Vehicular Engine Design (eBook)

Kevin Hoag is an Institute Engineer in the Engine, Vehicle and Emission Research Division at Southwest Research Institute. Prior to joining Southwest Research Mr. Hoag was Associate Director of the University of Wisconsin Engine Research Center and a program director with the Department of Engineering Professional Development. He has more than 35 years of experience in internal combustion engine development, 16 years of which were with Cummins Engine Company, prior to joining the university. He joined the University of Wisconsin in 1999, where he was active in research, consulting, course development and teaching in continuing engineering education. He continues to teach Engine Design, and Engine Performance and Combustion, in Wisconsin’s Master of Engineering in Engine Systems program. Mr. Hoag has been an active member in the Society of Automotive Engineers throughout his career. He was twice awarded Outstanding Younger Member and is a recipient of the Arch T. Colwell Award for technical publication pertaining to Second Law analysis of I.C. engines. He currently co-teaches SAE’s Turbocharging Internal Combustion Engines course and serves as a session organizer on engine thermodynamics modeling. Mr. Hoag holds bachelors and masters degrees in mechanical engineering from the University of Wisconsin-Madison. He is the author of two books, and over 30 technical papers. He holds two patents pertaining to internal combustion engine development.Brian Dondlinger is a Global Business Process Manager of Product Development at the Harley-Davidson Motor Company. He has sixteen years of experience in the motorcycle industry including roles in design, manufacturing and process development. He holds five patents pertaining to internal combustion engine design.  Mr. Dondlinger holds bachelors and masters degrees in mechanical engineering from the University of Wisconsin-Madison and is a licensed Professional Engineer in the state of Wisconsin. While at UW-Madison, he competed in the SAE student design competition Baja SAE, and currently volunteers as a design judge for both Baja SAE and Formula SAE competitions. He has continued his love of racing by competing in Rally America and as an SFI certified Technical Inspector. He has taught continuing education seminars on Internal Combustion Engine Design and Mechanical Development.

Preface 0
Acknowledgements 0
Contents 0
Chapter 1 15
The Internal Combustion Engine—An Introduction 15
1.1 ???Heat Engines and Internal Combustion Engines 15
1.2 ???The Reciprocating Piston Engine 17
1.3 ???Engine Operating Cycles 19
1.4 ???Supercharging and Turbocharging 21
1.5 ???Production Engine Examples 22
1.6 ???Basic Measures 23
1.7 ???Recommendations for Further Reading 29
References 29
Chapter-2 31
Engine Maps, Customers and Markets 31
2.1 Engine Mapping 31
2.2 Automobile, Motorcycle, and Light Truck Applications 36
2.3 Heavy Truck Applications 39
2.4 Off-Highway Applications 41
2.5 Recommendations for Further Reading 44
References 44
Chapter-3 45
Engine Validation and Reliability 45
3.1 ???Developing a Reliable and Durable Engine 45
3.2 ???Fatigue Analysis 47
3.3 ???Friction, Lubrication, and Wear 56
3.4 ???Further Wear and Failure Mechanisms 62
3.5 ???Recommendations for Further Reading 64
References 64
Chapter-4 65
The Engine Development Process 65
Chapter-5 75
Determining Displacement 75
5.1 The Engine as an Air Pump 75
5.2 Estimating Displacement 78
5.3 Engine Up-rating and Critical Dimensions 82
Chapter-6 83
Engine Configuration and Balance 83
6.1 Determining the Number and Layout of Cylinders 83
6.2 Determining the Number of Cylinders 83
6.3 Determining the Cylinder Bore-to-Stroke Ratio 87
6.4 Vibration Fundamentals Reviewed 93
6.5 Rotating Forces and Dynamic Couples 94
6.6 Reciprocating Forces 99
6.7 Balancing the Forces in Multi-Cylinder Engines 102
6.8 Gas Pressure Forces 108
6.9 Recommendations for Further Reading 109
References 109
Chapter-7 110
Cylinder Block and Head Materials and Manufacturing 110
7.1 Cylinder Block and Head Materials 110
7.1.1 Gray Cast Iron 110
7.1.2 Aluminum Alloys 113
7.1.3 Magnesium Alloys 115
7.2 Cylinder Block and Head Casting Processes 116
7.2.1 Sand Casting 116
7.2.2 Permanent Mold Casting 117
7.2.3 High Pressure Die Casting 118
7.2.4 Lost Foam Casting 118
7.2.5 The Cosworth Casting Process 119
7.3 Cylinder Block and Head Casting Design Considerations 120
7.4 Cylinder Block and Head Machining Processes 124
7.5 Recommendations for Further Reading 127
References 127
Chapter-8 129
Cylinder Block Layout and Design Decisions 129
8.1 Initial Block Layout, Function, and Terminology 129
8.2 Main Block Features 132
8.3 Main Block Design Dimensions 135
8.3.1 Deck Height 137
8.3.2 Vee Angle 140
8.3.3 Cylinder Bore Spacing 140
8.3.4 Other Block Dimensions 144
8.4 Crankcase Bottom End 145
8.5 Cylinder Design Decisions 148
8.5.1 Integral Cylinder Liner 148
8.5.2 Dry Cylinder Liner 149
8.5.3 Wet Cylinder Liner 150
8.5.4 Cylinder Cooling Passages 150
8.6 Camshaft Placement Decisions 155
8.7 Positive Crankcase Ventilation 157
8.8 Recommendations for Further Reading 158
References 158
Chapter-9 159
Cylinder Head Layout Design 159
9.1 Initial Head Layout 159
9.2 Combustion Chamber Design Decisions 161
9.2.1 Spark-Ignition (SI) Combustion Chambers 161
9.2.2 Direct-Injection Spark-Ignited (DISI) Combustion Chambers 164
9.2.3 Diesel or Compression-Ignition (CI) Combustion Chambers 165
9.3 Valve, Port and Manifold Design 167
9.3.1 Intake Port Swirl 174
9.3.2 Intake Port Tumble 175
9.3.3 Intake Port and Intake Manifold Length 175
9.3.4 Intake Port Surface Roughness and Flow Area 176
9.3.5 Intake Port Heat Transfer 177
9.3.6 Fuel Injector Placement, and Intake Manifold Design 177
9.3.7 Exhaust Port Heat Transfer 179
9.3.8 Exhaust Port and Exhaust Manifold Length 179
9.3.9 Exhaust Port and Manifold Surface Roughness and Flow Area 180
9.3.10 Exhaust Port and Exhaust Manifold Design 180
9.4 Head Casting Layout 182
9.5 Cylinder Head Cooling 186
9.6 Oil Deck Design 187
9.7 Recommendations ?for Further Reading 188
References 188
Chapter-10 189
Block and Head Development 189
10.1 Durability Validation 189
10.2 High-Cycle Loading and the Cylinder Block 189
10.3 Modal Analysis and Noise 192
10.4 Low-Cycle Mechanical Loads 195
10.5 Block and Head Mating and the Head Gasket 196
10.6 Cylinder Head Loading 199
10.7 Thermal Loads and Analysis 200
10.8 Recommendations for Further Reading 202
References 202
Chapter-11 204
Engine Bearing Design 204
11.1 Hydrodynamic Bearing Operation 204
11.2 Split Bearing Design and Lubrication 207
11.3 Bearing Loads 209
11.4 Classical Bearing Sizing 213
11.5 Dynamic Bearing Sizing 215
11.6 Bearing Material Selection 218
11.7 Bearing System Validation 220
11.8 Recommendations for Further Reading 223
References 224
Chapter-12 226
Engine Lubrication 226
12.1 Engine Lubricants 226
12.2 Crankcase Deposits 232
12.3 Lubrication Circuits and Systems 234
12.4 Oil Pumps 238
12.5 Oil Pans, Sumps, and Windage 241
12.6 Filtration and Cooling 244
12.7 Lubrication System Performance Analysis 246
12.8 Recommendations for Further Reading 251
References 252
Chapter-13 253
Engine Cooling 253
13.1 Tracking the Energy Transfers 253
13.2 Critical Issues in Temperature Control 255
13.3 Engine Cooling Circuits 257
13.4 Cooling Jacket Optimization 260
13.5 Thermal Mapping 263
13.6 Water Pump Design 264
13.7 The Cooling System 267
13.8 Venting and Deaeration 268
13.9 Trends in Cooling System Requirements 269
13.10 Air-Cooled Engines 270
13.11 Recommendations for Further Reading 270
References 271
Chapter-14 272
Gaskets and Seals 272
14.1 Gasketed Joint Fundamentals 272
14.2 The Gasket Operating Environment 277
14.3 Flange Sealing Types 277
14.4 Engine Cover Design 280
14.5 Clamping Load Parameters 283
14.6 Bolt Torque and Sealing Load Control 287
14.7 Shaft Seal Design 288
14.8 Example: Cylinder Head Gasket Joint Design 290
14.8.1 Calculated External Applied Loads and Target Fastener Clampload 291
14.8.2 Calculated Equivalent Stiffness and Load Factors 293
14.8.3 Calculate Fastener and Abutment Deflection and Loading 296
14.8.4 Calculate Thermal Affects 298
14.8.5 Design Margins 299
14.8.5.1 Minimum Gasket Contact Pressure and Joint Separation 299
14.8.5.2 Fatigue Life of Fastener 299
14.8.5.3 Thread Stripping of Nut Member 300
14.8.5.4 Embedment of the Fastener in the Cylinder Head 301
14.9 Test Methods for Gaskets 302
14.10 Recommendations for Further Reading 304
References 305
Chapter-15 306
Pistons and Rings 306
15.1 Piston Construction 306
15.2 Piston Crown and Ring Land Development 310
15.3 Piston Pin Boss Development 313
15.4 Piston Skirt Development 316
15.5 Piston Ring Construction 318
15.6 Dynamic Operation of the Piston Rings 319
15.7 Cylinder Wall Machining 324
15.8 Recommendations for Further Reading 326
References 327
Chapter-16 330
Cranktrain (Crankshafts, Connecting Rods, and Flywheel) 330
16.1 Definition of Cranktrain Function and Terminology 330
16.2 Description of Common Cranktrain Configurations and Architectures 332
16.2.1 Crankshaft Configurations 332
16.2.2 Connecting Rod Configurations 334
16.2.3 Flywheel Configurations 337
16.3 Detailed Design of Crankshaft Geometry 337
16.4 Crankshaft Natural Frequencies and Torsional Vibration 341
16.5 Crankshaft Nose Development (Straight, Taper, Spline Fit) 349
16.6 Crankshaft Flange Development 353
16.7 Crankshaft Drillings 354
16.8 Connecting Rod Development 355
16.8.1 Connecting Rod Column Forces 355
16.8.2 Connecting Rod Crankpin Bore Cylindricity 357
16.8.3 Connecting Rod-to-Cap Alignment 358
16.8.4 Connecting Rod Bushing Press Fit and Journal Bearing Crush 359
16.8.5 Connecting Rod Computational Stress Analysis 361
16.9 Flywheel Design Considerations 361
16.10 Crankshaft and Connecting Rod Construction 363
16.11 Analysis and Test 365
16.12 Recommendations for Further Reading 368
References 369
Chapter-17 370
Camshafts and the Valve Train 370
17.1 Valve Train Overview 370
17.2 Dynamic System Evaluation and Cam Lobe Development 372
17.3 Camshaft Durability 376
17.4 Valve Train Development 380
17.5 Drive System Development 384
17.6 Future Trends in Valve Train Design 385
17.7 Recommendations for Further Reading 387
References 388
Index 391
74617_2_En_18_Chapter_OnlinePDF.pdf 0
Erratum to: Chapter 4 "The EngineDevelopment Process" 390