushrod valve train of stationary diesel engines.
Ajay Pandey & et al [9] presented failures of automobile valves and discussed using the
Scanning Electron Microscope (SEM). Specimens were prepared from failed engine valves and also
new valves were also analyzed for the purpose of comparison. It was carried out by image analysis of
specimens of failed and new valves by using adequate magnification.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
2. MODES OF FAILURES
Following are different types of failure and their causes of inlet & exhaust valve.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
The significant hardness is lowered and the surface oxidation and fretting/galling on the valve
stem occur due to overheating. The fatigue properties of the alloy suffer due to high temperature.
This is the cause of multiple fatigue crack initiation. The failed exhaust valves are shown in Fig.,
There are two main radial splits in the plate, having both edges burnt. There are some small
circumferential cracks on the tapered plane of both sides of the splits. It was found that a lot of
carbon deposition appears on the plate surface
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
The failure analysis of inlet & exhaust valve of diesel engine can be carried out by using the
following tools and techniques:
3.1 Microscope
The objects which are too small and which are not visible by naked eyes are inspected using
microscope. The technique and science of investigating such type small object by the microscope
instrument is called microscopy. Microscopic means invisible to the eye unless aided by a
microscope.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print),
ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
Looking towards the mode and root causes of intake and exhaust valve failures, while
designing the valve important factors should be taken into account. These important factors are
chemical composition of valve material, engineering dimensions and tolerances, operating
temperatures, duty cycle, equipment applications, atmospheric condition, HP rating, pick torque
rating, RPM rating. Besides of design parameter, operation and maintenance plays very important
role for the failure of valves. For cause of fatigue failure, care should be taken likewise over
speeding of the engine, foreign material entry during induction, hydraulic locks etc,. For thermal
loading engine operating temperature is the key factor so intake & exhaust gas temperature should be
controlled by tracking of overloading, fuel quality and cooling system performance. In case of wear
failure valve adjustment and cleanliness of fresh air is most important. Dust entry in intake port is
greatest enemy which causes early wear. Poor compression, scale formation, are the prime sources of
valve failure due to corrosion-erosion.
5. CONCLUSION
In the Diesel engine various failure mode/trend affects the valve failures. Valve failures
occur due to mechanical fatigue, thermal fatigue, thermo mechanical fatigue which is due to cyclic
load, cyclic stresses. Fatigue failure occur at stresses that are well below the yield point of the
material. Failure due to high temperature is caused by elastic and plastic deformation of the valve
material. Failure of valve due to erosion and corrosion is the result of scale formation on the valve
surface due to exhaust flue gases. Failure of valve due to wear is the result of impact force between
sealing face of valve seat and seat insert. It is also due to sliding of the valve on seat insert during the
action of combustion pressure. The frequency of exhaust valve failure is more than the intake valve.
Any kind of valve failures affects on performance & efficiency of the engine, so due importance and
attention should be given while designing of the intake & exhaust valve by considering engineering
and operational factors.
6. ACKNOWLEDGMENT
The authors wish to acknowledge the support rendered by Mr. Suresh S. Rau (HOD) and Mr.
Indrajit Rau (Head-Business Development) & Mr. Sandeep Kudke (Manager- Recon) of Trinity
Mahalasa Durga Sales & Services. The authors also acknowledge the support of Dr. Ulhas Shiurkar,
Director, Deogiri Institute of Engineering and Management Studies.
REFERENCES
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ISSN 0976 6359(Online), Volume 5, Issue 3, March (2014), pp. 104-113, IAEME
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