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The research focuses on the solutions to avoid overheating the intake and exhaust valves due to engine overload.Subaru EJ25 engines are currently mounted in passenger cars such as Subaru Impreza but the author's innovative idea is to use them in small passenger airplanes. The paper describes the coupled thermo - mechanical load model of a supercharged Subaru EJ25 engine. The engine piston was tested thermally and mechanically, and the intake and exhaust valves only thermally. The calculations were done using the finite element method (FEM) in ABAQUS 6.10. Parts where divided into Hex and Tet mesh elements, depending of their geometry. The models used in the simulation were previously created using CATIA v5. Because there were only separate parts, the authors used only Part Module. The process of 3D scanning based on the method of reverse engineering was for fine mapping the surface of the examined parts, e.g. a piston. The boundary conditions and material properties are based on the literature and the information provided by the companies that sell spare parts for this engine. The simulations were done for varied heating times and mechanical load (25, 50, 100, 250, 400 seconds).
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