Browse Topic: Engine mechanical components

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Acoustic Assessment in a Small Displacement Diesel Engine2014-32-01291/30/2026
In the last years, the increasing concern for the environmental issues of IC engines has promoted the development of new strategies capable of reducing both pollutant emissions in atmosphere and noise radiation. Engines can produce different types of noise: 1) aerodynamic noise due to intake and exhaust systems and 2) surface radiated noise. Identification and analysis of noise sources are essential to evaluate the individual contribution (injection, combustion, piston slap, turbocharger, oil pump, valves) to the overall noise with the aim of selecting appropriate control strategies. Previous paper focused on the combustion related noise emission. The research activity aimed at diagnosing and controlling the combustion process via acoustic measurements. The optimal placement of the microphone was selected, where the signal was strongly correlated to the in-cylinder pressure development during the combustion process. Analysis and processing of the sound emission allowed the acoustic
Chiatti, Giancarlo, Recco, Erasmo, Chiavola, Ornella, Conforto, Silvia
Evaluation of Intercooler Effectiveness with No Fan, Single Fan, and Dual Fan: A Simulation and Experimental Study2026-26-05791/16/2026
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges-such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations-no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
PATRA, SOMNATH, HIBARE, NIKHIL, Ganesan, Thanigaivel, Gharte, Jignesh Rajendra
Design and Optimization of Air Intake Manifold for 4cylinder 4valve Turbocharged CNG Engines: Enhancing Performance Metrics and Emission Compliance2026-26-01241/16/2026
This study presents the development and optimization of an air intake manifold for a 3-liter, 4-cylinder, 4-valve turbocharged engine operating on Compressed Natural Gas (CNG). The intake manifold plays a critical role in determining engine performance, directly influencing parameters such as power output, brake-specific fuel consumption (BSFC), and emissions. A systematic design methodology was adopted, starting with standard design repository, which were refined through iterative improvements focused on manifold volume, runner geometry, injector location, and fuel injection pressure. Computational Fluid Dynamics (CFD) simulations were conducted to evaluate the influence of manifold geometry and injector positioning on air-fuel mixing. The analysis assessed three potential injector locations: the tangential port, the swirl port, and a common upstream point where air splits into individual intake runners. Among these, the common upstream point consistently demonstrated superior air
Lomada, Balaji, Vasudevan, Sindhuja, RAVI, HARIKRISHNAN, N, Harish, UG, Remesh
CAE Approach to Reduce Cylinder Head Development Cycle Time2026-26-04841/16/2026
Traditional engine cylinder head design processes using Finite Element Analysis (FEA) are often iterative and unsystematic. After initial FEA, Computer Aided Design (CAD) changes are implemented to improve initial results, and subsequent designs are explored to identify improved proposals using ad hoc criteria. This iterative process is complex and time-consuming, reducing the likelihood of finding an acceptable, highly durable design. To improve the traditional product development approach, a unique application of FEA techniques that involves morphing and sub modelling is presented in this paper. The study identifies a methodology to assess water jacket durability early in the design process to understand possible design solutions, reducing High Cycle Fatigue (HCF) risks. Critical HCF areas typically occur on the water jacket in the vicinity of the combustion dome, due to the tensile stresses induced by the thermal and combustion pressure loading. Critical areas are identified by
patil, Vijay Ganapati, Shi, Simon
Simulation driven design of robust Crank-train systems for elevated In-cylinder combustion pressure2026-26-04001/16/2026
The need for increased in-cylinder pressure to meet the higher engine rating and stringent emissions norms requires special attention on the Main moving components torsional behaviour and the bearing performance. The work presented in this paper utilizes the 1D and 3D simulation potential of AVL EXCITE for the assessment of design changes required in Crank-Train system for the increased in-cylinder pressure from 170bar to 220bar. The key feature of the executed work was that all the design changes were accommodated with minimal changes in packaging / layout interfaces. The given work was executed on 6-Cylinder Turbocharged In-cylinder with Type V valve-train configurations. Initial brain storming & 0d calculation helped in understanding the design optimization required in each and every crank-train parts. Considering the guidelines available in terms of L/d ratio for the bearing, connecting rod length, the overall linkage specification was set up for starting with design work for
Khandelwal, Meha
Development of high BMEP natural gas engine with knock mitigation2026-26-01211/16/2026
The stringent emission norms over the past few years have driven the need to use low carbon fuels and after treatment technology. Natural gas is a suitable alternative to diesel for heavy duty engines with applications in power generation and transportation sectors. Stoichiometric combustion mode offer the advantages of complete combustion and low carbon dioxide emissions. The combination of turbocharging and cooled exhaust gas recirculation (EGR) technology enhances the power density along with reduced exhaust emissions simultaneously. However, there are several constraints in the operation of natural gas spark ignition engine such as exhaust gas temperature (EGT) limit of 750 °C, sufficient before turbine (BT) pressure for EGR drivability, boost pressure (2.5 bar), peak cylinder pressure limit and knocking. These limits may restrict the brake mean effective pressure (BMEP) of the engine. In the present study, tests were conducted on a V12, 24 litre, dedicated heavy duty natural gas
Khaladkar, Omkar, Marwaha PhD, Akshey
EVALUATION OF DRIVELINE NVH PERFORMANCE USING LINEAR DYNAMIC FINITE ELEMENT SIMULATION2026-26-03221/16/2026
Automotive driveline design plays an important role in the NVH characteristics of the overall vehicle. Driveline systems are an integral part of delivering torque from the engine/transmission to the tires which propel the vehicle and drivelines often experience a wide frequency of excitation which poses unique NVH challenges. With the increasing trend in the automotive industry to introduce turbocharged engines with fewer cylinders while delivering the same torque / power, the driveline systems are excited with increased lower frequency torsional vibration in addition to other vibrations transmitted from powertrain and road. In this paper, we address the key design consideration for developing an optimal driveline system with consideration to NVH while keeping durability and other functional requirements in perspective. We consider the example of a front wheel drive-based vehicle architecture with independent suspension. The effect of fundamental prop shaft frequency to determine
JOSHI, ATUL KAMALAKARRAO, Subramanian, MANOJ
Key Parameters for Turbocharger selection & experimental validation for Off-Highway Applications2026-26-01041/16/2026
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
RAWAT, SAURABH, KUMAR, HARISH KUMAR, Singh, Amarinder, Singh, Sachleen, Dogra, DaljitSingh
Unveiling the Dynamics of Methanol-Diesel Dual Direct Injection Compression Ignition Combustion: A Synergistic Experimental and Numerical Study2026-26-01101/16/2026
The pressing global need for de-fossilization of the transport sector, especially within the heavy-duty segment, has intensified the exploration of alternative clean fuels. While light-duty applications are rapidly transitioning towards electrification, the heavy-duty sector remains a challenging frontier due to its high-power demand and extended runtimes. In this context, methanol gained traction due to their renewable production pathways, carbon-neutrality, and are being highly promoted by the Indian government to reduce CO2 emissions by 1 billion tons by 2030. This study presents a comprehensive investigation into the dual direct injection compression ignition (DDICI) strategy using methanol as primary fuel and diesel as a pilot for ignition assistance. In contrast to spark-ignited premixed methanol engines, this strategy involves a diffusion combustion of the methanol flame, thereby eliminating the knocking issue and running with high compression ratios. The work benchmarks the
Emran, Ashraf, Dhongde, Avnish, Singh, Inderpal, Raut PhD, Ankit, Güdden, Arne, Berry, Sushil
Design & analysis of Dual Mass flywheel during Engine startup condition in 3 Cylinder Gasoline application2026-26-03491/16/2026
Modern automotive powertrains are increasingly adopting engine downsizing and down speeding to meet stringent emission regulations and improving fuel efficiency However, these changes result in higher torsional vibrations and excitation amplitudes makes more challenge in NVH (Noise, Vibration, and Harshness) refinement. With growing customer expectations for premium driving experiences conventional clutch are no longer sufficient. To meet the NVH performance targets of the vehicle Dual Mass Flywheels (DMFs) are used In DMF due to lower stiffness and inertia separation there is a great advantage on torsional filtration in normal drive and idle condition. but the resonance frequency of the connected DMF is lower than the idle RPM. Engine startup is a key drawback with DMF equipped vehicles. The proper tuning of starter motor performance & DMF stiffness is required to cross the resonance zone faster otherwise it will lead to DMF to stay in the resonance zone for a longer time leading to
Jayachandran, Suresh kumar, Vijayaragavan, Thirupathi, M, DEVAMANALAN, Kanagaraj, Pothiraj, ahire, Manoj, Vellandi, Vikraman
Comprehensive Validation Methodologies for Hydrogen IC Engines: Combustion Analysis and Performance Metrics2026-26-02561/16/2026
The validation of hydrogen-fuelled internal combustion engine (H2 ICE) is critical to assess its feasibility as sustainable transportation with zero carbon emissions. Validation of H2 ICE necessitates a specialized testing & analysis methodologies to achieve reliable test results. This study shows the adverse effects on engine performance due to barometric pressure variation, turbo compressor out temperature variation due to increase in ambient temperature. The analysis also shows experimental results of engine performance variation based on hydrogen gas quality. Charge air quality reduces due to presence of nitrogen and moisture content in hydrogen gas and has direct impact on combustion. Engine Performance variation also observed due to engine components detoriation like valve seat wear & spark plug gap expansion. This study emphasizes the significance of precise instrumentation of thermocouples across engine on cylinder head, intake manifold & exhaust manifold, to detect performance
Vasudevan, Sindhuja, J, Narayana Reddy, Bolar, Yogesh Ganesh, Pandey, Sunil, N, Harish, N R, Varatharaj, Karthikeyan, K, Kumar D, Kishore
Simulation based optimization of the NVH characteristics in modern high speed engine during development phase2026-26-03261/16/2026
Engine noise mitigation is paramount in powertrain development for enhanced performance and occupant comfort. Identifying NVH problems at the prototype stage leads to costly and time-consuming redesigns and modifications, potentially delaying the product launch. NVH simulations facilitate identification of noise and vibration sources, informing design modifications prior to physical prototyping. Early detection and resolution of NVH problems through simulation can significantly shorten the overall development cycle and multiple physical prototypes and costly redesigns. During NVH simulations, predicting and optimizing valvetrain and timing drive noise necessitates transfer of bearing, valve spring, and contact forces to NVH simulation models. Traditional simulations, involved continuous force data export and NVH model evaluation for each design variant, pose efficiency challenges. In this paper, an approach for preliminary assessment of dB level reductions across design iterations is
Rai, Ankur, Deshpande, Ajay Mahadeo, YADAV, RAKESH
INVESTIGATING THE IMPACT OF CAM LOBE PHASING AND HYDRAULIC TENSIONER CHARACTERISTICS ON CHAIN DYNAMICS2026-26-00601/16/2026
The main objective of this study is to enhance the lifespan of a 2.2-litre automotive diesel engine that has faced challenges of extinction due to advancements in system technology, particularly the Fuel Injection Pump (FIP). Within this engine architecture, the FIP camshaft is linked with the FIP sprocket and driven by the crankshaft sprocket and chain system. The introduction of a new FIP, chosen based on drive ratios to meet fuel quantity requirements, presents a significant challenge in terms of increased chain load dynamics in the engine systems. To address this issue, two primary strategies are proposed: (i) reducing the FIP camshaft drive torque; and (ii) implementing adjustments to the hydraulic tensioner. Optimizing the FIP camshaft drive torque is an important factor for maintaining chain system performance and durability. Reductions in camshaft drive torque are achieved through strategic modifications to the cam lobe lift, phasing angle, and drive ratios. Simulation results
Dharan R, Bharani, KAWATKAR, AMIT, Loganathan, S
Engine Management System Strategies for Mitigating Dual Mass Flywheel Resonance in Gasoline Powertrains2026-26-00521/16/2026
In today's fast paced and competitive automotive market meeting the customers expectations is the key to any OEM. This has led to development of downsized high performance engines with refinement as an important deliverable. However developing such high output engines do come with challenges of refinement, especially higher torsional vibrations leading to transmission noise issues. Hence, it becomes important to isolate the transmission system from these high torsional vibration input. To address this, one of the most common method is to adopt Dual Mass flywheel (DMF) as this component dampens torsional vibrations and isolates the transmission unit from the same. While Dual Mass Flywheel assemblies do great job in protecting the transmission units by not allowing the oscillations to pass through them, they do have their own natural resonance frequency band close to the engine idle (low) engine speeds, which must be avoided for a continuous operation otherwise it may lead to Dual Mass
Raiker, Rajan, viswanatha, Hosur C, Jadhav, Aashish, Jain, Ojase, Jadhav, Marisha
A Mathematical Modelling Approach Based on Artificial Neural Network for Estimation of Key Parameters in Internal Combustion Engine2026-26-06591/16/2026
In a conventional powertrain driven by Internal combustion (IC) engines, there are many key sensors such as intake manifold temperature sensor, exhaust temperature sensor, Nitrogen oxide (NOx) sensors etc. to monitor engine performance and emissions. For enabling various diagnostics strategies and engine monitoring, virtual sensors or modelled values of such sensors play an important role. Conventional strategies incorporate the use of regression models, map-based models and physics-based models. There are a few drawbacks with conventional models in terms of accuracy and model calibrations efforts. Data driven models or neural networks have fairly better accuracy and reliability for estimating complex parameters. Representing the neural network with a mathematics-based model would help to eliminate drawbacks associated with conventional modelling approach. The proposed methodology uses artificial intelligence technique called artificial neural network (ANN) for estimation, for example
Jagtap, Virendra Shashikant, Shejwal, Sanket, Mitra, Partha
Condition-Based Monitoring for Prompt Identification of Component Failures to Safeguard the Entire System.2026-26-05761/16/2026
Condition-based monitoring (CBM) has emerged as a transformative approach in predictive maintenance, enabling the proactive identification of potential component failures. It offers numerous advantages like Cost Savings, Increased Equipment Lifespan, RCA of failed parts, Optimized Resource Utilization, Reduced Disruptions, Enhanced Reliability and Safety and many more making it a vital approach for effective maintenance and operational efficiency. This paper presents a comprehensive methodology for monitoring and analyzing vibration trends to predict and prevent the breakdown of critical components in IC Engine in its testing phase. The good part here is that this methodology is not just limited to IC Engine but can be applied across wide range of industries and mechanical systems as from the literature and past vibration data, it was observed that before any such failure engine vibration increases. If the engine is stopped at that moment, it can be preserved, allowing for further
Gupta, Gaurav, Verma, Vivek
AI-Driven Stress and Fatigue Life Prediction of Engine Connecting Rods using Geometric Deep Learning2026-26-06331/16/2026
The connecting rod is one of the critical components of the engine which is subjected to complex cyclic loading, demanding precise evaluation of stress distribution and fatigue life. Conventional Finite Element Method (FEM)-based simulations, while accurate, are computationally expensive and time-intensive—especially when iterating through multiple design variations. To address this, we present an AI/ML-based predictive framework using Graph Neural Networks (GNNs) and Geometric Deep Learning (GDL) techniques to efficiently predict stress and fatigue life of the connecting rod. The methodology involves representing FEM mesh data as graph structures, where nodes and edges capture geometric and physical relationships. GNN architectures, including MeshCNN and PointNet++, are trained on historical simulation data to learn spatial dependencies and nonlinear mappings between geometry, load conditions, and resulting stress/life outputs. The framework significantly reduces computation time
Pathan, Mohammed Shakil, K, Karthikeyan, pilla, sashanka, S Kangde, Suhas
Structural analysis and Design optimization of Cylinder Head of Cummins Light duty Engine for Medium Wheelbase (MWB) pick-up truck2026-26-04951/16/2026
This paper presents the design, structural analysis, and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used F2.5L (4-cylinder) engine that has 154hp, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 177hp (Drive New F2.5L, 15% uprate) and 197hp+ (Drive New F3.0L, 22% uprate) from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. This paper addresses the challenges and risks in current cylinder head design driven by new power demands, specifically reduced fatigue margins in the water jacket area and increased temperatures on the combustion face under high thermomechanical loads. It explores the design modifications made to the cylinder head design to
Pathak, Arun Jyoti, Adiverekar, Vaidehi, Singh, Rahul, Biyani, Mayur
Risk assessment of cold side components using quick modal analysis correlation technique.2026-26-04411/16/2026
Abstract: Modal analysis is performed to determine the natural frequencies and mode shapes of a structure or system. It helps engineers understand how a system vibrates and how external forces, such as mechanical loads, might excite unwanted resonances. To check the stresses due to vibration inputs, certain G levels are assumed, and stresses are scaled to those vibration levels. This gives an understanding of the stresses of component with respect to its EFR limit and design margins are calculated. But, assumed acceleration levels in pre-prototype stage level can over predict or under predict the design margins. A quick modal analysis corelation technique can be used by using test measured accelerations conducted at prototype stage of the program. In this work, a modal analysis corelation technique is used to perform risk assessment of intake manifold. The intake manifold failed due to high vibration levels which were not captured from high cycle fatigue analysis with assumed G-level
Bale, Shrikant Bhaskar, Bawache, Krushna
A numerical approach to optimize the flow characteristics for the enhancement of casting soundness of Al 6061 alloy die-casting2026-26-02841/16/2026
The optimization of flow characteristics such as filling time, flow velocity, viscosity and temperature play a vital role in the die-casting to enhance the casting soundness. Experimental trial and error methods for optimizing the flow characteristics of mold filling are costlier and time-consuming methods. A digital approach could significantly minimize the cost and time for the prediction of the flow characteristics of the casting. Z-Cast Pro is the casting simulation software used for simulating the whole casting process such as filling, solidification etc. This software basically utilizes the finite difference and finite volume approximation techniques to numerically unravel the molten metal flow and solidification equations. In this study, A 3D model of the valve housing is used to analyze the mold-filling behavior through high and low-speed plunger movement of the molten Al 6061 alloy using Z-Cast Pro software version 24. Higher-speed plunger movement required a total mold
Choudhary, Chandan, Subramaniam, Anand, Karle, Manish, Karle, Ujjwala
Source Level Vibration Control of a Tractor Engine Through Inertial Force Balancing2026-26-03231/16/2026
Controlling the source vibrations in internal combustion engines is a crucial approach to minimizing the vibration levels experienced by the driver. The driver's subjective perception of vibration is primarily dictated by the vehicle's low-frequency response (<100 Hz). In IC engines used in agricultural tractor applications, the primary sources of vibration include (a) first-order inertial force, (b) couples generated by rotating and reciprocating components such as the piston assembly, connecting rod, and crankshaft, and (c) in-cylinder combustion. In this study, an order ranking analysis was conducted on a single-cylinder, air-cooled, naturally aspirated tractor engine within the driver's operating range to identify the dominant contributors to source vibrations. The first-order inertial force was observed to be the dominant contributor to the engine's vibration levels. Subsequently, an attempt was made to mitigate the unbalanced forces by implementing counterweight-based balancing
Bhuntel, Ajay, Rajput, Surendra, Rawat, Ashish
Improving Cold Start and Transient Performance of Medium BMEP CEV Stage V Engines at Low Ambient Temperature and Pressure2026-26-01421/16/2026
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges, particularly concerning cold startability. Low ambient temperatures and pressures intensify the cold start difficulties which are characterized by prolonged cranking, incidences of misfiring, compromised transient response and overall engine performance. This paper highlights the strategies and technologies employed to enhance cold start and transient performance of medium BMEP engines under such demanding environmental conditions. Investigations were conducted up to an altitude of 4500m and ambient temperatures as low as-20°C, utilizing only air heater at intake manifold as the sole cold start aid. This cost effective approach is integrated with an optimized combustion chamber design, along with minimal pilot injection timing and quantity to facilitate smooth ignition and stable combustion during cold start. The paper also explore the techniques to improve the
Saxena, Harshit, Lokare, Prasad, Santhosh, Ajith, Gandhi, Naresh, Shinde, Prashant
Optimization of Negative Crankcase Pressure Mechanism to Minimize Oil Pumping into Combustion chamber and Ensure Particulate Number Compliance in Euro VI Emission for Naturally Aspirated Gas Engine.2026-26-02231/16/2026
Emissions regulations, such as Euro VI, drives the Automotive industry to innovate continuously in Engine development. One significant challenge is the engine oil pumping from the crankcase into the combustion chamber, where it participates in combustion, which contributes to increased Particulate Numbers and fails to meet Euro VI emission compliance. This issue is most noticeable during engine idling and motoring conditions. During this time, a higher negative pressure difference develops between the intake manifold, which is acting above the combustion chamber and the engine crankcase. Within the crankcase, engine oil is present along with aerosols carried in the blow-by gas. This pressure difference causes oil passes through piston rings during suction stroke and valve stem seals in Naturally Aspirated Gas engines. The impact of the pressure difference between the intake manifold and crankcase was studied by varying the crankcase pressure through crankcase ventilation system. The
R, MAHESH BHARATHI
Optimization of a Positive Displacement Type Supercharger Using Response Surface Modeling (RSM)2026-26-04291/16/2026
Air suction in a naturally aspirated engine is a crucial influencing parameter to dictate the specific fuel consumption and emissions. For a multi-cylinder engine, a turbocharger can well address this issue. However, in a single or two-cylinder engine, the usage of turbocharger is not recommended, due to the lack of availability of continuous exhaust energy pulses. A supercharger solution comes handy in this regard for a single or two-cylinder engine. In this exercise, we explore the possibility of the usage of a positive displacement type supercharger, to enhance the air flow rate of a single cylinder, naturally aspirated, diesel engine for genset application, operating at 1500 rpm. The supercharger parametric 3D CAD model was prepared in Creo, with (a) Generating radius, (b) depth of blower and (c) clearance between lobes & lobe and casing, being treated as three parameters. The optimum supercharger design was expected to (a) generate a boost pressure of minimum 0.4 bar (gauge), (b
Satre, Santosh Dadasaheb, Mukherjee, Nalini, Rajput, Surendra, Nene, Devendra
Experimental Investigation of n-C7H16/Ethanol Blended Fuels on Auto-ignition and Flame Propagation in High Temperature/Pressure Constant-Volume Combustion Vessel2024-32-00504/18/2025
This study aims to investigate the effect of ethanol blends on flame propagation and auto-ignition under high pressure and high temperature conditions. Experimental investigations are conducted using n-C7H16 / ethanol blends at various blending ratios (0, 5, 10, 20, 40, 70, and 100 vol%). The blends are premixed with air at stoichiometric ratios and ignited centrally in a cylindrical constant-volume combustion chamber (20-mm inner diameter, 80-mm long) under elevated temperature (500 K) and pressure (1.0 MPa) conditions. The results show that auto-ignition occurs at an ethanol blend ratio of 10% or less and ceases above 20%. Increasing the ethanol blend to 70% results in a slight change in flame propagation speed, with a noticeable delay at 100%. The pressure measurements show a peak of about 5.6 MPa at a blend ratio of 5%, which gradually decreases with increasing ratios. High-pass filtering reveals the maximum pressure fluctuation amplitude at the 5% blend ratio, indicating increased
Tateishi, Tokua, Yamaguchi, Riki, Shimokuri, Daisuke, Terashima, Hiroshi, Hara, Takaya, Honda, Yuya, Kawano, Michiharu
Development of Pistons Suitable for Compact Air-Cooled Engines2024-32-00304/18/2025
For the realization of carbon neutrality, we are working on research to improve the thermal efficiency of engines for motorcycles. Friction losses in the cylinder bore account for about 40% of the total friction losses of the engine (Figure 1), which is directly related to thermal efficiency improvement [1]. Air-cooled engines are suitable for motorcycles due to their simplicity and light weight, but it is difficult to achieve both efficiency and reliability. Friction in the cylinder is generated by piston scuffing. The oil film distribution of the piston-skirt(=skirt) is thin at the center of the skirt and thick at the edge. To reduce piston friction, it is effective to make the thin oil film at the center of the skirt thicker. On the other hand, to reduce oil consumption, the oil film must be thinned. However, air-cooled engines, which are difficult to keep the cylinder temperature constant, cannot make the clearance between the cylinder bore and the piston small. An increase in
Suda, Naoyuki, Hihara, Taiki, Ninomiya, Yoshinari
Effect of Ignition Position on Lean Limit of Main Chamber Combustion in Pre-Chamber Ignition2024-32-00224/18/2025
An engine was built in this study that enabled the conditions in a pre-chamber and in the main combustion chamber to be visualized simultaneously for the purpose of elucidating the mechanism of pre-chamber combustion. An investigation was made of how the state of pre-chamber combustion, including the location of initial flame generation and its subsequent propagation, influenced pre-chamber jet combustion. The state of pre-chamber combustion was intentionally varied by changing the position of pre-chamber ignition. As a result, it was found that changing the position of pre-chamber ignition varied the location where the pre-chamber flame occurred, how the flame propagated and the timing and strength of the flame jet that was ejected into the main chamber. The results revealed that these differences in the state of pre-chamber combustion markedly changed the rate of combustion fluctuation, combustion period, lean-burn limit and other combustion characteristics depending on the ignition
Onuma, Takeru, Yamada, Hiroto, Ugajin, Taisei, Shinozaki, Kaito, Tahara, Ryota, Iijima, Akira
Statistical Analysis of Data Acquired from Propagating Flames in Gasoline Engines Using a Multiple Ion Probe2024-32-00354/18/2025
Multiple-ion-probe method consists of multiple ion probes placed on the combustion chamber wall, where each individual ion probe detects flame contact and records the time of contact. From the recorded data, it is also possible to indirectly visualize the inside of the combustion chamber, for example, as a motion animation of moving flame front. In this study, a thirty-two ion probes were used to record flames propagating in a two-stroke gasoline engine. The experiment recorded the combustion state in the engine for about 3 seconds under full load at about 6500 rpm, and about 300 cycles were recorded in one experiment. Twelve experiments were conducted under the same experimental conditions, and a total of 4,164 cycles of signal data were obtained in the twelve experiments. Two types of analysis were performed on this data: statistical analysis and machine learning analysis using a linear regression model. Statistical analysis calculated the average flame detection time and standard
Yatsufusa, Tomoaki, Okahira, Takehiro, Nagashige, Kohei
Study on the Optimal Pre-Chamber Geometry for Active Pre-Chamber Gas Engines2024-32-00234/18/2025
In a pre-chamber engine, fuel in the main-chamber is ignited and combusted by the combustion gas injected from the pre-chamber. Therefore, further fuel dilution is possible and thermal efficiency can be also improved. However, adding a pre-chamber to an engine increases the number of design parameters which have a significant impact on the main combustion and the exhaust gas. Then, in this study, the optimum geometry of the pre-chamber in an active pre-chamber gas engine was investigated. The considered parameters were the volume of pre-chamber, the diameter of a nozzle hole, and the number of nozzle holes. 18 types of pre-chambers with different geometries were prepared. Using these pre-chambers, engine experiments under steady conditions were conducted while changing the conditions such as engine speeds, mean indicated pressure and air excess ratio. Based on the experimental data, neural network models were constructed that predict thermal efficiency, NOx and CO emissions from the
Yasuda, Kotaro, Yamasaki, Yudai, Sako, Takahiro, Takashima, Yoshitane, Suzuki, Kenta
Detailed Approach for Pre-Chamber Heat Release Analysis for the HSASI Pre-Chamber Spark Plug Using a Pressure Sensor Glow Plug2024-32-00634/18/2025
The hot surface-assisted spark ignition (HSASI) pre-chamber spark plug, which was developed at the Karlsruhe University of Applied Sciences, increases the dilution limit with excess air and the tolerance to residual gas in the pre-chamber compared to a conventional passive pre-chamber spark plug. In this study, the conventional glow plug which is integrated in the pre-chamber of the HSASI pre-chamber spark plug was replaced by a pressure sensor glow plug (PSG) from BERU. This allows for a detailed combustion analysis in the pre-chamber. The signal of the PSG was validated with a piezoelectric cylinder pressure sensor and a method to analyse the pre-chamber heat release was introduced. Experimental investigations were carried out on a single-cylinder gasoline engine. A series of operating points diluted with excess air and a variation in load were conducted. The gas flow rate through the orifices of the pre-chamber was calculated from the pressure difference between the pre-chamber and
Holzberger, Sascha, Kettner, Maurice, Kirchberger, Roland
Fuel Film Measurement in a SI Gasoline Engine Using a Newly Developed MEMS Sensor2024-32-00714/18/2025
The previously developed capacitance sensor for detecting a liquid fuel film was modified to apply to the in-cylinder measurement. On the developed sensor surface, comb-shaped electrodes were circularly aligned. The capacitance between the electrodes varies with the liquid fuel film adhering. The capacitance variation between the electrodes on the sensor surface was converted to the frequency variation of the oscillation circuit. In the previous study, it was revealed that the frequency of the oscillation circuit varies with the variation of the liquid fuel coverage area on the sensor surface. The developed sensor was installed in the combustion chamber of the rapid compression and expansion machine, and the performance of the developed sensor was examined. Iso-octane was used as a test fuel to explore the sensor that had been developed. As a result, the adherence of the liquid fuel directly injected into the cylinder was successfully detected under the quiescent and motoring
Kuboyama, Tatsuya, Moriyoshi, Yasuo, Takayama, Satoshi, Nakabeppu, Osamu
Experimental Study of Port Water Injection System on Single Cylinder Diesel Engine Performance and Exhaust Emission2024-32-00254/18/2025
Vehicle emission standards have become more and more stringent and have driven the development of advanced engine design with low-cost emission control technologies. For small diesel engine which is used in three-wheel (3W) passenger and load carrying vehicles, it was major task to improve lower engine rpm torque and performance to comply with stringent exhaust emissions standard as well, especially for Oxides of Nitrogen (NOx) and Particulate Matter (PM) emissions. Bharat Stage (BS) VI emission standards for three-wheel vehicles was implemented from April 2020 onwards in India. Water injection technology has proven advantageous for low-cost solution with Mechanical fuel injection system on small diesel engines, Intake port water injection is the easiest method to introduce water to engine cylinder, which calls for minimal modification of existing engine structure. In the present study 435cc naturally aspirated DI Diesel engine used for three-wheel vehicle was explored by adding water
Syed, Kaleemuddin, Chaudhari, Sandip, Khairnar, Girish, Katariya, Rahul, Jagtap, Pranjal, Bhoite, Vikram
Enhancements in Hydrogen Low Pressure Injection on Small Two-Stroke Engines2024-32-00474/18/2025
The use of small 2-stroke crankcase scavenged engines running on hydrogen is very attractive for low power rates, when low cost and compact dimensions are the fundamental design constraints. However, achieving optimal performance with hydrogen fuel presents challenges, including uneven air-fuel mixtures, fuel losses, and crankcase backfiring. This research focuses on a small 50cc 2-stroke loop-scavenged engine equipped with a patented Low-Pressure Direct Injection (LPDI) system, modified for hydrogen use. Experimental results demonstrate performance comparable to the gasoline counterpart, but further optimizations are needed. Consequently, CFD-3D simulations are employed to analyses the injection process and guide engine development. The numerical analysis focuses on a fixed operating condition: 6000 rpm, Wide Open Throttle (WOT), with a slightly lean mixture and injection pressure fixed at 5 bar. A numerical model of the entire engine is set up with the primary objective of improving
Caprioli, Stefano, Schoegl, Oliver, Oswald, Roland, Kirchberger, Roland, Mattarelli, Enrico, Rinaldini, Carlo Alberto
A Concept for Functional Modelling of an E-Bike Powertrain2024-32-00174/18/2025
The increasing popularity of e-bikes, especially pedelecs, has led to a growing interest in consideration of e-bike cycling. To achieve a deeper understanding on the process of e-bike cycling and in particular the effects on the rider it can be instrumental to use simulation methods. In this context, the e-bike drive system and its function are of central importance for e-bikes. Therefore, this work proposes a functional modeling of the powertrain of an e-bike with a mid-drive motor, considering legal constraints and support functionalities. The model incorporates the mechanical transmission between pedals, motor, and crank shaft, allowing for a detailed analysis of the e-bike’s performance. Additionally, the support mechanism is depicted, where an electric motor amplifies the rider’s pedaling torque. The electrical behavior of the motor, energy consumption, and battery state of charge are also integrated into the model. This comprehensive approach aims to provide a generic
Rauch, Yannick, Kettner, Maurice, Kriesten, Reiner
TitleAIRS12242024 (Current)12/24/2024
SS
A-20A Crew Station Lighting
TightAIR12122024A (Current)12/12/2024
New Scoop
A-6 Aerospace Actuation, Control and Fluid Power Systems
testARPTEST3008A (Current)12/12/2024
Sc
A-6 Aerospace Actuation, Control and Fluid Power Systems
TTAIR12092024 (Current)12/9/2024
SS
A-6 Aerospace Actuation, Control and Fluid Power Systems
Demo Title 12/3/2024AIR12032024 (Current)12/3/2024
Demo Scope 12/3/2024
A-6 Aerospace Actuation, Control and Fluid Power Systems
Influences of Lubricant Viscosity and Metallic Content on Diesel Soot Oxidation Reactivity2024-01-50848/23/2024
This study examined the effects of lubricant viscosity and metallic content on the oxidation reactivity of diesel particles. In the first part, the factors affecting thermogravimetric analysis (TGA) experiments was discussed and confirmed. The influences of initial soot mass, heating rate, and airflow rate on soot oxidation rate and experimental reproducibility were investigated to develop an optimized TGA method. On the basis of these experiments, an initial soot mass of 2.0 mg, airflow rate of 4.8 L/h, and heating rate of 2.5°C/h were used for all subsequent TGA tests. It could be found that the TGA experiments had high repeatability, and the differences were less than 0.1%. In the second part, a four-cylinder diesel engine was lubricated with seven kinds of lubricant with different viscosity and metallic content by the use of viscosity index improver (VII), antioxidant and corrosion inhibitor (ACI), and ashless dispersant (AD). Particle samples were subjected to TGA to test their
Meng, Hao, Yang, He, Zhang, Weili, Xing, Jianqiang, Xu, Yan, Wang, Yajun
Impact of Detailed SFC on Hybrid-Electric VTOL SizingF-0080-2024-13415/7/2024
Data from a 3.43 kW piston engine-generator is integrated with rotorcraft sizing analysis to assess its impact. First, the measured SFC map of the powerplant is modeled. Second, the sizing is validated with XV-15 flight test aircraft and NASA conceptual reference quadrotor. The power and platform models are then integrated to size a hypothetical quadrotor bi-plane unmanned air vehicle of 5 lb payload. Several cases for how the engine can be operated to meet the vehicle torque and speed are detailed. The key conculsion is that a detailed SFC model is as important as the aircraft model. Without it, errors in tip speed reduction, gross weight, and range would be quite dramatic from 50-100%. A tip speed reduction to 65% hover in cruise was found to strike the best balance between rotor performance and engine performance of the hypothetical aircraft, resulting in a gross weight of 50 lb and range of 120 nm at 60 kts cruise speed.
Arace, Matt, Datta, Anubhav
EFFECT OF PISTON SECONDARY MOTION ON LUBRICATING OIL CONSUMPTION, BLOW-BY AND FRICTION2024-26-02591/16/2024
As per pieces of literature, 40 to 60 % of friction losses in an Internal combustion engine occur in piston-ring pack-liner assembly and, there is a significant supportive role of simulation in improving this assembly. Literature is also available which tells, how changes in pistons affect oil consumption. Thus, piston dynamics plays an important role in oil consumption. Furthermore, the Piston Movement Module simulation results also serve as a very important input for postprocessing to calculate piston ring dynamics. This research work is conducted to understand the effect of piston secondary motion, on oil consumption, blow-by, and friction. In this work, the results of ring dynamics and oil consumption simulation modules are studied with consideration and non-consideration of piston secondary motion results. The parameters like minimum oil film thickness, lubricating oil consumption, blow-by, friction, and friction power loss are investigated. Results indicate that oil throw-off and
Sanadhya, Kunjan, Nandgaonkar, M., Aghav, Yogesh
Effects of Low Temperature on Forged Steel Materials in Hydrogen Internal Combustion Engines Applications: Assessing Ductile-Brittle Transition2024-26-01741/16/2024
In Hydrogen internal combustion engines (H2ICE), the hydrogen is stored and operated at very low temperature before it enters the combustion chamber. The effect of hydrogen on steel materials is detrimental because of hydrogen embrittlement. Forged steel parts are used in engine specifically crankshafts, connecting rods, camshafts, and pistons. The objective of the work is to analyze the effect of low temperature i.e. 35 °C to -60 °C on three types of forged steel materials i.e. 40Cr4, 42CrMo4 and EN8 and assess any potential changes in their properties due to ductile brittle transition. The ductile to brittle transition charpy impact test is widely used to determine the temperature at which a material shifts from exhibiting ductile behavior to brittle behavior. This transition is critical for understanding the safety and reliability of steel components, as brittle fracture can lead to catastrophic failures. The steel samples were subjected to five different temperature temperatures
Parasumanna, Ajeet Babu Kumar, Karle, Ujjwala, Ambhore, Yogesh
Development of 8L Hydrogen IC Engine2024-26-01701/16/2024
Throughout the world the efforts are being carried out to reduce the GHG emissions from transportation sector. As Volvo Group is a signatory of SBTi and having internal target of Carbon neutrality by 2040, we have intensified & also diversified our R&D efforts to develop powertrains of the future having mix of conventional, various alternate fuels, electric etc. There will not be a unique solution or strategy suiting for all the markets in the world. Each market will have its own motivation & factors which OEMs need to consider while deciding the short term, midterm & long-term strategy for powertrain technology. Accordingly, OEMs must be ready with product mix suitable for all global markets. This paper will talk about the efforts taken and lessons learned during development of Hydrogen fueled IC Engine. We used 8L Diesel IC engine as a base to convert it to Hydrogen powered IC engine, in a retrofit spirit, so that with minimum changes we could make the working prototype. This engine
LAD, MAKRAND RAJENDRA, Neveu, Jean Marc, S, ANOOP KRISHNA
Motorcycle Engine Vibrations Prediction for Inertia Loads Using Multi Body Dynamics Calculations2024-26-02321/16/2024
Motorcycles are a preferred means of transportation in most of the countries due to its economic factor and ease in travelling. Rider comfort is an important aspect while designing a vehicle. Rider comfort is often compromised by unwanted vibrations experienced at human interface points also called as tactile points. These unwanted vibrations also affect rider's motorcycle control and overall health. There are two major source of vibrations in a motorcycle that is engine & road inputs. In current study, a method is being explored to predict engine induced vibrations. Engine induced vibrations at various locations are simulated through multi body dynamics (MBD) and finite element (FE) simulation methods at vehicle level. Motorcycle model comprising of engine, frame and subassemblies are modeled in FE tool and then condensed to be used in MBD tool. Piston assembly, connecting rod, bearings and engine mounts are modeled in MBD tool. Vibration response resulting from unbalanced inertia
Kumar, Virender, Joshi, Gaurav, Garg, Ankit
Cost Effective Pathways Toward Highly Efficient and Ultra-Clean CI Engines, Part I: Combustion System Optimization2024-26-00371/16/2024
Following global trends of increasingly stringent greenhouse gas (GHG) and criteria pollutant regulations, India will likely introduce within the next decade equivalent Bharat Stage (BS) regulations for Diesel engines requiring simultaneous reduction in CO2 emissions and up to 90% reduction in NOx emission from current BS-VI levels. Consequently, automakers are likely to face tremendous challenges in meeting such emission reduction requirements while maintaining performance and vehicle total cost of ownership (TCO), especially in the Indian market which has experienced significant tightening of emission regulation during the past decade. Therefore, it is conceivable that cost effective approaches for improving existing diesel engines platforms for future regulations would be of high strategic importance for automakers. In this first of a two-part article, cost effective means of improving the combustion process in a Diesel engine to reduce engine-out emissions, specifically of NOx and
Shah, Ashish, Kumar, Praveen, Sari, Rafael, Cleary, David, Gothekar, Sanjeev, Thipse, Sukrut S
An experimental approach to investigate the FEAD cover failure & its design optimization.2024-26-03711/16/2024
In automotive Front End Accessory Drives (FEAD), the crankshaft supplies power to accessories like alternators, pumps, etc. FEAD undergoes forced vibration due to crankshaft excitation, dynamic tension fluctuations can cause the belt to slip on the accessory pulleys. By considering the criticality of the system, when engine mounting is longitudinally to the vehicle which makes it directly exposed to the air flow containing foreign particles which may cause the damage to the FEAD system and deteriorate the intended functionality. FEAD cover is introduced in the system to enhance belt-pully system functionality by restricting the entry of foreign particles during engine operation. This paper contains study of FEAD cover failure and provide the stepwise approach to capture such issue during novel model development for 4 cylinder naturally aspirated engine during engine bench testing. Failure mechanism was studied using various methodology such as CAE and G-Load measurement to identify the
PATEL, HARDIK MANUBHAI, KUMAR, NITISH, Chand, Subhash, Gupta, Vineet
Predictive Underhood Thermal Management Model2024-26-02721/16/2024
In the automotive industry, thermal management is a very important way to solve the problems of energy saving and emission. The underhood thermal management is one of the critical aspects in vehicle thermal management since it caters to critical aspects of engine cooling, charge air cooling, air conditioning and turbocharger cooling. The appropriate thermal management of these critical components is necessary for ensuring the appropriate performance by the vehicle. Hence, under-hood thermal management is the core of the integrated vehicle thermal management. In the thermal management analysis approaches, the numerical simulation is widely adopted as an important approach. Hence, in this paper a model is developed in MATLAB to handle 1D parametric analysis of the cooling system, while reducing the testing time and resources taken for the product development. The developed model can be used to evaluate multiple aggregate options for CAC, Radiator, Engine, Fan etc. The model predicts the
P V, NAVANEETH, Prasad, Suryanarayana A N, ML, SANKAR
Enhancing Electric Vehicle Performance and Battery Life through Flywheel Energy Storage System: Modelling, Simulation, and Analysis2024-26-01361/16/2024
This research paper focuses on the modelling and analysis of a flywheel energy storage system (FESS) specifically designed for electric vehicles (EVs) with particular emphasis on the flywheel rotor system associated with active magnetic bearings. The methodology used simulation approaches to investigate the dynamics of the flywheel system. The objective of this study is to explore the effects of implementing the flywheel energy storage system on the performance of the EV. The paper presents a comprehensive model of the flywheel energy storage system, considering the mechanical and electrical aspects. The mechanical model accounts for the dynamic behaviour of the flywheel, including parameters such as rotational speed, inertia, and friction. The electrical model describes the interaction between the flywheel and the power electronics, such as the converter and motor/generator. To evaluate the benefits of the flywheel energy storage system, simulations are conducted. Simulation studies
Akhtar, Juned
A mechanism to maintain negative crankcase pressure in a turbocharged gas engine to meet Euro-VI emission regulation and to reduce oil consumption.2024-26-01451/16/2024
Emissions regulation continually drives the automotive industry to innovate and develop. This pushes to introduce mechanism to maintain negative crankcase pressure in gas engine to meet this changing regulation. The way a turbocharger is used, to meet engine performance, can impact the pressure balance over the compressor and turbine end seals. This pressure difference can allow oil to leak through turbocharger seals. In normal engine operating condition, the pressure in the turbocharger end housings is higher than the bearing housing and oil/gas flows into the bearing housing, through the oil drain to the crankcase. Under certain operating conditions, such as low idle and thermal management, this pressure difference can be reversed with a higher bearing housing pressure than the pressure behind the turbine compressor wheel. Under this condition oil/gas will flow out of the bearing housing to the recess behind the compressor wheel. The bearing housing pressure will always track the
R, MAHESH BHARATHI
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