International Journal of Engineering Trends and Technology (IJETT) – Volume 36 Number 5- June 2016

Analysis of Causes of Engine Overheating due

to Cooling System Failure Using Pareto
Principle
Gurusaheb Singh Missan#1, Dr. I. P.Keswani*2
#
(Department of Industrial Engineering, Shri Ramdeobaba College of Engineering and Management Nagpur, India)
*
(Department of Industrial Engineering, Shri Ramdeobaba College of Engineering and Management Nagpur, India)

Abstract - Cooling system plays an important role to parts will burn and may result into seizing or welding
control the temperature of the engine. The of the same.
overheating of the engine can be prevented by using
an efficient cooling system and assists the vehicle So for the engine to work more efficiently
running at its optimal performance. The failure of the temperature must be reduced to about 140-200°C.
cooling system component results in overheating of Too much cooling will tend to reduce the thermal
an engine. This paper presents the study conducted to efficiency of the engine so, the objective of the
find out the causes of engine overheating because of cooling system is to keep the engine cool and
cooling system failure through Pareto analysis, cause maintain it in it in most efficient operating
and effect diagram is prepared to classify the causes temperature.
into sub causes and the thermal analysis of the
cylinder liner is done using Ansys two different When it is cold It has been noted that the engine is
materials gray cast iron and aluminium alloy 6061 quite inefficient and hence the cooling system is
were used. designed in a manner to prevent cooling when the
engine is warming up and till it attains to maximum
Keywords- Cooling system, cylinder liner, Engine operating temperature, then it starts cooling.
overheating, Thermal analysis, Pareto analysis
Pareto analysis is a statistical technique in decision
I. INTRODUCTION making that is used for the selection of a limited
number of tasks that produce significant overall
Although engines have improved a lot, they effect. It is one of the most commonly used, and easy
are still not very efficient at turning chemical energy to implement method [8]. The results of a Pareto
into mechanical power. Most of the energy in the analysis are typically represented through a Pareto
gasoline (perhaps 70%) is converted into heat, and it chart. The chart represents the various factors under
is the job of the cooling system to take care of that consideration in ranked order. The presentation of
heat. The primary job of the cooling system is to keep this chart is in the form of a bar graph in descending
the engine from overheating by transferring this heat order and helps to predict easily which factors are
to the air, but the cooling system also has several vital few by providing a clear indicator through
other important jobs [5]. superimposing a line graph that cuts an 80 percent
cumulative percentage and also helps in determining
In the case of Internal Combustion engines, those factors which have least amount of benefits and
combustion of fuel and air takes place inside the vice-versa. In this paper the data collected regarding
cylinder of the engine and hot gases are generated. the causes of engine overheating are studied and
The temperature of the gases generated will be critical causes were identified using pareto analysis.
around 2300-2500°C. This is a very high temperature it helps to identify different defects and classify them
because of which the oil film between the moving according to their significance.

ISSN: 2231-5381 http://www.ijettjournal.org Page 242

 International Journal of Engineering Trends and Technology (IJETT) – Volume 36 Number 5- June 2016

motion of the vehicle. Through the water jackets The

cooled water is again recirculated.

Fig 1.1 The Basic Parts of the cooling system

II. TYPES OF COOLING SYSTEMS

There are mainly two types of cooling systems : Air Fig 2.2.1 Components of water cooling system
cooled system, and Water cooled system.

2.1 AIR COOLING SYSTEM Water cooling system mainly consists of :

(a) Radiator,
In small engines say up to 15-20 kW (b) Thermostat valve,
generally Air cooled system is used and also in aero (c) Water pump,
plane engines. In this system fins or extended (d) Fan,
surfaces are provided on the cylinder walls, cylinder (e) Water Jackets, and
head, etc. Heat generated due to combustion in the (f) Antifreeze mixtures.
engine cylinder will be conducted to the fins and
when the air flows over the fins, heat will be
dissipated to air. (a)Radiator
It mainly consists of an upper tank and
Advantages of Air Cooled System lower tank and between them is a core. The upper
tank is connected to the water outlets from the
Following are the advantages of air cooled system: engines jackets by a hose pipe and the lover tank is
connect to the jacket inlet through water pump by
(a) The system is light due to absence Radiator/pump means of hose pipes.
(b) There are no leakages in case of air cooled
engines. When the water is flowing down through the
(c) Coolants are not required. radiator core, it is cooled partially by the fan which
(d) Where if water is used it may freeze This system blows air and partially by the air flow developed by
can be used in those cold climates. the forward motion of the vehicle. the radiators are
generally made out of copper and brass and their
Disadvantages of Air Cooled System joints are made by soldering.

(a) Comparatively it is less efficient. (b) Thermostat Valve

(b) air cooled systems are used where the engines It is a valve which prevents flow of water from the
are exposed to air directly. engine to radiator, so that engine readily reaches to
its maximum efficient operating temperature, it
automatically begins functioning After attaining
2.2 WATER COOLING SYSTEM maximum efficient operating temperature

In this method, cooling water jackets are (c) Water Pump

provided around the cylinder, cylinder head, valve The circulating water is pumped by it. Impeller type
seats etc.the heat of combustion is absorbed when the pump will be mounted at the front end. the pump
water is circulated through the jackets. This hot water casing comprises of enclosed shaft on which impeller
will then be cooling in the radiator partially by a fan is mounted . The pump casing has inlet and outlet
and partially by the flow developed by the forward openings. The pump is driven by means of engine

ISSN: 2231-5381 http://www.ijettjournal.org Page 243

 International Journal of Engineering Trends and Technology (IJETT) – Volume 36 Number 5- June 2016

output shaft only through belts. When it is driven

water will be pumped. Table 3.1 Causes of engine overheating

(d) Fan Sr.no Causes of

It is driven by the engine output shaft through same Engines overheating Sub Causes
belt that drives the pump. 1 Damaged
Cummins Radiator cores
2 Cummins Fan Loose belt
(e) Water Jackets
3 Damaged o
Cooling water jackets are provided around the
Tata 709 Water pump ring
cylinder, cylinder head, valve seats and any hot parts
which are to be cooled. Heat generated in the engine 4 Cummins Fan Fan blade
cylinder, conducted through the cylinder walls to the 5 Improper
jackets. The water flowing through the jackets Tata 1109 Coolant concentration
absorbs this heat and gets hot. This hot water will 6 Damaged
then be cooled in the radiator. Tata 1210 Radiator cores
7 Cummins Fan Loose belt
(f) Antifreeze Mixture 8 improper
The ideal antifreeze solutions should have the Hino Coolant Level
following properties: 9 Tata 1612 Gasket Installation
(a) It should dissolve in water easily. 10 Improper
(b) It should not evaporate. Tata 709 Coolant concentration
(c) in cooling system It should not deposit any 11 Tata 1613 Gasket Thickness
foreign matter. 12 improper
(d) It should be cheap and easily available. Cummins Coolant Level
(e) It should not corrode the system.
13 Improper
Hino Coolant concentration
Advantages of Water Cooling System
14 Tata 2515
(a) Cooling is uniform in cylinder, cylinder head and
ex Radiator loose hoses
valves.
15 Hino Fan Fan blade
(b) By using water cooling system Specific fuel
consumption of engine is improved . 16 Improper
(c) Engine need not to be provided at the front end of Tata 608 Coolant concentration
moving vehicle if we employ water cooling system. 17 Cummins Radiator loose hoses
18 improper
Disadvantages of Water Cooling System Tata 909 Coolant Level
(a) It depends upon the supply of water. 19 Cummins Fan Loose belt
(b) Water pump requires considerable power for 20 Damaged
circulating water. Hino Radiator cores
(c) If the water cooling system fails then it will result 21 Improper
in severe damage of engine. Tata 1612 Coolant concentration
22 improper
III. DATA COLLECTION Cummins Coolant Level
23 MAN Gasket Thickness
The data regarding the causes of engine 24 Damaged
overheating is collected from the mechanics, the data Cummins Radiator cores
of 25 engines were collected. The causes related to 25 Damaged
the engine overheating due to inefficient cooling Tata 1612 Radiator cores
system were identified.

ISSN: 2231-5381 http://www.ijettjournal.org Page 244

 International Journal of Engineering Trends and Technology (IJETT) – Volume 36 Number 5- June 2016

Fig 3.1 cause and effect diagram of engine overheating

IV. ANALYSIS

ANSYS is general-purpose finite element The Required data is taken for the Analysis:
analysis (FEA) software package. Finite Element
Analysis is a numerical method of deconstructing a
complex system into very small pieces (of user Table 4.1 materials for analysis
designated size) called elements. The software
implements equations that govern the behavior of
these elements and solves them all; creating a
SR. COMPONENT MATERIAL
comprehensive explanation of how the system acts as
NO
a whole. These results then can be presented in
tabulated or graphical forms. This type of analysis is 1 LINER Gray Cast
typically used for the design and optimization of a Iron
system far too complex to analyze by hand.
2 LINER Aluminium
A THERMAL ANALYSIS OF CYLINDER Alloy 6061
LINER

The analysis of the cylinder liner is done

with two different materials. And the type of the
analysis is Thermal Analysis.

ISSN: 2231-5381 http://www.ijettjournal.org Page 245

 International Journal of Engineering Trends and Technology (IJETT) – Volume 36 Number 5- June 2016

Aluminum Alloy 6061 Apply Loads

Loads – Define Loads – Apply – Thermal –
Table 4.2 properties of cylinder liner Temperature

Bounding Box

Length X 108.97 mm

Length Y 108.97 mm

Length Z 203.2 mm

Properties

1.9905e+005 mm³
Volume

Mass 1.5625 kg

Generate Mesh
Meshing is done by using size controls command of Temperatures Inside liner=700ºc Outside liner=40ºc
lines, the line of specimen is divided to get a good Fig 4.2 total heat flux of aluminium cylinder liner
mesh. After that mesh area is selected as shown.

Gray cast iron

Table 4.3 properties of cylinder liner

Bounding Box

Length X 108.97 mm

Length Y 108.97 mm

Length Z 203.2 mm

Properties

Volume 1.9905e+005 mm³

Mass 0. kg
Fig 4.1 Meshed model of aluminium cylinder liner

ISSN: 2231-5381 http://www.ijettjournal.org Page 246

 International Journal of Engineering Trends and Technology (IJETT) – Volume 36 Number 5- June 2016

Repeat the meshing procedure for Gray cast iron V. RESULTS

cylinder liner
The causes of the engine overheating data is analyzed
using pareto technique and based on the Pareto
principle of 80/20 rule it is found that the major
causes of engine overheating were coolant, radiator
and fan since marker line cuts the cumulative
percentage line at 80%.so the L.H.S shows the
critical causes

10 100%
9 90%
8 80%
7 70%
6 60%
5 50%
4 40%
3 30%
2 20%
1 10%
0 0%
Coolant Radiator Fan Gasket water
Fig 4.3 Meshed model of gray cast iron cylinder pump
liner
Fig 5.1 pareto analysis

Apply Loads Table 5.1 critical causes of engine overheating

Loads – Define Loads – Apply – Thermal –
Sr.no Cause Contribution
Temperature
Temperatures Inside liner=700ºc Outside liner=40ºc
1 Coolant 36%

2 Radiator 28%

3 Fan 20%

In ansys Using thermal analysis two different

materials gray cast iron and aluminium alloy 6061
were studied the result of which are shown

Table 5.2 Total heat flux of liner material

Liner Inside Outside Total

Material Temperature Temperature heat
Flux

Gray cast 700°C 40°C 1.33e7

iron w/mm2
Aluminium 700°C 40°C 1.60e7
alloy 6061 w/mm2
Fig 4.4 total heat flux of gray cast iron cylinder liner

ISSN: 2231-5381 http://www.ijettjournal.org Page 247

 International Journal of Engineering Trends and Technology (IJETT) – Volume 36 Number 5- June 2016

VI. CONCLUSION

Using Pareto technique the causes of overheating in

25 engines were studied in which cooling system is
considered it is found that coolant, radiator and fan
were the critical causes of overheating. In engines it
is found that the coolant level was below the limit
and coolant is not being used in proper concentration.
Radiator cores were found to be damaged and
because of loose hoses water was not properly
circulated through radiators. In some engines fan belt
is found to be loose and broken fan blades were also
observed. In ansys the thermal analysis is done using
two different materials it has been seen that the total
heat flux is more in aluminium alloy 6061 than gray
cast iron since the heat flux is more therefore the rate
of heat transfer will be more it is recommended to
use aluminium alloy 6061 as liner material.

REFERENCES

[1] Prof. J.A. Doshi, J.D. Kamdar, Prof. S.Y. Jani, Prof. S. J.
Chaudhary / “ Root Cause Analysis Using Ishikawa Diagram For
Reducing Radiator Rejection” International Journal of
Engineering Research and Applications (IJERA) ISSN: 2248-9622
www.ijera.com Vol. 2, Issue 6, November- December 2012,
pp.684-689

[2] Gogineni. Prudhvi, Gada.Vinay, G.Suresh Babu ” Cooling

Systems in Automobiles & Cars” International Journal of
Engineering and Advanced Technology (IJEAT) ISSN: 2249 –
8958, Volume-2, Issue-4, April 2013

[3] Tanu Singhai 1, Abhishek Mishra 2 , Rajiv Saxena 3 , Sanjay

Chhalotre 4 “Analysis and Performance of Automobile Engine
Components Considering Thermal and Structural Effects”
International Journal of Innovative Research in
Science,Engineering and Technology (An ISO 3297: 2007
Certified Organization) Vol. 3, Issue 1, January 2014

[4] Quazi Mohd. Jawed Ali ** Dr. Suwarna Torgal “Failure

Analysis of Engine over Heating Issues Observed in Vibratory
Compactor Powered by Air Cooled Diesel Engine (Part-01)”
Indian journal of research Volume : 3 | Issue : 5 | June 2013

[5]Shantkumar.B..Bocharrei “Improving the performance of engine

block by varying cooling fluids” Proceeding of NCRIET-2015 &
Indian J.Sci.Res. 12(1):408-416, 2015

[6] ken nelson “ engine overheating” Shade tree A’s volume 36 No

7 july 2009

[7]Mohiuddin Ahmed1,*; Nafis Ahmad2 “An Application of

Pareto Analysis and Cause-and-Effect Diagram (CED) for
Minimizing Rejection of Raw Materials in Lamp Production
Process” Management Science and Engineering
Vol. 5, No. 3, 2011, pp.87-95
DOI:10.3968/j.mse.1913035X20110503.320

ISSN: 2231-5381 http://www.ijettjournal.org Page 248