Browse Topic: Crankshafts

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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
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
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
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
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
Optimization of HEV Vehicle’s Engine Modulated Noise2025-01-00845/5/2023
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
dan, Kong
Multi-Dimensional CFD Studies of Oil Drawdown in an I4 Engine2022-01-04733/29/2022
A computational study based on unsteady Reynolds Averaged Navier Stokes that resolves the gas-liquid interface was performed to examine the unsteady multiphase flow in a 4 cylinder Inline (I-4) engine. In this study, the rotating motion of the crankshaft and reciprocating motion of the pistons were accounted for to accurately predict the oil distribution in various parts of the engine. Three rotational speeds of the crankshaft have been examined: 1000, 2800, and 4000 RPM. Of particular interest is to examine the mechanisms governing the process of oil drawdown from the engine head into the case. The oil distributions in other parts of the engine have also been investigated to understand the overall crankcase breathing process. Results obtained show the drawdown of oil from the head into the case to be strongly dependent on the venting strategy for the foul air going out of the engine through the PCV system. Results also show the dynamic holdup of oil in the steady operation to be
Pandey, Ashutosh, Schlautman, Jeff, Nichani, Varun
Design Challenges & Solution in Modifying Compact 4-Stroke Diesel Engine while Adapting D-Cycle Technology2022-01-07253/29/2022
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
Numerical Study of an I4 Engine Oil Ejection During an Accidental Cap-off Running Condition for Two Baffle Designs2022-01-04723/29/2022
Three-dimensional transient numerical simulations are conducted to mimic the operating conditions of a four-cylinder internal combustion engine running without its engine-oil cap on. Navier-Stokes equations are solved together with the multiphase Volume of Fluid (VOF) model and the k-ϵ turbulence model. The engine crank shaft is mechanically connected to two cam shafts through a chain, which operates below the oil-cap open boundary. A baffle is located between the chain and the oil-cap opening to minimize oil spills. The chain geometry and dynamics are captured accurately through volume remesh and conformal mapping techniques. The motion of the four pistons, crank shaft, and two cam shafts is also considered. Retaining all these mechanical and geometrical details in the simulations is essential to obtain accurate oil ejection results. The crank shaft rotates at 1200 RPM and the study is conducted for two different baffle designs. Experimental results indicate a steady-state oil
Jorda Juanos, Albert, Schlautman, Jeff, Parsons, Neal, Pandey, Ashutosh
Unique Helmholtz induction for new GM LT6 V822AUTP02_102/1/2022
The 2023 Corvette Z06 recently arrived, powered by a 5.5-L LT6 V8 spinning a radical flat-plane crankshaft. Now that additional engineering details have emerged, the LT6's top hat has supplanted its crankshaft as this engine's most interesting feature. That topper - an active induction system - is capable of filling this DOHC V8 with the air needed to produce SAE-certified 670 hp (499 kW; 121.8 hp/L) at 8400 rpm without any kind of supercharging. Let the record show that the LT6 is the most powerful naturally aspirated V8 ever produced. The 6.6-L 622-hp (94.2 hp/L) M159 engine energizing the Mercedes-Benz SLS AMG Black Series coupe has been bumped down to second place. While exemplary output qualifies the Z06 as a legitimate supercar, bountiful torque is what owners will most appreciate on the street.
Sherman, Don
NVH Analysis and Optimization of Engine Balance Shaft Module2021-01-10328/31/2021
For any combustion engine, balance has always been important regardless of types of cylinder layout. One of the disadvantages of the inline four engines is the second-order unbalanced forces, which leads to high-frequency excitation of vehicle’s structure and consequent internal noise. Balance shaft modules (BSM) are often used in inline-four engines, to reduce the second-order vibration and mitigate engine imbalance. Balance shafts are often running at light load and high-speed condition which could induce both gear rattle and gear whine from the BSM gear set. Typically, scissor gear set is used between crankshaft and BSM to reduce the gear rattle noise. However, a poor scissor gear design could easily lead to unpleasant gear whine noise. There is an increasing trend to shorten development cycles and reduce cost using simulation models. This paper discusses an analytical method to simulate gear whine and rattle generated by engine BSM. Simulation software MASTA is a robust and fast
Ba, Jing, Sun, Zhaohui, Sandstrom, Alexander, Hu, Kevin, Li, Corey, Shi, Zhenghong
Modeling and Analysis for Dynamic Performances of a Two-Layer Engine Front End Accessory Drive System with an Overrunning Alternator Decoupler2021-01-06564/6/2021
Two-layer engine front end accessory drive systems (TEFEADS) are adopted generally by commercial vehicles due to the characteristics of the accessory pulleys, which have large torque and moment of inertia. An overrunning alternator decoupler (OAD) is an advanced vibration isolator which can reduce the amplitude of torsional vibration of alternator rotor effectively by an one-way transmission and they are more and more widely used in vehicles. This paper established a model of a generic layout of a TEFEADS with an OAD. The coupling effect between the TEFEADS, the nonlinear characteristics of OAD, the torsional vibration of crankshaft and the creeping on the belt were taken into account. A nine pulleys model was provided as a study example, the dynamic responses, which are respectively under steady and accelerating conditions, of the system were calculated by the established method and compared with the bench experiment. The influence of different belt material, the stiffness of OAD
Sun, Yi, Li, Liping, Shangguan, Wen-Bin
Parametric Study on Electric Turbocharging for Passenger Cars2020-01-22249/15/2020
The motor generator unit installed on the turbocharger shaft (MGU-H) provides a fundamental contribution to the amazing performances and efficiency of the last Formula 1 power units. The excess of exhaust gas energy - normally dumped through the waste-gate - can be converted into electric energy and used to push the car, by means of a second motor generator unit installed on the engine crankshaft (MGU-K). The goal of this paper is to assess pros and cons of the MGU-H technology when applied to a family of engines of different displacement, installed on a typical passenger car. The influence of engine size and cylinders layout is investigated, under the same set of hypotheses, considering both transient and steady engine operations. The baseline engine is a commercial 2.0 L, SI, 4-cylinder in-line, rated at 200 HP at 4500-5000 rpm. The study considers the following other SI configurations: a) 1.5L, 3-cylinder in-line, 150 HP; b) 3.0L, V6, 300 HP; c) 4.0L, V8, 400 HP; d) 6.0L, V12, 600
Mattarelli, Enrico, Scrignoli, Francesco, Rinaldini, Carlo Alberto
Simulation Study of Force Distribution in the Multiple Linkage System of a Spark Ignition Engine Operating in the Atkinson Cycle2020-01-22269/15/2020
The tests were carried out on an 3D engine model with an unconventional multiple linkage system. Compared to a classic crankset, the mechanism consists of more elements. In this multiple linkage system the camshaft, the piston rod and the main rod are connected to one common element. The camshaft rotating during operation at twice the speed of the crankshaft makes possible to achieve different piston stroke lengths with each revolution. With proper synchronization of the camshaft revolution with the crankshaft, the suction and compression stroke is smaller in relation to the expansion and exhaust strokes. For this reason, the Atkinson cycle was obtained without interfering with the variable valve timing. The thermal cycle is characterized by increased theoretical thermal efficiency. Due to the unique mechanism, the piston movement has different characteristics compared to classic solutions. Therefore, work was undertaken to analyze the distribution of forces in the system. For the
Urbański, Patryk, Daszkiewicz, Pawel, Bajerlein, Maciej, Rymaniak, Lukasz, Merkisz, Jerzy
Automated Diagnostic System for Engine Cylinder-Piston Group2020-01-20229/15/2020
The work is aimed at increasing the reliability, accuracy, information content and depth of the process of diagnosing the cylinder-piston engine group. For this, an automated diagnostic system has been developed, which includes a system unit with a monitor, special software for measuring and processing information, a measuring analog-to-digital module, adapters for connecting to the engine. The diagnostic system allows you to record the change in pressure of the cylinder for every degree of rotation of the crankshaft with an error that does not exceed 1.7%. Measurements are performed in test mode, when the crankshaft of the engine is scrolled with a starter, and strain gauges are screwed in place of spark plugs. The measurement results are presented in the form of diagrams, text and digital values. The system also allows you to save, reproduce and transmit diagnostic information in digital, graphic and text form. Using the developed diagnostic system, the engines of automobiles of
Saraiev, Olexii, Saraieva, Iryna, Gritsuk, Igor V., Volkov, Vladimir, Litikova, Oleksandra, Belousov, Evgen, Savchuk, Volodymyr, Samarin, Oleksandr, Ahieiev, Maksym, Volodarets, Mykyta, Vrublevskyi, Roman, Kurnosenko, Daria
Impact of Using Residual Fuels on the Wear of Selected Elements of Self-Ignition Internal Combustion Engines2020-01-21039/15/2020
The article presents the results of research on the impact of fuel type on the consumption of selected, components and piston nodes of internal combustion engines. The objects of research are medium-speed piston self-ignition engines, which drive generators feeding by residual fuels. Engines, powered by residual fuels was subject to intensive wear, as the fuels contained significant amounts of sulfur and water and are characterized by a high Conradson number. Wear has been examined under various natural operating conditions, including those prevailing in tropical regions. Significant wear has been found of combustion chamber elements, such as cylinder liners, pistons, cylinder heads, timing valves and injection apparatus. The wearstates of selected elements has been compared to the degree of supply of distillation fuels. Intensive wear of the investigated engines under analysis results from their design, where the lubrication system of pistons and sleeves and is not separated from that
Monieta, Jan
Study of Friction Reduction Potential in Light- Duty Diesel Engines by Lightweight Crankshaft Design Coupled with Low Viscosity Oil2020-37-00066/23/2020
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
A Study on the Design and Development of an Integrated 48V Motor with Motorized Internal Combustion Engine2020-01-04464/14/2020
The electrification of the internal combustion engine is an important subject of future automotive technology. By using a motorized internal combustion engine, it is possible to recover waste energy by regeneration technology and to reduce various losses that deteriorate the efficiency of the internal combustion Engine. This paper summarizes the results of the development of an engine-integrated motor that can be applied to a 48V mild hybrid system for motorization of an internal combustion engine. Like the 48V MHSG-mounted mild hybrid system designed to replace the generator in the auxiliary belt system, the motorized internal combustion engine is designed with the scalability as the top priority to minimize the additional space for the vehicle and to mount the same engine in various models. The addition of an integrated motor to the crankshaft instead of the MHSG of a belt-driven mild hybrid system that replaces the generator will allow the removal of components with redundant
Lee, Jongwon, Ha, Kyoung-Pyo, Lee, Jeongjong, Nam, Kihoon
Study of the Effects of Oil Supply and Piston Skirt Profile on Lubrication Performance in Power Cylinder Systems2019-01-236412/19/2019
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
Nondestructive Measurement of Residual Strain in Connecting Rods Using Neutrons05-12-03-001810/15/2019
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
Effect of Injector Cone Angle and NTP on Performance and Emissions of BS6 Engine2019-28-010810/11/2019
The combustion phenomenon of diesel engines has got a very major impact on the performance and exhaust emission levels. Several important factors like engine components design, combustion chamber design, Exhaust gas recirculation, exhaust after treatments systems, engine operating parameters etc. decide the quality of combustion. The role of fuel injector is crucial on achieving the desired engine performance and emissions. Efficient combustion depends on the quantity of fuel injected, penetration, atomization and optimum timing of injection. The nozzle through flow, cone angle, no of sprays and nozzle tip penetration are the factors which lead to the selection of perfect injector for a given engine. This paper focusses on the selection of the best fit injector suiting the BS6 application on evaluating the performance and emission characteristics. Injectors used were with varying cone angles and NTP. The nozzle tip protrusion of the injectors were varied by changing the sealing washer
Muthusamy, Anbarasu, Shangar Ramani, Vagesh, Sinha, Pranav Kumar
Numbering System for Single Diameter DrillsJ2122_201910 (Current)10/9/2019
This SAE Recommended Practice provides a systematic method for the identification of single diameter drills. It is intended to assist in the cataloging and supplying of these tools. NOTE 1— Caution must be taken when assigning codes for designators to prevent specifying drills that cannot be physically or economically manufactured. NOTE 2— In particular without limitation, SAE disclaims all responsibility for the accuracy or completeness of information contained within this report if the standards of this report are retrieved, combined, or used in connection with any software.
Motor Vehicle Council
Ford ‘cranks’ it up with another big V8 for Mustang19AUTP09_119/1/2019
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.
Visnic, Bill
Characteristics of Bending Stress with Whirling at the Rear End of a Crankshaft in an Inline 4-Cylinder High Speed Diesel Engine2019-01-15926/5/2019
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
2-Stroke Engine Options for Automotive Use: A Fundamental Comparison of Different Potential Scavenging Arrangements for Medium-Duty Truck Applications2019-01-00711/15/2019
The work presented here seeks to compare different means of providing scavenging systems for an automotive 2-stroke engine. It follows on from previous work solely investigating uniflow scavenging systems, and aims to provide context for the results discovered there as well as to assess the benefits of a new scavenging system: the reverse-uniflow sleeve-valve. For the study the general performance of the engine was taken to be suitable to power a medium-duty truck, and all of the concepts discussed here were compared in terms of indicated fuel consumption for the same cylinder swept volume using a one-dimensional engine simulation package. In order to investigate the sleeve-valve designs layout drawings and analysis of the Rolls-Royce Crecy-type sleeve had to be undertaken. A new methodology for optimization was developed and the analysis process also took into account work done by the charging system, this being assumed to be a combination of supercharger and turbocharger to permit
Turner, James W. G., Head, Robert A., Chang, Junseok, Engineer, Nayan, Wijetunge, Roshan, Blundell, David W., Burke, Paul
Evaluation and Selection of Turbocharger Meeting BS6 Emission Norms for 1.99l Engine2019-26-00581/9/2019
Migration to BS6 emission norms from BS4 levels involves strenuous efforts involving advanced technology and higher cost. The challenging part is on achieving the stringent emission norms without compromising the engine fuel economy, performance and NVH factors. Selection of hardware and attaining an optimal behaviour is therefore vital. This article focuses on the evaluation of three different configuration of turbochargers for the same engine to meet the BS6 emission norms and performance. The turbocharger samples used measure the same compressor diameter with varying trim ratios. Simulation and testing of turbochargers ensured positive results for confirmation of the system. Parameters like low speed torque, smoke and compressor efficiency were evaluated and analysed for all configurations. The safe limits of surge and choke regions of all the compressors were also studied and verified. Influence of varying compressor trim on the performance and emissions were examined thoroughly in
J, Giftson, Muthusamy, Anbarasu, Shangar Ramani, Vagesh, Bhachchu, Gurtej, R, Sivasubramamanian, Anand, M, K, Arun
Analysis of Rotational Vibration Mechanism of Camshaft at High Engine Speed in Engines with In-Line Four-Cylinder DOHC Configuration2018-32-007210/30/2018
In engines having an inline four cylinder DOHC configuration, the rotational vibrations of camshaft increase at high engine speeds above 10000 rpm, causing an increase of tension in the cam chain. It is therefore difficult to realize an optimum designing of a cam chain system when the durability has to be taken into considerations. Using the simulation we analyzed in this research how the rotational vibrations and tension increase at high engine speeds in an inline four cylinder DOHC engine. As its consequent, it is understood that the increases of rotational vibrations and tension caused by the resonance of the spring mass vibration system in which the cam chain serves as springs and the camshafts as the equivalent masses. Also it is found out that the vibration system is of a unique non-linear type in which the resonance of the fourth order frequency is also excited by the crankshaft torque fluctuations of the second order frequency. Furthermore, it is uncovered that the natural
Hatakeyama, Ryoh, Niino, Tadashi
Development of Horizontal Water Cooled Diesel Engine to Achieve High Power Density2018-32-006410/30/2018
The horizontal water cooled diesel engine has a structure including all component parts such as a fuel tank that are necessary to drive engine, and is often a single cylinder engine. It is mounted on many applications such as power tiller and water pump because of high general versatility of installing owing to belt drive. It has a simple structure because of single cylinder, and is active mainly in Southeast Asia. At the same time, the market requires this type of engine higher power while a compact structure is also required from the viewpoint of easy to supply and use. In other words, “High power density” that is improving the output per body size has been required. We have responded to the demand of “High power density” by increasing output without changing the engine size. In order to keep the engine size, we have been enlarging displacement by using our peculiar stroke-up expertise and original bore-up contrivance. In addition to those techniques, we introduced analytic
Komai, Yoshinobu, Takashima, Yusuke, Fujiwara, Tsukasa, Okamoto, Hisao, Kawahara, Minoru
Study of a Turbocharged Engine for Motorbike Application2018-32-007910/30/2018
Nowadays, the engine charging practice is widely adopted in the automotive field in relation to the “downsizing” technology: the reduction of the displacement and the adoption of a higher boost pressure, through a charging system, allow shifting the engine operating point in a zone of higher efficiency for a given engine torque. On the other hand, given a certain displacement, a supercharger can be adopted to increase the performance of the engine. The objective of this work is to provide a detailed analysis about the feasibility of the implementation of a charged engine to a motorbike, with main focus on the possibility to achieve a challenging performance target: in a first stage, several engine architectures (In-line, V-configuration, Boxer) together with different charging concepts (centrifugal or volumetric compressor, with mechanical or fluid-dynamic connection to the engine) have been analyzed from the point of view of packaging. In a second part, a V4 engine architecture has
Bevilacqua, Vincenzo, Corvaglia, Giovanni, Fuoss, Klaus, Penzel, Matthias
Limitations of Two-Stage Turbocharging at High Flight Altitudes03-11-05-00349/17/2018
High-altitude long-endurance (HALE) unmanned aerial vehicles (UAVs) are used for high flight altitudes, which enable low drag and fast flight with minimal fuel consumption. Two-stage turbocharging is necessary to sustain sea-level power at high flight altitudes. In this study, the limitations of two-stage turbocharging at high flight altitudes typical for HALE UAVs are analyzed for the first time. The obtained results show that the minimum available engine power increases as the altitude rises. This will limit the ability of the aircraft to descend rapidly. Furthermore, at high altitudes, if a lower operating point is required for a fast descent, further recovery to full power for climbing or cruising could be unavailable. In the latter cases, a lower altitude must be reached before full power would be available again. A basic algorithm for the assessment and analysis of the limitations of UAV engines with two-stage turbochargers operating at high altitudes is suggested.
Fass, Yehuda, Tartakovsky, Leonid
DRIVE – TYPE XV ENGINE ACCESSORY - DESIGN STANDARD FORAS20005A (Current)7/16/2018
E-25 General Standards for Aerospace and Propulsion Systems
Comparative Studies of Different VGT Designs on Performance and Smoke of CRDe Engine2018-28-00747/9/2018
Diesel engines have occupied a significant position in passenger car applications in the present automotive sector. Turbochargers find a very prominent role in diesel engines of all applications in order to achieve desired power and better fuel economy. Gaining higher torque at lower engine speeds with low smoke levels is a very tough task with fixed geometry turbochargers due to availability of lower air mass resulting in higher smoke emissions. Variable geometry turbochargers are capable of providing better torque at lower speeds and reduced smoke emissions on Common Rail Diesel engines. The Variable Geometry Turbocharger types used in this study are straight profile nozzle vanes (sample A) and curved profile nozzle vanes (sample B). The curved profile vanes as seen in sample B results in reduced variation of circumferential pressure distortions. Curved blade profile vane sample results in better low speed torque along with reduced fuel consumption and smoke emissions when compared
Shangar Ramani, Vagesh, Muthusamy, Anbarasu, Bahl, Sachin, Ramanathan, Hariharan, Halbe, Vasudeo Ganesh
PROPELLER SHAFT END, FLANGED TYPE - NO. 1, 2, 3, 4, 5, & 6AS127E (Current)5/7/2018
E-25 General Standards for Aerospace and Propulsion Systems
Influence of Miller Cycles on Engine Air Flow03-11-02-00114/18/2018
The influence of the intake valve lift of two Miller cycles on the in-cylinder flow field inside a DISI engine is studied experimentally since changes of the engine flow field directly affect the turbulent mixing and the combustion process. For the analysis of the impact of the valve timing on the general flow field topology and on the large-scale flow structures, high-speed stereo-scopic particle-image velocimetry measurements are conducted in the tumble plane and the cross-tumble plane. The direct comparison to a standard Otto intake valve lift curve reveals evidently different impacts on the flow field for both Miller cam shafts. A Miller cycle that features late intake valve closing shows a flow field comparable to the standard Otto valve timing and a tumble vortex of strong intensity can be identified. Hence, turbulent mixing is as sufficient as for the standard Otto valve timing, although the Miller cycle intake valve timing leads to a pressure reduction of approximately 20%. In
Braun, Marco, Klaas, Michael, Schröder, Wolfgang
Crank Shaft Torsional Vibration Analysis on the perspective of Improving the Crank Angle Measurement Accuracy for Closed-loop Combustion Control in ICES2018-01-11614/3/2018
Crank shaft torsional vibration has impact on the crank angle measurement accuracy in large-bore Internal Combustion Engines (ICE). In large bore engine, the torsional vibration angular displacement can be up to 1 degree, which in turn can cause a fault of 2 bar in Indicated Mean Effective Pressure (IMEP) and a fault of 0.6 degrees in the Crank Angle of 50% burned (CA50). IMEP and CA50 are critical feedback parameters for closed-loop combustion control, therefore to compensate torsional vibration effect in real-time engine control system can not only provide higher accuracy crank angle data but especially improve the combustion analysis and closed-loop control accuracy. Thus, in this work, a torsional vibration dynamic model is established to improve the accuracy of the crank angle measurement. A lumped parameter model of torsional vibration is established for a Wärtsilä engine, the numerical computing method is determined, harmonic analysis is applied, the Transfer Matrix Method (TMM
Storm, Xiaoguo, Hyvonen, Jari, Salminen, Heikki J, Virrankoski, Reino, Niemi, Seppo
Integrated Exhaust Rocker Arm Lost Motion Compression Release Engine Brake with Novel Reset Mechanism for Heavy Duty Diesel Engines2018-01-03814/3/2018
A new compression release engine brake system has been developed which utilizes the well-known lost motion idea along with an entirely new valve resetting mechanism. The engine brake is fully integrated into the exhaust rocker arm, making it highly compact. The novel reset mechanism provides a pressure sensing reset timing which optimizes engine brake performance and valve train stress at all engine speeds. Hydraulic system simulation studies were performed to first verify the concept on paper. Once acceptable performance was predicted, physical prototypes were produced. The Cummins ISL 8.9 L engine was chosen as a proof of concept platform due to its availability and its factory engine brake option. The factory engine brake gives a data set for comparison while validating this new technology. All targets for engine brake function were achieved, and a substantial increase in performance was demonstrated.
Batcheller, Devin, Taylor, Kody
A Study on Front End Auxiliary Drive(FEAD) System of 48V Mild Hybrid Engine2018-01-04144/3/2018
48V mild hybrid engine is one of major eco-friendly technology for global CO2 reduction policy. The 48V mild hybrid engine enables to operate torque boost, recuperation and ISG status by MHSG(Mild Hybrid Starter and Generator). The FEAD(Front End Auxiliary Drive) system is a very important role to transfer MHSG power to crankshaft at the mild hybrid engine. The conventional FEAD configuration is relatively simple because it transfers power from crankshaft to auxiliary drive components in one direction. But the FEAD configuration of 48V mild hybrid engine is not simple due to bidirectional power transmission between crankshaft and MHSG. For instance, in case of torque boost mode, the tight side of auxiliary belt is entry span of MHSG. On the contrary, the tight side of auxiliary belt is exit span of MHSG at recuperation mode. As a result, to continue auxiliary belt tension constantly is very difficult and important for 48V mild hybrid engine development because the change of belt
Yoon, Kibong, Hong, Jisoo, Shim, JaeYoung
Review of Exhaust Gas Heat Recovery Mechanism for Internal Combustion Engine Using Thermoelectric Principle2018-01-13634/3/2018
Automotive power packs have been the focus of research over a long period of time. Among various power packs when we consider internal combustion engines, there is an ample opportunity in developing systems that can make optimal utilization of all the energy streams related to the automotive engine. In this regard utilization of internal combustion engine exhaust waste heat and environmental pollution have been the focus of research in the recent past. About 35% of the automotive input fuel energy is converted to useful crankshaft work and about 30% energy is expelled with exhaust. This leaves about one-third (35%) of the total energy that must be transmitted from the enclosed cylinder through the cylinder walls and head to the surrounding. The exhausted energy from engine results in entropy elevation and solemn environmental pollution. So it is desired to utilize waste heat to the extent possible. The recuperation and utilization of waste heat not only conserves fuel but also
Rathore, Souvik Singh, Singh, Anand, Kumar, Prashant, Alam, Nazish, Sahu, Mithilesh Kumar, R, Sanjay
Divided Exhaust Period Implementation in a Light-Duty Turbocharged Dual-Fuel RCCI Engine for Improved Fuel Economy and Aftertreatment Thermal Management: A Simulation Study2018-01-02564/3/2018
Although turbocharging can extend the high load limit of low temperature combustion (LTC) strategies such as reactivity controlled compression ignition (RCCI), the low exhaust enthalpy prevalent in these strategies necessitates the use of high exhaust pressures for improving turbocharger efficiency, causing high pumping losses and poor fuel economy. To mitigate these pumping losses, the divided exhaust period (DEP) concept is proposed. In this concept, the exhaust gas is directed to two separate manifolds: the blowdown manifold which is connected to the turbocharger and the scavenging manifold that bypasses the turbocharger. By separately actuating the exhaust valves using variable valve actuation, the exhaust flow is split between two manifolds, thereby reducing the overall engine backpressure and lowering pumping losses. In this paper, results from zero-dimensional and one-dimensional simulations of a multicylinder RCCI light-duty engine equipped with DEP are presented. It is shown
Bharath, Anand Nageswaran, Reitz, Rolf, Rutland, Christopher
Sensor Less Rough Road Detection Method Research2017-01-221610/8/2017
This study presents the development of sensor less rough road detection by using frequency analysis of instantaneous crankshaft rotation speed signal. Combustion diagnosis (misfire detection) is enforced by OBD requirement. Eliminating rough road’s effect on misfire detection is critical for getting robust diagnosis result, especially for crankshaft rotation speed based misfire detection. Although some kind of sensor is often used to identify vehicle driving on rough road, sensor less rough road detection method is still attractive for OEM to reduce cost and some approaches have been developed in past years for the aim [1] [2] [3]. This paper presents a new rough road detection approach based on crankshaft rotation speed frequency domain analysis. It firstly collects the signal from vehicle driving with misfire on public road and without misfire on rough road. Fluctuation exists in crankshaft rotation speed under such condition. It is processed as vibration signal in this paper. The
Fu, Yumin
The Development of the Szorenyi Four-Chamber Rotary Engine2017-01-241310/8/2017
A four-chamber Otto cycle rotary engine, the Szorenyi Rotary Engine, has been invented and developed by the Rotary Engine Development Agency (REDA) in Melbourne, Australia. The engine concept has been awarded a U.S. Patent (Number 6,718,938 B2). A prototype engine has been constructed and a successful proof-of-concept engine test was achieved in 2008. The stator of the Szorenyi engine is a similar shape to a Wankel engine. However, the geometric shape of the engine rotor is a rhombus, which deforms as it rotates inside the contour of the mathematically defined stator. This geometry translates to a rotary engine with four combustion chambers. Each revolution of the crankshaft produces one revolution of the rotor; a complete engine cycle in each of the four chambers; and therefore four power strokes. In contrast, the Wankel engine produces one power stroke per crankshaft revolution. Additionally, the Wankel engine is rev limited due to the excessive crankshaft bending resulting from the
King, Peter
A Prediction Method of Fatigue Strength for Crankshaft Fillet Rolling Process2017-01-240610/8/2017
This work addresses the problem of fatigue strength prediction of crankshaft fillet rolling processes to improve its accuracy. It is empirical to usually consider the effect of fillet rolling process on crankshaft fatigue performance. The fatigue performance of rolling process is mainly determined by induced compressive residual stresses, increased hardness and reduced roughness. Because the first two factors are difficult to measure the arc surface of fillet rolled cranks, it is difficult to predict the enhanced rate of crankshaft rolled performance to baseline unrolled’s. In this work a prediction method of fatigue strength for ductile cast iron crankshafts rolling process is presented. This method indirectly predicts the effect of the increased hardness on fatigue performance by the resonant bending fatigue test and modelling of crankshaft fillet rolling dynamic for the induced compressive residual stress. The finite element (FE) model for the resonant bending fatigue test rig is
Yang, Wu, Yin, Xiuting, Zhan, Zhang Song, Shen, Huixian, Qing, Huibin, Zeng, Qingqiang, Kang, Liyun
Study on the Lubrication Performances of Crankshaft Main Bearings in a 16V Marine Diesel Engine2017-01-242310/8/2017
As the key components of internal combustion engine(ICE), the crankshaft main bearings are used to support the crankshaft and connecting rod mechanism whose rotary motion realizes the energy conversion from heat energy to mechanical power in cylinder. The lubrication performances and wear life of crankshaft main bearings directly affect ICE working efficiency and reliability. Therefore, it is very important to study the lubrication performances of crankshaft main bearings. In this paper, a 16V marine diesel engine was studied. Based on the AVL-Designer software platform, a dynamic model of crankshaft and connecting rod mechanism and a hydrodynamic lubrication model of crankshaft main bearing were built. The numerical analyses were carried out on the lubrication performances of crankshaft main bearings under different speed conditions. The results were obtained, such as the external load, the maximum oil film pressure, the minimum oil film thickness, the relative eccentricity, the
Ye, Xiaoming, Fu, Yan, Li, Wei, Jiang, Yuze, Zhu, Shixin
Resonance Charging Applied to a Turbo Charged Gasoline Engine for Transient Behavior Enhancement at Low Engine Speed2017-24-01469/4/2017
Upcoming regulations and new technologies are challenging the internal combustion engine and increasing the pressure on car manufacturers to further reduce powertrain emissions. Indeed, RDE pushes engineering to keep low emissions not only at the bottom left of the engine map, but in the complete range of load and engine speeds. This means for gasoline engines that the strategy used to increase the low end torque and power by moving out of lambda one conditions is no longer sustainable. For instance scavenging, which helps to increase the enthalpy of the turbine at low engine speed cannot be applied and thus leads to a reduction in low-end torque. Similarly, enrichment to keep the exhaust temperature sustainable in the exhaust tract components cannot be applied any more. The proposed study aims to provide a solution to keep the low end torque while maintaining lambda at 1. The tuning of the air intake system helps to improve the volumetric efficiency using resonance charging effects
Raimbault, Vincent, Migaud, Jerome, Chalet, David, Bargende, Michael, Revol, Emmanuel, Montaigne, Quentin
Self-Tuning Torsional Vibration Dampers for V8 Engines2017-01-18196/5/2017
The problem of crankshaft torsional vibrations for heavy car engines is important for the V8 engines. The paper describes the results of the dynamical study of the new patented Torsional Vibration Dampers mounted on a crankshaft in V8 engines. Design and structure of Torsional Vibration Damper is based on author’s US Patent 7,438,165 having the control system with instantaneous frequencies tuner for all frequencies of running engine. Analysis and disadvantages of conventional rubber and viscous Crank Dampers are shown. The focus of the study is on Torsional Vibration Damper having the mechanical self-tuning structure applicable for V8 engines. Mathematical model based on the system of ordinary differential equations describing the rotation and vibration of mechanical components has been used for the analysis of the dynamic behavior of V8 engine crankshaft system having proposed Torsional Vibration Damper. Significant part of the study is dedicated to design and selection of the optimal
Nerubenko, Cyril, Nerubenko, George
Study for the Radiated Noise from Engine Depending on Assembly Condition2017-01-18436/5/2017
This paper presents the influence of radiated noise from engine surface according to assembly condition between the engine block and oil pan. At the first, the force exciting the main bearing of cylinder block is calculated by using a multi-body dynamics model of the engine crankshaft. Secondly, the modal analysis is processed to obtain the mode contribution and modal participation factors for the FEM of a virtual cylinder block. Thirdly, the radiated noise from a structure is calculated by acoustic-FEM analysis. This structure is assembled by the virtual oil pan with a rigid connection method and a soft connection method. The sandwich panel connection model is used for the soft connection method. The sound radiated from this assemble structure is calculated according to two different connection properties respectively. The sound matrices for two results are compared using an objective method. Finally, the influence of the connection condition on the sound quality is investigated for
Shin, Taejin, Jin, Jaemin, Lee, Sang Kwon, Jung, Insoo
Whirl of Crankshaft Rear End, Part1: an L6-Cylinder Diesel Engine2017-01-18106/5/2017
As the issue of global warming has become more serious, needs for downsizing or weight saving of an engine has been getting stronger, and forces exerted on engine parts, especially force on a crankshaft, have been getting larger and larger. In addition, since a crankshaft is a heavy engine part, needs for saving weight have been getting stronger and stronger. Therefore, determining the mechanism of high stress generation in a crankshaft system is urgently needed. This paper describes the characteristics and mechanism of a severe bending stress caused by the whirl of crankshaft rear end of an inline 6-cylinder medium-duty diesel engine. The authors measured bending stress on the fillets of the crankshaft, and found severe levels of sharp peaks in the stress curves for the crankshaft rear. To figure out why the severe levels of sharp peaks appear, they analyzed and studied the measured data. As a result, they have revealed that the crankshaft rear end whirls, and have determined the
Kobayashi, Shinichiro, Hakomoto, Kenjiro, Kawase, Kousuke, Kidokoro, Makoto, Kimura, Jouji
Whirl of Crankshaft Rear End, Part 2: an L4-Cylinder Diesel Engine2017-01-18116/5/2017
Since the sizes of the flywheel and clutch have been enlarged due to downsizing of diesel engines, the mass and moment of inertia at the crankshaft rear end have increased. Consequently, the serious bending stresses have appeared in the crankshaft rear. This paper describes the characteristics of those serious bending stresses, based on the mechanism for whirl resonance. The whirl resonance is largely impacted by the mass of the flywheel and clutch and by the distance from the crank-journal center of the rear end to the center of gravity of the flywheel and clutch.
Kimura, Jouji, Tanaka, Tatsuya, Hakomoto, Kenjiro, Kawase, Kousuke, Kobayashi, Shinichiro
Local Deformation of Hollow Crankshafts under Transient Conditions and their Effect on Durability and Slider Bearing Behavior2017-01-13313/28/2017
This paper describes a numerical study of the effect of hollow crankshafts on crankshaft local strength and durability as well as slider bearing contact behavior. Crankshaft dynamic simulation for durability is still a challenging task, although numerical methods are already worldwide established and integrated part of nearly every standard engine development process. Such standard methods are based on flexible multi-body dynamic simulation, combined with Finite Element analysis and multi-axial fatigue evaluation. They use different levels of simplification and consider the most influencing phenomena relevant for durability. Lightweight design and downsizing require more and more detailed methods due to higher deformation of the crankshaft. This is especially true for hollow shafts, as present in motorsport design or aerospace applications, but also for standard engine having high potential for significant weight savings. Here the local deformation of shaft cross section under dynamic
Basic, Marko, Resch, Thomas
Analysis of Engine Flywheel Wobbling Vibration2017-01-10233/28/2017
Large axial displacement at the edge of a flywheel causes a clutch to fail to disengage in high-speed rotation. To find out the root cause, a numerical procedure is proposed to investigate the vibration source and to understand dynamic behavior of the crank-train system. A simulation of the whole engine system including block, crankshaft, piston, and connecting rod was performed with AVL/Excite. The resulting CAE baseline model had good correlation with measurements. A comprehensive study was conducted for a set of flywheel and crankshaft models with different materials and unbalanced masses. The contribution to flywheel wobbling of each vibration order was carefully investigated, and an optimal design was presented.
Jiang, Yaqun, Hsieh, C., Festag, Georg, Ahmed, Masood, Jiang, William
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