Abstract
In an internal combustion engine, the cylinder head is a casting bolted to the top of the cylinder block. One of the parts of head assembly is the cup plug (Expansion plug/Welch plug). The fundamental motivation behind the cup attachments is to fill the gaps that were made during the throwing procedure, so the foundry could expel the center sand from the coolant entries. Obviously Saving the cylinder head from splitting if there should be an occurrence of a stop was never the maker’s purpose for these cup plugs. The study aims to find the contact pressure developed due to interference fit in Standard Cup Plug and Standard cylinder head of water-cooled diesel engine in FEA. This is done using, 3D simulation model for Standard Head and FEA and Leak Test setup for Standard Head. The investigation aims to provide the design intent to resolve cup plug loosing issue in operating conditions.
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