Comparative Finite Element Analysis of Structural Steel and Magnesium Alloys in a Five-Cylinder Radial Engine

Abstract

Radial engines are widely recognized for their balanced configuration, compact design, and ability to deliver smooth power output in aeronautical and industrial applications. However, the performance and reliability of such engines are highly dependent on material selection and effective thermal management. In conventional systems, radial engines are typically designed using standard materials with limited analytical optimization, where weight reduction is often prioritized without fully addressing the resulting structural deformation, vibrational stresses, and thermal inconsistencies. These limitations can lead to reduced component life and decreased operational efficiency, particularly under high-load conditions. To overcome these challenges, the present research focuses on a systematic evaluation of material performance using advanced computational tools. A five-cylinder radial engine model was developed in SolidWorks, and detailed simulations were conducted in ANSYS Workbench, incorporating static structural, modal, and thermal analyses. The proposed approach compares Structural Steel with lightweight magnesium alloys such as Mg-8Al-0.5Zn and ZK60 to identify the optimal balance between strength, stiffness, and heat dissipation. The results demonstrate that Structural Steel significantly reduces total deformation and elastic strain while maintaining stable thermal behavior, thereby ensuring higher durability and reliability. Although magnesium alloys contribute to weight reduction, their lower stiffness limits their performance in high-vibration environments. This research is successfully completed by integrating multi-physics simulation techniques to validate material behavior, ultimately recommending steel as the most suitable material for enhancing power output, structural integrity, and long-term performance of the radial engine.