Optimization Design of Integrated High-Temperature Valve Bonnet Heat Dissipation Structure and Orthogonal Sensitivity Analysis of Key Parameters

Dan Yao; Junxiao Sun; Zhenyu Lei; Feng Hu; Ruihong Ma; Shuangjiang Li

doi:10.6919/ICJE.202511_11(11).0017

Optimization Design of Integrated High-Temperature Valve Bonnet Heat Dissipation Structure and Orthogonal Sensitivity Analysis of Key Parameters

Dan Yao, Junxiao Sun, Zhenyu Lei, Feng Hu, Ruihong Ma, Shuangjiang Li

International Core Journal of Engineering, (2025), Vol.11, No.11, pp.156-166

Published: November 22, 2025

DOI: 10.6919/ICJE.202511_11(11).0017

PDF: Download Full Text PDF

Abstract

This study investigates a compact Integrated High-Temperature Upper Bonnet by quantifying how cooling-fin geometry affects the valve-stem packing gland and setting optimization priorities for high-temperature valves. A 3D steady-state thermal model was built in ANSYS Workbench using the Finite Element Method and evaluated under 525 °C process gas. Orthogonal Experimental Design with range analysis assessed fin number, fin diameter depth, and fin spacing. Simulations show that heat conduction across the 1.5 mm stem-to-bonnet gap must be modeled; otherwise the packing-gland peak temperature is overestimated by up to 15.7%. Benchmarking indicates the integrated bonnet (235 mm) matches the cooling of a traditional extended bonnet (380 mm) while reducing height by 38.2%. Parameter influence ranks as fin number (R_A = 36.89) > fin diameter depth (R_B = 21.12) > fin spacing (R_C = 9.50), identifying fin number as the primary design lever. These results validate the integrated bonnet’s thermal performance and compactness and provide quantitative evidence for design and safety certification of high-temperature industrial valve accessories.

Keywords: Integrated High-Temperature Upper Bonnet; Finite Element Method; Orthogonal Optimization; Cooling Fin; Heat Dissipation; Packing Gland Temperature.

APA Citation: Dan Yao, Junxiao Sun, Zhenyu Lei, Feng Hu, Ruihong Ma, Shuangjiang Li (2025). Optimization Design of Integrated High-Temperature Valve Bonnet Heat Dissipation Structure and Orthogonal Sensitivity Analysis of Key Parameters. International Core Journal of Engineering, 11(11), 156-166. https://doi.org/10.6919/ICJE.202511_11(11).0017

References

SERALATHAN, S., SANTHOSH, G. B., SIVANANDAM, P. Thermal analysis on different exhaust valve materials of compression ignition engine[J]. Materials Today: Proceedings, 2020, 33(3): 4105-4111. DOI: 10.1016/j.matpr.2020.06.550.
LIU, L., ZHANG, L., YANG, D., et al. Two-phase flow-based numerical investigation of the temperature maps of sodium-cooled exhaust valves in a turbocharged engine[J]. Applied Thermal Engineering, 2020, 181: 115977. DOI: 10.1016/j.applthermaleng.2020.115977.
YONG, M., KU, P. X. Study on the performance characteristics and failure analysis of exhaust valves[C]//Journal of Physics: Conference Series. Bristol: IOP Publishing, 2023, 2523(1): 012047.
SIVAKUMAR, E. R., KRISHNA, R., SENTHILKUMAR, P., et al. Comprehensive study of diesel engine characteristics of valves coated by titanium nitride (TiN)[J]. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2023: 09544089231157950. DOI: 10.1177/09544089231157950.
XU, L., LIN, H., HU, N., et al. Multi-Objective Optimization towards Heat Dissipation Performance of the New Tesla Valve Channels with Partitions in a Liquid-Cooled Plate[J]. Energies, 2024, 17(13): 3106. DOI: 10.3390/en17133106.
CHENG, J., WANG, Z., GUO, J., et al. Thermal-mechanical coupling analysis of high-temperature control valve bonnet under transient conditions[J]. Journal of Mechanical Engineering, 2021, 57(12): 101-110.
UDIN, S. M. K., HASAN, N. Enhanced Thermal Performance Analysis Of Engine Cooling Fins With Varying Geometries And Materials[J]. International Journal of Mechanical and Production Engineering Research and Development, 2024, 14(1): 164-173.
ZHAO, K., CHEN, W., WANG, H., et al. Optimization of Heat Transfer and Flow Performance of Microchannel Liquid-Cooled Plate Based on Orthogonal Test[J]. Sustainability, 2023, 15(6): 905. DOI: 10.3390/su15060905.
SILVA, C. T. B., OLIVEIRA, A. P. Analysis of the temperature and stress distributions on an automotive valve train due to friction effects[J]. International Journal of Engineering Research and Applications, 2020, 10(7): 20-27.
MAVROPOULOS, G., MARKOPOULOS, A. G., TSANAS, A. Heat Losses in the Exhaust Manifold of a 4-Stoke DI Diesel Engine Subjected to Pulsating Flow[J]. Journal of Sustainable Energy, 2024, 13(9): 223. DOI: 10.3390/su1309223.
AHMED, S. S. H. S., ALI, W. J. Investigation of the Effect of Different Fins Configurations on the Thermal Performance of the Radiator[C]//Journal of Physics: Conference Series. Bristol: IOP Publishing, 2024, 2733(1): 012028.
CHEN, X., FAN, H., MA, J., et al. Innovative Designs of 3D Heat Sinks by Topology Optimization[J]. Journal of Mechanical Design, 2024, 147(8): 081705. DOI: 10.1115/1.4065600.
ZHU, Z., SHEN, H., WANG, Z., et al. Thermal stress analysis of high-temperature high-pressure butterfly valve body[J]. Fluid Machinery, 2022, 50(11): 45-50.
ALWAN, H. G., MOHAMMAD, H. K. Enhancement of Heat Transfer from Extended Surfaces (Fins): A Comprehensive Review[J]. International Journal of Thermal Sciences, 2023, 187: 108154. DOI: 10.1016/j.ijthermalsci.2023.108154.
QASIM, T. M., ABBAS, H. T. Computational thermal stress analysis of control valve body using finite element method[J]. Journal of Engineering Science and Technology, 2022, 17(2): 1104-1117.
GOUDARZI, S. A. Effect of contact pressure and frequency on contact heat transfer between exhaust valve and its seat[J]. International Journal of Engineering-Transactions B: Applications, 2020, 33(3): 401-408. DOI: 10.5829/ije.2020.33.03c.12.