Thermal Design of Fins for 100 cc Engine Cylinders Based on FEM and Multi-criteria Selection (k–ρ–cost): Comparison of Al 5182-H19, Mg Z6, ZA-27, Zn–Cu–Ti and EN-GJL-300
This study evaluated the thermal performance of a 100 cc internal combustion engine cylinder through the integration of geometry–material–FEM criteria aimed at a techno-economic co-optimization. Four fin geometries (rectangular, circular, angular, and trapezoidal prismatic) and five alloys preselected using CES EduPack (Al 5182-H19, Mg Z6, lamellar graphite cast iron EN-GJL-300, Zn–Cu–Ti Korloy 3130, and Zn–Al ZA-27) were analyzed. The developed method comprised: (i) CAD modeling in SolidWorks, (ii) material preselection based on thermal conductivity (k), density (ρ), and cost, and (iii) steady-state thermal simulations in ANSYS, where minimum and maximum temperatures (Tmin/Tmax), heat flux, and fin mass were quantified. The results showed that the angular geometry maximizes heat dissipation, reaching a maximum heat flux of approximately 0.069 W/mm² (Al 5182-H19: 0.069172; Mg Z6: 0.069177), outperforming rectangular (≈ 0.056–0.063 W/mm²), trapezoidal (≈ 0.044–0.050 W/mm²), and circular (≈ 0.038–0.042 W/mm²) geometries. With the Mg Z6 alloy, fin mass remained low (0.360 kg for angular), offering advantages over aluminum (≈ 0.522 kg) and particularly over cast iron (≈ 1.424 kg). In relative terms, the angular + Mg Z6 combination increased maximum heat flux by approximately 85% compared with circular + Mg Z6 (0.069177 vs. 0.037448 W/mm²) and by 24% compared with rectangular + Mg Z6 (0.055613 W/mm²), maintaining Tmax ≈ 585 K and reducing Tmin to ≈ 552 K, thereby enhancing the thermal dissipation gradient at the fin base. In summary, the main contribution of this study is a reproducible methodology for form–material co-optimization based on the finite element method and a multicriteria selection (k–ρ–cost), enabling quantitative decision-making for small-displacement cylinder redesign. Consequently, the combination of angular fins with the Mg Z6 alloy is identified as the most favorable option for lightweight engines, balancing thermal performance, mass, and cost.
Vega Anticona, A. Yushepy , Tello de la Cruz, E. , Torres Ruiz, O. and Sánchez Haro, R. (2025). Thermal Design of Fins for 100 cc Engine Cylinders Based on FEM and Multi-criteria Selection (k–ρ–cost): Comparison of Al 5182-H19, Mg Z6, ZA-27, Zn–Cu–Ti and EN-GJL-300. Journal of Heat and Mass Transfer Research, (), -. doi: 10.22075/jhmtr.2025.37971.1761
MLA
Vega Anticona, A. Yushepy, , Tello de la Cruz, E. , , Torres Ruiz, O. , and Sánchez Haro, R. . "Thermal Design of Fins for 100 cc Engine Cylinders Based on FEM and Multi-criteria Selection (k–ρ–cost): Comparison of Al 5182-H19, Mg Z6, ZA-27, Zn–Cu–Ti and EN-GJL-300", Journal of Heat and Mass Transfer Research, , , 2025, -. doi: 10.22075/jhmtr.2025.37971.1761
HARVARD
Vega Anticona, A. Yushepy, Tello de la Cruz, E., Torres Ruiz, O., Sánchez Haro, R. (2025). 'Thermal Design of Fins for 100 cc Engine Cylinders Based on FEM and Multi-criteria Selection (k–ρ–cost): Comparison of Al 5182-H19, Mg Z6, ZA-27, Zn–Cu–Ti and EN-GJL-300', Journal of Heat and Mass Transfer Research, (), pp. -. doi: 10.22075/jhmtr.2025.37971.1761
CHICAGO
A. Yushepy Vega Anticona , E. Tello de la Cruz , O. Torres Ruiz and R. Sánchez Haro, "Thermal Design of Fins for 100 cc Engine Cylinders Based on FEM and Multi-criteria Selection (k–ρ–cost): Comparison of Al 5182-H19, Mg Z6, ZA-27, Zn–Cu–Ti and EN-GJL-300," Journal of Heat and Mass Transfer Research, (2025): -, doi: 10.22075/jhmtr.2025.37971.1761
VANCOUVER
Vega Anticona, A. Yushepy, Tello de la Cruz, E., Torres Ruiz, O., Sánchez Haro, R. Thermal Design of Fins for 100 cc Engine Cylinders Based on FEM and Multi-criteria Selection (k–ρ–cost): Comparison of Al 5182-H19, Mg Z6, ZA-27, Zn–Cu–Ti and EN-GJL-300. Journal of Heat and Mass Transfer Research, 2025; (): -. doi: 10.22075/jhmtr.2025.37971.1761
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