Browse Topic: Connecting rods

Items (1,523)

060002To be published on 01/01/2099

USUALLY UNOBSERVED REFINEMENTS OF AUTOMOBILE CONSTRUCTION

08000301/01/2024

ELLSWORTH, JOHN MAGEE, FAY, THOMAS J.

Optimization of HEV Vehicle’s Engine Modulated Noise

2025-01-008405/05/2023

One 1.5L Miller-cycle turbocharged four cylinder gasoline hybrid engine is installed on a certain hybrid vehicle. When accelerating at low to medium speeds with a small throttle, there is a "da da" knocking noise inside the car, which seriously affects the overall sound quality of the vehicle. By analyzing the vibration and noise data of the engine, it was found that the frequency of the abnormal knocking sound is 200-1000Hz, which presents a half order characteristic in the time domain, that is, one knocking occurs when the engine crankshaft rotates twice. Through Hilbert demodulation analysis of the vibration data in the problem frequency range, it was found that the knocking noise was modulated in the frequency domain, with a modulation frequency of half of the crankshaft rotation frequency. By building a fully flexible multi-body dynamic model of a hybrid powertrain and inputting the engine's cylinder pressure excitation, the combustion excitation is coupled with mechanical

Design, Fabrication, and Analysis of Vertical Press Cut Machine

2022-28-048311/18/2022

This study involves the design, fabrication, and analysis of a vertical press-cut machine (henceforth machine*) to cut wooden plates of 1mm thickness to directly produce an output of the required shape and dimension in one press. The aim is to manufacture a machine that could be portable, cost less (also includes operating costs and labor costs) and be able to produce outputs of any dimensions and shapes. This machine operates on the principle of slider crank mechanism which utilizes a slider, a connecting rod, and a crank. The necessary punch force required in this study to shear a wooden plate of 1mm thickness completely, is 3198 N. This necessary downforce is achieved by fabricating a die of mass 2kg with Mild Steel material and attaching 4 stainless steel blades (total mass = 0.68 kg) with 2mm allowance to the die using eight 12mm bolts. This die is bolted (8mm diameter) to a mild steel plate (150*60*6: l*b*t) which acts as the connecting rod in this setup, which is then bolted

S, Ravindran, Renganathan, Srikanth, D, Venkatragavan, S, Sundar, R, Steephan Raj, Sadhasivam, Navin

Engine vibration-dampening (reduction) through split engine mounting arm for passenger vehicle.

2022-01-024403/29/2022

Automotive industry is focusing on NVH reduction and customer comfort for passenger vehicle. Structural optimization is an one of the effective tool to obtain an optimum design to achieve NVH reduction. For an internal combustion engine, there exist two basic dynamic disturbances: a) the firing pulse due to the explosion of the fuel in the cylinder and b) the inertia force and torque caused by the rotating and reciprocating parts (piston, connecting rod and crank). The usage of engine mounts is the best solution for dampening the effect of vibrations and transmitting forces between the engine and the automotive body structure. In this paper, application of structural optimization in the design of a engine mount has been carried out. Effort has been taken to develop engine-mounting arm with two different designs solution. Further, engine with two different configuration has been tested at Engine test bed and vehicle level to understand the behavior in real environment. Further results

Gavade, Sujit Vithoba, Gangurde, Prashant, Bhargava, Aashish, Walhekar, Vishal, Mishra, Abhishek, Sawant, Yogesh

DESIGN OF LOAD CELL OPERATED MAGNETIC BRAKING SYSTEM

2022-01-110603/29/2022

The traditional braking system uses hydraulic fluid with components such as master cylinder, floating calliper, brake pedal, and connecting rod. The disadvantage with this system is regular maintenance, changing of oil and leakage. To overcome these disadvantages and making it cost effective this work is proposing a Load-cell operated magnetic braking system. It is reliable and requires less maintenance. The braking process involves impressing load on the load cell installed upon the steering wheel of the car. The load is converted to electric signals and will be transferred to the amplifier, then this amplified signal is supplied to hub of the rotor which is magnetic operated and applies brake. This braking system has more safety and accuracy compared to traditional braking system. Brakes are disengaged magnetically and engaged electrically. This brake system is used for dynamic stopping and holding halt and has flexibility in controlling the braking force through voltage applied

Srivastava, Jay Prakash

Design Challenges & Solution in Modifying Compact 4-Stroke Diesel Engine while Adapting D-Cycle Technology

2022-01-072503/29/2022

This paper reviews application of 2-Stroke D-Cycle (i.e. Differential Stroke) technology to compact tractor 4-Stroke 2.7L 4-Cylinder CRS (Common Rail System) Naturally aspirated (NA) Diesel engine for improving efficiency & power. The study considers design challenges that are presented for accommodating D-cycle technology in engine. The paper also covers resolving those challenges with established technical solutions. Study focuses on modifying conventional compact 4-stroke diesel engine with the intention of keeping design changes minimal for incorporating differential stroke technology. Designing of vertically splitting lightweight piston crown which can smoothly engaged and separated from main piston body without any impact, stem rod which connects piston crown with rocker arm, hollow connecting rod and rocker arm which is actuated by additional camshaft in addition to present camshaft. Lubrication of additional camshaft is done by extending existing oil galleries. Gear train

Telshinge, Pravin, Paulraj, Lemuel

Reducing Power Cylinder Friction with Advanced Coatings and Optimized Lubricants

2022-01-063003/29/2022

Power cylinder friction accounts for a significant amount of total engine friction within reciprocating, internal combustion engines. The power cylinder consists of the piston, piston rings, and cylinder liner, mitigating friction in these tribocouples is key to the development of efficient internal combustion engines. However, isolating these components for detailed analysis can be challenging. In this work, a new reciprocating liner test rig is developed and used to evaluate several technologies for reduced piston ring and liner friction. The rig design is novel, using a stationary piston and a reciprocating cylinder liner. Friction is calculated from the force measured in the connecting rod which supports the piston. The rig is very flexible and allows independent control of peak cylinder pressure, speed, and lubricant temperature. Using the newly developed test rig, several technologies for friction reduction are evaluated and compared. Friction reducing technologies include a

Bachu, Pruthvi, Michlberger, Alexander, Bitsis, Chris

Overcoming manufacturing challenges in mass production of vanadium micro-alloyed steel connecting rods

2022-01-026403/29/2022

With recent advancements to create light weight engines and therefore, to design stronger and lighter connecting rods, automobile manufacturers have looked upon vanadium micro-alloyed steels as the material of choice. These materials have been developed keeping in mind the strength and manufacturing requirements of a connecting rod. Since, 36MnVS4 has been the most popular of this category, the same has been discussed in this paper. The transition of manufacturers from the traditional C70S6 grade to the new 36MnVS4 has to be dealt with in-depth study and modification of processes to adapt to new set of properties of the latter. C70S6 is a high carbon grade with superior manufacturability whereas 36MnVS4 is a medium carbon grade with superior strength and ductility owing to the presence of vanadium. This paper deals with the study of challenges in mass production of connecting rod using 36MnVS4 grade and overcoming the same using optimization of processes like controlled cooling, stress

Pillai, Pratik, Gopalan, Vijaysankar, Venugopal, Sivakumar

Development of 1.5L Diesel Engine for Stage V with common rail system

2022-32-005201/09/2022

Recently, EU StageV emissions regulations have been enforced in the European market since 2019, increasing environmental requirements for diesel engines. EU StageV has been tightened compared to EPA Tier4 regulation, which demand PM (Particulate Matter) reduction and added new PN (Particle Number) regulations. Until the previous regulation EU Stage IIIA, the power category of 19kW or more and less than 37 kW had adopted mechanical IDI (Indirect-Injection). This mechanical engine is characterized by compactness and lightweight because of simple structure. Therefore, this engine is appreciated by customer with easy installation. On the other hand, to achieve EU StageV, it is necessary to adopt the electronic direct injection common rail system with more precise fuel injection and advanced exhaust gas aftertreatment device. The newly developed V1505-CR-T engine is not only small displacement of 1.5L, but also four-cylinders, and it is low vibration in addition compactness and lightweight

Okimi, Shoichi, Nagai, Kentaro, Yoshida, Reo, Akitomo, Tomoya, Yamazaki, Takahiro

Digital Approach for Dynamic Balancing of Three Cylinder Gasoline Engine Crank-train

2021-26-026509/22/2021

Due to ever increasing demand of more fuel efficient engine with lower manufacturing cost, compact design and lower maintenance cost; OEM’s prefer three cylinder internal combustion engine over four cylinder engine. Though customer demands NVH characteristics of a three cylinder engines to be in line with four cylinder engine. Crank-train balancing plays most vital role in NVH aspects of three cylinder engines. A three cylinder engine crankshaft with phase angle of 120 degrees poses a challenge in balancing the crank train. In three-cylinder engines, total sum of unbalanced inertia forces occurring in each cylinder will be counterbalanced among each other. However, parts of inertia forces generated at No.1 and No. 3 cylinders will cause primary and secondary resultant moments about No. 2 cylinder. Conventional method of designing a dynamically balanced crank train is time consuming and leads to rework during manufacturing. Also, different vehicle models with a same engine can call for

Gupta, Akash K, B, Venkatakiran, K, Rahul, Panwar, Anupam, Joshi, Manoj

Development of a Novel Dynamically Loaded Journal Bearing Test Rig

2021-01-121809/21/2021

In this work, a dynamically loaded hydrodynamic journal bearing test rig is developed and introduced. The rig is a novel design, using a hydraulic actuator with fast acting spool valves to apply load to a connecting rod. This force is transmitted through the connecting rod to the large end bearing which is mounted on a spinning shaft, simulating a crankshaft journal. The hydraulic actuator allows for fully variable load control and can be used to apply either static load in compression and tension or dynamic loading to simulate engine operation. A variable speed electric motor controls shaft speed and is synchronized to the hydraulic actuator motion to accurately simulate loading from each stroke in a four-stroke cycle. In addition to these dynamically loaded cycles, the journal bearing rig is also capable of controlled static loading. This static loading is used to simulate stop/start engine operation. A high precision torque meter enables direct measurements of journal bearing

Michlberger, Alexander, Bachu, Pruthvi, Bitsis, Daniel Christopher

Revisiting Mobility-Based Predictions of Cyclic Minimum Film Thickness in Big-End Connecting Rod Bearings

03-15-02-001209/07/2021

This article compares elastohydrodynamic lubrication (EHL) and mobility-based solution methods for the determination of cyclic minimum film thickness hmin * encountered in four-stroke, big-end connecting rod bearings. Mobility-based solution methods are substantially faster than the EHL method for such bearings, so quantifying the accuracy of mobility-based methods is an obvious benefit to the engine designer. Production-level connecting rods are modeled and analyzed using an established mass-conserving mode-based EHL formulation, accounting for realistic oil feed arrangements and realistic housing deformation associated with structural inertia and surface pressures. From a large set of dimensional studies, it is observed that hmin * calculated using mass-conserving EHL can be bounded by results obtained from finite-bearing mobility formulations, provided that a non-dimensional bearing number Λ falls below a critical value Λ crit ≈ 4. A set of five independent validation dimensional

Boedo, Stephen, Blais, Travis M.

A Two-Stage Variable Compression Ratio System for Large-Bore Engines with Advanced Hydraulic Control Circuit and Mechanical Locking Device

03-15-02-001108/19/2021

In order to meet upcoming emission targets, an increasing number of ships using Liquefied Natural Gas (LNG) as fuel have been put into service. In this context, many shipowners are particularly interested in the dual-fuel (DF) large-engine technology, which enables ships to operate with both gaseous and conventional liquid fuels. The use of different combustion principles in DF engines requires a layout of the base engine with a relatively low compression ratio (CR) for the gas mode to prevent unstable combustion (knocking). However, this layout leads to disadvantages in the Diesel operation mode, which requires a higher CR for optimal fuel efficiency. Therefore, a two-stage variable compression ratio (VCR) system is a technology particularly suitable for DF engines. It allows to reduce fuel costs by approximately 5.5%. This article presents an innovative VCR connecting rod (conrod) design for modern DF engines that adapts the piston position by changing the effective conrod length

Marten, Christopher, Pendovski, Denis, Pischinger, Stefan, Bick, Werner

BMW reveals its first “M” performance-badged two-wheeler

20AUTP11_1111/01/2020

BMW has revealed its first-ever M-badged motorcycle, the M 1000 RR superbike. A heavily reworked version of the already-capable S 1000 RR sportbike, the new machine is riding the trend of track-focused machines, as the motorcycle industry watches sportbike sales follow the same path as sedans in the automotive world. BMW's highly regarded Motorsports division produced its first racecar (the 3.0 CSL) in 1972 and its first road-going car with the mid-engine M1 in 1978. Since then, the Munich-based auto- and motorrad-maker has since produced an M version of nearly every car it has manufactured, the 7 Series being a notable exception.

Seredynski, Paul

Lubricating Oil, Aircraft Piston Engine (Ashless Dispersant)

J1899_202010 (Current)

10/28/2020

This SAE Standard establishes the requirements for lubricating oils containing ashless dispersant additives to be used in four-stroke cycle, reciprocating piston aircraft engines. This document covers the same lubricating oil requirements as the former military specification MIL-L-22851. Users should consult their airframe or engine manufacturers manuals for the latest listing of acceptable lubricants.

E-38 Aviation Piston Engine Fuels and Lubricants

Lubricating Oil, Aircraft Piston Engine (Ashless Dispersant)

J1899_202010-TEST-REC (Historical)10/28/2020

This SAE Standard establishes the requirements for lubricating oils containing ashless dispersant additives to be used in four-stroke cycle, reciprocating piston aircraft engines. This document covers the same lubricating oil requirements as the former military specification MIL-L-22851. Users should consult their airframe or engine manufacturers manuals for the latest listing of acceptable lubricants.

E-38 Aviation Piston Engine Fuels and Lubricants

Cycle-Resolved Evaluation of Directly Injected Methane Using a High-Speed Laser-Induced Fluorescence Measurement System

2020-01-210609/15/2020

The usage of alternative fuels inside internal combustion engines (ICE), is one promising approach to meet the higher requirements concerning the efficiency and emission of modern combustion systems. The injection and mixture formation of such fuels has a major impact on the subsequent combustion as well as the formation of pollutants. To rate the influence and to gain a better understanding of those new alternatives a basic understanding of these dominant processes is mandatory. The principle of laser-induced fluorescence (LIF) is a well-known method to display and evaluate fuel distributions inside combustion chambers. A suiting online calibration routine allows the visualization of air-fuel equivalence ratio (λ) two-dimensionally during different operation modes. As cyclic variations can become a more critical issue while using alternative fuels, cycle- resolved test series become more and more important. To obtain several crank-angle-resolved measurements during one cycle as well

Geiger, Mirko, Zoellner, Christian, Brueggemann, Dieter

Advanced Methods to Handle LSPI in TGDI Engines

2020-28-000808/18/2020

In order to meet the stringent emission norms like EU6 and EU7 together with CAFÉ/CAFC norms, down-sizing of the engine is one of the thrust areas of focus among the OEMs. To this end, keeping the engine size small but to achieve the required power output, advanced Turbo charged Gasoline Direct Injection engine technology (TGDI) has emerged. However, TGDI technology is susceptible to an abnormal combustion phenomenon termed as Low Speed Pre-Ignition (LSPI) event. This event happens prior to the intended combustion, which causes the catastrophic engine damage. Several studies in terms of simulation and experiments to understand this phenomenon are reported in the literature. The main factors influencing this occurrence are found to be engine design and calibration, fuel types and engine oil formulation (in terms of calcium content). In this paper, advanced methods to handle the LSPI occurrence severity and component level advances in design robustness to avoid the engine damage are

N, Sekarapandian, KANNAIYAN, Ashok, ARIVUKKARASU, Hariprasath, Mani, Rajkumar, Muthu, Selvaraji

Study of Friction Reduction Potential in Light- Duty Diesel Engines by Lightweight Crankshaft Design Coupled with Low Viscosity Oil

2020-37-000606/23/2020

Over the last two decades, engine research has been mainly focused on reducing fuel consumption in view of compliance with more stringent homologation cycles and customer expectations. As it is well known, the objective of overall engine efficiency optimization can be achieved only through the improvement of each element of the efficiency chain, of which mechanical constitutes one of the two key pillars (together with thermodynamics). In this framework, the friction reduction for each mechanical subsystem has been one of the most important topics of modern Diesel engine development. The present paper analyzes the crankshaft potential as contributor to the mechanical efficiency improvement, by investigating the synergistic impact of crankshaft design itself and oil viscosity characteristics (including new ultra-low-viscosity formulations already discussed in SAE Paper 2019-24-0056). For this purpose, a combination of theoretical and experimental tools have been used to design an

Mafrici, Salvatore

Further Experiments on the Effect of Bulk In-Cylinder Temperature in the Pressurized Motoring Setup Using Argon Mixtures

2020-01-106304/14/2020

Mechanical friction and heat transfer in internal combustion engines have long been studied through both experimental and numerical simulation. This publication presents a continuation study on a Pressurized Motoring setup, which was presented in SAE paper 2018-01-0121 and found to offer robust measurements at relatively low investment and running cost. Apart from the limitation that the peak in-cylinder pressure occurs around 1 DegCA BTDC, the pressurized motoring method is often criticized on the fact that the gas temperatures in motoring are much lower than that in fired engines, hence might reflect in a different FMEP measurement. In the work presented in SAE paper 2019-01-0930, Argon was used as the pressurization gas due to its high ratio of specific heats. This allowed to achieve higher peak in-cylinder temperatures which close further the gap between fired and motored mechanical friction tests. In 2019-24-0141, Argon was mixed in different proportions with Air to synthesize

Caruana, Carl, Farrugia, Mario, Sammut, Gilbert, Pipitone, Emiliano

A New Cavitation Algorithm to Support the Interpretation of LIF Measurements of Piston Rings

2020-01-109104/14/2020

Laser induced fluorescence (LIF) is used to investigate oil transport mechanisms under real engine conditions. The engine oil is mixed with a dye that can be induced by a laser. The emitted light intensity from the dye correlates with the residual oil at the sensor position and the resulting oil film thicknesses can be precisely determined for each crank angle. However, the general expectation is not always achieved, e.g. an exact representation of piston ring barrel shapes. In order to investigate the responsible lubrication effects of this behavior, a new cavitation algorithm for the Reynolds equation has been developed. The solution retains the mass conservation and does not use any switch function in its mathematical approach. In contrast to common approaches, no vapor-liquid ratio is used, but one or several bigger bubbles are approximated, as have been observed in other experiments already. As a result, not only the known boundary conditions for the Reynolds equation become

Ruch, Fabian H., Wachtmeister, Georg

Connecting Rod Durability and Big-End Bore Distortion Study

2020-01-018404/14/2020

The prediction of the connecting rod behaviour is one of the most important aspects of the engine design to estimate the engine life and its NVH behaviour. Connecting rod is usually simulated as a stand-alone component replacing the connected members with boundary conditions. These kinds of simulation usually underestimate the life of the connecting rod and overestimate the crankpin distortion. This unreal behaviour of simulation can result in over design of the crankshaft and wrong crankpin bearing selection, which can result in a noisy engine. The current Finite Element Analysis (FEA) is modelled by considering crankshaft, bearings, 3D bolts and crankcase substructure along with the connecting rod to predict the fatigue life and bearing distortion. A multi-body dynamics (MBD) simulation of the Cranktrain has been carried out to predict the forces and accelerations on the connecting rod by including the combustion force with a constant crankshaft speed for different conditions. The

Thekke Kolayath, Nabeel, T, Sreenivasulu, Giles, Rod

Functionality Analysis of Thermoplastic Composite Material to Design Engine Components

2020-01-077404/14/2020

Developing of innovative technologies and materials to meet the requirements of environmental legislation on vehicle emissions has paramount importance for researchers and industries. Therefore, improvement of engine efficiency and fuel saving of modern internal combustion engines (ICEs) is one of the key factors, together with the weight reduction. Thermoplastic composite materials might be one of the alternative materials to be employed to produce engine components to achieve these goals as their properties can be engineered to meet application requirements. Unidirectional carbon fiber reinforced PolyEtherImide (CF/PEI) thermoplastic composite is used to design engine connecting rod and wrist pin, applying commercial engine data and geometries. The current study is focused on some elements of the crank mechanism as the weight reduction of these elements affects not only the curb weight of the engine but the overall structure. As a matter of fact, by reducing the reciprocating mass

Razavykia, Abbas, Delprete, Cristiana, Rosso, Carlo, Baldissera, Paolo

The Isochoric Engine

2020-01-079604/14/2020

For the gasoline engine, the isochoric process is the ideal limit of the ideal processes. During the project, a combustion engine with real isochoric boundary conditions is built. A “resting time” of the piston for several degrees crank angle in the top dead center (TDC) can be realized with a special crank drive. This crank drive consists of two crankshafts with different strokes, which are combined. The two crankshafts rotate with a ratio of two to one in opposite directions. The total stroke corresponds to the amount of the first crankshaft, so it is possible to investigate different strokes of the second crankshaft in the same crankcase. Different “resting times” can be achieved by different strokes of the second crankshaft. A specific combination of both crankshafts make a stroke possible which corresponds to that of a conventional combustion engine. In addition to the standard cylinder pressure sensor, a quick surface temperature probe is also used as supplementary measurement

Burger, Benjamin, Bargende, Michael

Impact of High Performance Combustion Chamber Alloys on Fuel Efficiency

2020-01-133804/14/2020

Internal combustion engines have been developed for over one hundred and twenty years and are a very mature technology. Over this time, significant improvements in power density and brake thermal efficiency have been realized from improvements in design, processing and material properties. Huge advances in computer simulation capability over the past thirty years have enabled the former two categories to be explored and exploited very thoroughly, leaving materials specifications as the fundamental key to unlocking further efficiency gains. This paper summarizes the design advantages of a range of alternative materials developed for piston, ring connecting rod and bushing applications. A Ford Ecoboost 2.3l RS engine was selected as a baseline engine and the reciprocating parts were re-designed to take advantage of the improved characteristics of these materials. Reciprocating mass, mechanical efficiency and crevice volume savings have been demonstrated from the re-designed components

Tricker, David, Egger, Andrew, Krus, David, Bredda, Scott

Internal Combustion Engines - Piston Vocabulary

J2612_202002 (Current)02/18/2020

This SAE standard defines the most commonly used terms for pistons. These terms designate either types of pistons or certain characteristics and phenomena of pistons.

Piston and Ring Standards Committee

Development of a Novel Hybrid-Piston for Application in High Performance Two-Stroke Engines

2019-32-050801/24/2020

The current development trends for high performance two-stroke engines have been identified in raising combustion pressures and therefore higher cylinder temperatures [1] [2]. Thus, the requirements on piston assembly are increased in such a way that pistons based on aluminium-silicon alloys – as most commonly used in high performance two-stroke engines - reach their application limit. A suitable solution has been shown by research work such as that conducted by Mahle König, by using a piston consisting of different materials. With this approach, the higher stressed piston crown consists of steel, while the lower stressed piston skirt is made out from aluminium. Previous basic examinations showed the high potential of the hybrid piston concept in terms of pressure and temperature increase, while also showing the need for a temperature-stable and pressure-tight joint between crown and skirt. This paper will focus on the development of two novel hybrid-piston concepts, where the piston

Bechter, Christian, Jahn, Axel, Zimmermann, Frieder, Stamm, Uwe, Herb, Thomas

Friction Reduction of an All-aluminum Cylinder for Motorcycles by a Mirror Finished Bore with Dimples

2019-32-053001/24/2020

In recent years, the demand for fuel economy of small engines has been increasing for further improvement of product competitiveness. As a solution for this issue, a lot of developments on reduction of friction losses of engine components have been actively performed by engine manufacturers, especially the friction loss between the cylinder bores and pistons or piston rings is main issue to solve because these frictions highly contribute to the fuel economy for the small engines. In this study, focusing on the effect of the texture of the all-aluminum cylinder bore on friction loss, we verified the friction loss of all-aluminum cylinders having several kinds of surface textures by a floating liner method. For the evaluation, we prepared cylinders which have the texture of the following three types, 1) plateau type (having conventional cross-hatches), 2) mirror finished type (having no cross-hatches and no irregular surface characteristics), 3) dimple type (most of part is mirror

Murase, Yuta, Kumagai, Hideya

A study of Measurement for Oil Film at the Bearing of the Small End of Diesel Engine Connecting Rod

2019-01-233212/19/2019

Downsizing and slowing down of engine speed reduce mechanical losses and improve fuel economy. However, they exacerbate lubrication condition. The oil film thickness of the bearing of the small end of the connecting rod, which was one of the sliding surfaces with the severest lubrication condition in a diesel engine, was measured in this study to clarify the lubrication condition. Optical fibers were embedded in the bearing, and oil film was measured by means of the laser induced fluorescence method. It was found that oil film thickness was affected combustion gas pressure and distortion of the piston pin.

Suzuki, Shotaro, Yamada, Shota, Ito, Akemi

Dynamic oil pressure in connecting rod bearings and their influence on innovative cranktrain technologies

2019-01-233312/19/2019

In order to lower friction losses and hence ensure low fuel consumption of internal combustion engines, borderline design of hydrodynamic cranktrain bearings is often unavoidable. To realize this without the risk of failures, detailed modelling of hydrodynamic effects is gaining more and more relevance. In this publication, an approach using flow simulation to couple hydrodynamic bearings with each other, will be introduced. This allows the state variables of the fluid in the supply bore of the crankshaft to be calculated transiently. One important aspect of this concerns the solubility of gas in oil. This paper demonstrates that the gas fractions in the supply bore of the crankshaft influence the pressures at the hydrodynamic bearings. Additionally, simulation results will be shown and also validated with measurement data. Beside the application for conventional cranktrains, the developed methodology can also be applied to investigate lubrication systems, which include innovative

Pendovski, Denis, Pischinger, Stefan

Study of the Effects of Oil Supply and Piston Skirt Profile on Lubrication Performance in Power Cylinder Systems

2019-01-236412/19/2019

In internal combustion engines, the majority of the friction loss associated with the piston takes place on the thrust side in early expansion stroke. Research has shown that the Friction Mean Effective Pressure (FMEP) of the engine can be reduced if proper modifications to the piston skirt, which is traditionally barrel-shaped, are made. In this research, an existing model was applied for the first time to study the effects of different oil supply strategies for the piston assembly. The model is capable of tracking lubricating oil with the consideration of oil film separation from full film to partial film. It is then used to analyze how the optimized piston skirt profile investigated in a previous study reduces friction. It was found that the profile is able to maintain a larger amount of lubricant between the lower part of the piston skirt and the cylinder liner during compression stroke, thereby generating more hydrodynamic pressure, instead of asperity contact pressure, to balance

Meng, Zhen, Ahling, Sebastian, Tian, Tian

Research of the High Altitude Control Strategy of the Piston Aero-engine Using Two-stage Turbocharger Coupled with single Supercharging System

2019-01-221112/19/2019

Aiming at the high altitude operation problems for piston-type aero-engines and to improve the practical ceiling and high altitude dynamic performance, this thesis analyzes a controllable three-stage composite supercharging system, using a two-stage turbocharger coupled supercharger method. The GT-Power simulation model of a four-cylinder boxer engine was established, and the control strategy of variable flight height was obtained. The simulation research of engine performance from 0 to 20,000 meters above sea level has been carried out, which shows that the engine power is at the same level as the plain condition, and it could still maintain 85.28 percent of power even at the height of 20,000 meters, which meets the flight requirements of the aircraft.

Yao, Ye, Shi, Lei, Zhang, Zhe, Xiao, Maoyu, Liu, Mingwei, Tan, Jianwei

Effect of Eccentric Imbalance of Various Crank Train Components on Vibrations in Single Cylinder Diesel Engines

2019-28-241711/21/2019

Diesel engine is the main source of power for many agricultural applications such as water pump sets, compressors and tractors. At the same time it is also the main source of vibrations. Mechanical vibrations have instantaneous and long term effects on human body. Kinds of effects depend upon duration of exposure and frequency of vibrations. The increasing demands of improved comfort levels of operators are putting pressures on tractor manufacturers on reducing the vibration levels which thereby resulting in improving diesel engine vibrations. Vibration is the movement or mechanical oscillations about an equilibrium position of a machine or component. A Vibration analysis is about the art of looking for changes in the vibration pattern and then relating those changes. Vibration always occurs when there is unbalanced body in reciprocating or rotary motion. In an internal combustion engine there are many parts in reciprocating and rotary motion such as pistons, connecting rod, crankshaft

Julaha, Puneet, Arde, Vasundhara, Chirakkal, Remesan

Feasibility of Multiple Piston Motion Control Approaches in a Free Piston Engine Generator

2019-01-259910/22/2019

The control and design optimization of a Free Piston Engine Generator (FPEG) has been found to be difficult as each independent variable changes the piston dynamics with respect to time. These dynamics, in turn, alter the generator and engine response to other governing variables. As a result, the FPEG system requires an energy balance control algorithm such that the cumulative energy delivered by the engine is equal to the cumulative energy taken by the generator for stable operation. The main objective of this control algorithm is to match the power generated by the engine to the power demanded by the generator. In a conventional crankshaft engine, this energy balance control is similar to the use of a governor and a flywheel to control the rotational speed. In general, if the generator consumes more energy in a cycle than the engine provides, the system moves towards a stall. If the generator consumes less energy, then the effective stroke, compression ratio and maximum translator

Bade, Mehar, Clark, Nigel, Famouri, Parviz, Guggilapu, PriyaankaDevi

Nondestructive Measurement of Residual Strain in Connecting Rods Using Neutrons

05-12-03-001810/15/2019

Abstract Increasing the strength of materials is effective in reducing weight and boosting structural part performance, but there are cases where the residual strain generated during the process of manufacturing of high-strength materials results in a decline of durability. It is therefore important to understand how the residual strain in a manufactured component changes due to processing conditions. In the case of a connecting rod, because the strain load on the connecting rod rib sections is high, it is necessary to clearly understand the distribution of strain in the ribs. However, because residual strain is generally measured by using X-ray diffractometers or strain gauges, measurements are limited to the surface layer of the parts. Neutron beams, however, have a higher penetration depth than X-rays, allowing for strain measurement in the bulk material. The research discussed within this article consists of nondestructive residual strain measurements in the interior of connecting

Ikeda, Tomohiro, Jeffery, Bunn R., Fancher, Christopher M., Motani, Ryuta, Matsuda, Hideki, Okayama, Tatsuya

Design of Light Weight Hydraulic Connecting Rod for Agricultural Tractor

2019-28-001610/11/2019

Hydraulic power train assembly of an agricultural tractor is meant to controls the position and draft of the implement depending upon the type of crop, farming stage, implement type and soil conditions. These variations induce extreme range of loads on the hydraulic system, thus making it challenging to design these components. Hydraulic connecting rod is critical component of hydraulic power train assembly. Standards like IS12224, IS4468 governs the design of hydraulic power train components which regulates the test method for hydraulic power and lift capacity of the tractor. In this paper, a virtual simulation process has been established to design a hydraulic connecting rod to meet the requirements. The hydraulic connecting rod basically functions as a short load transferring link, which is subjected to the operating hydraulic pressure of the hydraulic lifting mechanism. The current circular connecting rod is higher in weight and cost. So, there is scope for optimizing the design of

Dumpa, Mahendra, Perumal, Solairaj, Redkar, Dinesh, Gomes, Maxson, Subbaiyan, Prasanna Balaji

Design and Analysis of Aluminium-Flyash Composite for Connecting Rod

2019-28-016610/11/2019

In this modern era of rapid growth of technology and need of economical machining processes and materials, there is an increasing demand for new materials for different mechanical applications. Composites with fly ash as reinforcement are likely to overcome the cost barrier for wide spread applications in automotive and small engine applications. To improve wettability, elements such as Mg and Si are added into Al melt to incorporate the ceramic particles. The chemical composition and engineering properties of fly ash, its physical and chemical properties make it an ideal raw material for producing various application based composites. The main objective is to fabricate an Aluminium- Flyash composite material suitable for parts like engine connecting rod which demand high strength and temperature sustainability at comparatively less weight. The composite will be made using casting process and Engine connecting rod will be designed in AutoCAD software. The design will be analyzed with

Nuthalapati, Suresh, Malkapuram, Devaiah

Design and Analysis of Hybrid Metal Matrix Composite Connecting Rod via Stir/Squeeze Casting Route

2019-28-011310/11/2019

The connecting rod was manufactured by forging process for enhancing high tensile and compressive load so that it was followed by the machining process and suite the IC engine as a part of the component. The main intern of our proposed work is to manufacture a two set of composites specimen of A356 alloy with reinforcement of 5 wt.% silicon carbide and 10 wt.% flyash processed through two different techniques like stir casting and stir cum squeeze casting route and obtain better mechanical properties. Further, the same properties were taken for modeling and analysing of the developed connecting rod model. Due to the commercial demand, the hybrid composite materials take a vigorous role in the analysis part of the connecting rod model. The FEA analysis is done on the connecting rod for a180cc engine by using Ansys 18.1. The static analysis is done by considering four different cases by altering material library property. The output parameter such as total deformation, Von Mises stress

Ranganathan, Soundararajan, Kuppuraj, Sathishkumar, Soundarrajan, Karthik, Perumal, Ashokvarthanan

Performance Engine Building Recommended Practices

J2379_201910 (Current)10/03/2019

This SAE Recommended Practice applies to the function of building reciprocating spark-ignition engines which are used in conjunction with standard and high-performance ancillary components in applications intended to achieve a minimum of 1 hp/in3. This document does not apply to rebuilt engines which may only be partially repaired with little or no machining, nor does it apply to second-hand or used engines.

Motor Vehicle Council

Piston Bowl Geometry Effects on Combustion Development in a High-Speed Light-Duty Diesel Engine

2019-24-016709/09/2019

In this work we studied the effects of piston bowl design on combustion in a small-bore direct-injection diesel engine. Two bowl designs were compared: a conventional, omega-shaped bowl and a stepped-lip piston bowl. Experiments were carried out in the Sandia single-cylinder optical engine facility, with a medium-load, mild-boosted operating condition featuring a pilot+main injection strategy. CFD simulations were carried out with the FRESCO platform featuring full-geometric body-fitted mesh modeling of the engine and were validated against measured in-cylinder performance as well as soot natural luminosity images. Differences in combustion development were studied using the simulation results, and sensitivities to in-cylinder flow field (swirl ratio) and injection rate parameters were also analyzed. In-cylinder mixture formation analysis showed that ignition of the pilot injection mixture develops nearly as it would in a homogeneous adiabatic reactor, being mostly advected, not mixed

Perini, Federico, Busch, Stephen, Zha, Kan, Reitz, Rolf, Kurtz, Eric

Modeling of a Spark Ignition Engine with Turbo-Generator for Energy Recovery

2019-24-008409/09/2019

Increasingly stringent regulations in the field of pollutant are forcing engine manufacturers to adopt new solutions to contain exhaust emissions, such as Hybrid Electric Vehicles (HEV) or Full Electric Vehicles (FEV). Still far from the wide diffusion of FEV limited from electrochemical storage systems together with the difficulty of creating adequate infrastructure distributed throughout the territory to recharging batteries, the HEV seems to be actually a better solution. The hybrid vehicle is already able to guarantee satisfactory autonomy and low pollution levels by combining the advantages offered by the two technologies of thermal and electric propulsion. Currently on the market there are several types of hybrid vehicles, with different degree of hybridization (electric motor power versus propulsion total power), capacity to store electricity and type of scheme constructive adopted for the integration between the thermal engine and the electric machine. A particular interest is

Arminio, Fabio, Cameretti, Maria Cristina, De Simio, Luigi, Iannaccone, Sabato, Terzo, Teodoro

Ford ‘cranks’ it up with another big V8 for Mustang

19AUTP09_1109/01/2019

When Ford introduced the Mustang Shelby GT350 in 2015, it was the pinnacle of Mustang-ness thanks to its 5.2-L DOHC “Voodoo” V8 that featured a flat-plane crankshaft design to enable sky-high revs (the GT350's 8200-rpm redline is one reason Ferrari has long specified flat-plane V8s) and a rollicking 526 hp at 7,500. Then there's the exotic “rip” exhaust note unique to flat-plane V8s. But contemporary musclecar development times seemingly are as quick as their ever-dropping 0-to-60 mph runs-and before Ford released the Shelby GT350, its SAE-certified 526 hp already had been eclipsed by the 707-hp supercharged 6.2-L Hemi V8 in the Dodge Challenger SRT Hellcat and later the 797-hp Hellcat Redeye. Prior to all this, GM's Chevrolet started the hyper-power frenzy by generating 650 hp from the supercharged 6.2-L OHV V8 launched for the 2012 Camaro ZL1.

SAE 17.6 Cubic Inch Spark Plug Rating Engine

J2203_201906 (Current)06/11/2019

This SAE Standard defines the standard engine to be used in determining spark plug preignition ratings. The engine is known as the SAE 17.6 Cubic Inch Spark Plug Rating Engine.

Ignition Standards Committee

Characteristics of Bending Stress with Whirling at the Rear End of a Crankshaft in an Inline 4-Cylinder High Speed Diesel Engine

2019-01-159206/05/2019

As engines become lighter and achieve higher output to meet carbon dioxide emissions targets, it becomes more challenging to design a crankshaft that is both lighter and capable of handling higher loads. Therefore, it is necessary to understand the characteristics of forces imposed on the crankshaft, and the mechanisms by which stresses are created in the crankshaft. This paper describes the characteristics of bending stresses measured on the rearmost crank pin fillet of a crankshaft. Two basic crankshaft resonant modes are described. Forward crankshaft whirl then has the effect of increasing the system natural frequencies by the stiffening effect, while reverse whirl reduces the system natural frequencies by the softening effect. The effect of whirl grows with increasing engine speed. This results in what appears to be four crankshaft natural frequencies rather than two. The four resonances appear at all non-zero engine speeds. The influence of flywheel mass on the stresses and

Kobayashi, Shinichiro

Modeling of Oil Transport between Piston Skirt and Cylinder Liner in Internal Combustion Engines

2019-01-059004/02/2019

The distribution of lubricating oil plays a critical role in determining the friction between piston skirt and cylinder liner, which is one of the major contributors to the total friction loss in internal combustion engines. In this work, based upon the experimental observation an existing model for the piston secondary motion and skirt lubrication was improved with a physics-based model describing the oil film separation from full film to partial film. Then the model was applied to a modern turbo-charged SI engine. The piston-skirt FMEP predicted by the model decreased with larger installation clearance, which was also observed from the measurements using IMEP method at the rated. It was found that the main period of the cycle exhibiting friction reduction is in the expansion stroke when the skirt only contacts the thrust side for all tested installation clearances. The main reason for lower skirt friction with larger clearance is greater amount of oil available during the expansion

Meng, Zhen, Ahling, Sebastian, Tian, Tian

Investigation and Optimization of Cam Actuation of an Over-Expanded Atkinson Cycle Spark-Ignited Engine

2019-01-025004/02/2019

An over-expanded spark ignited engine was investigated in this work via engine simulation with a design constrained, mechanically actuated Atkinson cycle mechanism. A conventional 4-stroke spark-ignited turbo-charged engine with a compression ratio of 9.2 and peak brake mean effective pressure of 22 bar was selected for the baseline engine. With geometry and design constraints including bore, stroke, compression ratio, clearance volume at top dead center (TDC) firing, and packaging, one over-expanded engine mechanism with over expansion ratio (OER) of 1.5 was designed. Starting with a validated 1D engine simulation model which included calibration of the in-cylinder heat transfer model and SI turbulent combustion model, investigations of the Atkinson engine including cam optimization was studied. The engine simulation study included the effects of offset of piston TDC locations as well as different durations of the 4-strokes due to the mechanism design. Incremental effects of adjusted

Yang, Zhuyong, Miganakallu Narasimhamurthy, Niranjan, Miller, Tyler, Naber, Jeffrey

Analysis of the Increase Level of Vibration in an Internal Combustion Engine due to the Degradation of the Lubricating Oil

2019-01-078004/02/2019

When analyzing vibrations in internal combustion engines, it is noticed that the greatest sources of vibrations are generated by combustion and mechanical forces. These forces occur over a wide frequency range and are transmitted to the outer surface of the engine through several paths, such as through the piston mechanism, connecting rod, crankshaft and engine block. As a result of the action of these forces, the external surfaces of the engine are subjected to vibrations of various amplitudes. Vibration problems in internal combustion engines are common due to the wide variety of parts and components that make up such engines. The crankshaft undergoes transverse, longitudinal and torsional vibrations due to the dynamics of the stresses sustained mainly during the combustion phase of the engine. The effects of vibration produce premature wear on the internal components of the engine, which contributes both to reduce the lifespan of the engine itself as well as cause discomfort to the

Santana, Claudio Marcio, Mautone, Jose, almeida, helder

Effect of Diamond-Like Carbon Coating on Anti-Scuffing Characteristics of Piston Pins

2019-01-018404/02/2019

It has been proposed that downspeeding combined with high boost levels would effectively reduce fuel consumption in heavy-duty diesel engines. Under low-speed and high-boost operating conditions, however, the in-cylinder gas pressure, which acts on the piston crown, is greater than the piston inertia force (such that there is no force reversal), over the entire range of crank angles. Therefore, the piston pin never lifts away from the main loading area (the bottom) of the connecting rod small-end bushing where the contact pressure against the piston pin is highest. In such operating conditions, lubricant starvation is easily induced at the interface between the piston pin and small-end bushing. Through carefully devised engine tests, the authors confirmed that the piston pin scuffing phenomenon arises when the boost pressure exceeds a critical value at which the no-force reversal condition appears. Furthermore, to prevent this piston pin scuffing when there is no force reversal, the

Usui, Shoichiro, Kato, Hideki, Nakajima, Hiroshi, Shimokawa, Kiyohiro

Integrating a Proactive Quality Control Concept into Machining Operation of a Crankshaft Manufacturing Process

2019-01-050704/02/2019

Competition in the manufacturing industry is ever increasingly intense. Manufacturing organizations that want to grow and prosper must embrace a discipline of constant improvement. Their engineering departments are tasked with improving existing manufacturing processes in terms of quality and throughput, which is vital to competing on a global scale. Manufacturers strive to utilize technologies to extract efficiencies from their existing processes. Reducing scrap and rework is the paramount goal in increasing a processes’ efficiency. The foundation of this study is to analyze a production line to determine the quality status throughout the manufacturing process. The intention is to react to process instability before the production becomes non-compliant (scrap/rework) which will significantly improve productivity. By incorporating the proposed technology into the production process, the desired achievement will be to spot process variables at the earliest stages so that counter

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