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INTRODUCTION
Today, typical combustion engines have efficiencies ranging from 20%-30% at part-load
operating conditions, resulting in wasted energy. New internal combustion engines being
developed have the potential to reach part-load brake thermal efficiencies of 50% [1]. Internal
combustion engines have been prevalent since 1890, but emission laws established in the
twentieth century led to the downfall of these engines as they were environmentally unfriendly.
They consumed a lot of fuel resulting in many emissions. The technology then was unable to
handle these emissions – catalyst plugging made it hard to convert nitrogen oxides. Today, they
are being reconsidered for use due to their potential thermal efficiency, low emissions, power
density, and cost advantages. Developments for such engines are underway as seen in opposed
piston two strokes, split cycle types, and variable-compression-ratio engines. This report will
focus on the advantages of the opposite-piston engine. The focus in the new design is thermal
and emission management.
In this design, two pistons operating with opposed motion are placed in one cylinder. As
the pistons move away from each other, the intake and exhaust ports are activated. This enables
efficient air scavenging. As the pistons move towards each other, the fuel-air mixture gets
compressed, and ignition occurs. These results in the power stroke, which movies the pistons
away from each other, and the cycle repeats. Firstly, many significant improvements were
applied to cylinder bore materials and finishing to reduce oil consumption . Piston rings now
have a different location in the engine and are made of steel rather than cast iron in order to
account for the high temperatures it must withstand. This, coupled with the use of synthetic oils,
and the proper management of cylinder bore oil impingement have made reduced oil
consumption possible.
. In an opposed piston engine, two pistons with opposed motion work in one cylinder with
no use for a cylinder head. Experimenting with different cylinder configurations worked
favorably. All the configurations performed exceptionally, and some were found to have added
benefits such as zero cyclic torque recoil.
The aim of this report is to introduce the fundamentals of Internal Combustion Engines
(ICE). The report traces the mechanism of operation of ICE and its different kinds based on the
operation mechanism, specially the two stroke and four stroke engines. It also involves the
thermodynamics relations that govern the processes of these engines, highlighting two main
important cycles, which are: Otto Cycle and Diesel cycles. Thus, it uses both cycles to introduce
the second categorization of ICE based on the thermodynamic relations, introducing Gasoline
engines and Diesel engines. There are two main cycles based on which we can categorize
internal combustion engines, which are: Otto cycle and Diesel cycle
Otto cycle is the typical cycle for most of the cars internal combustion engines that work
using gasoline as a fuel. Otto cycle is exactly the same one that was described for the four-stroke
engine. It consists of the same four major steps: Intake, compression, ignition and exhaust.
On the PV-diagram,
1-2: Intake: suction stroke
2-3: Isentropic Compression stroke
3-4: Heat addition stroke
4-5: Exhaust stroke (Isentropic expansion)
5-2: Heat rejection
The distance between points 1-2 is the stroke of the engine. By dividing V2/V1, we get:
Where is called the compression ratio of the engine. The efficiency is taken to be:
In the Diesel Cycle, named after Rudolf Christian Karl Diesel (1858-1913), only air is
admitted in the intake stroke. The air is then adiabatically compressed, and fuel is injected into to
the hot air in the form of many small drops (not a vapor). Each drop burns over a small time,
giving an approximation of a isobaric explosion. The explosion pushes the cylinder outwards.
The power stroke, valve exhaust, and exhaust stroke which follow are identical to those in the
Otto Cycle.
A - 1 to 2: Isentropic compression
B - 2 to 3: Reversible constant pressure heating
C - 3 to 4: Isentropic expansion
D - 4 to 1: Reversible constant volume cooling
In other words, the only difference between is the Otto engine and diesel engine is that the
latter does not require a spark plug to ignite the fuel; the fuel here is ignited under the effect of
increase in pressure and temperature. In Diesel engines, compression ratios are as high as 22.5 to
1, where for Otto engines it normally does not reach even one fifth that number.
17th century: Christian Huygens designs gunpowder to drive water pumps, to supply
3000 cubic meters of water/day for the Versailles palace gardens, essentially creating the first
idea of a rudimentary internal combustion piston engine.1798: Tippu Sultan, the ruler of the city-
state of Mysore in India, uses the first iron rockets against the British Army.
The internal combustion engine was invented by Jean Joseph Etienne Lenoir (Belgian
Born). Lenoir made the first internal combustion engine that provides a reliable and continuous
source of power, which was the gas engine using coal gas, in 1860, in France.
Fig1.5 compression
ignition engine
The Spark Ignition (SI) engines work on the principle of cycle of operations invented by Nicolas
A. Otto in the year 1876.
In a gasoline engine the compression ratio (which controls the compression temperature) is
limited by the air-fuel mixture entering the cylinders. The lower ignition temperature of gasoline
will cause it to ignite (burn) at a compression ratio of less than 10:1. The average car has a 7:1
compression ratio.
Gasoline engines are self-speed-limiting, due to the method the engine uses to control the
amount of air entering the engine.
Two stroke engines are normally found in low power vehicles, such as: garden
equipment, jet skis, and some motorcycles engines. From its name, the two-stroke engine refers
to a type of an engine in which the process of combustion of a fuel and the liberation of
mechanical energy takes place in only two strokes of the piston, the first goes from the top dead
centre to the bottom Dead centre, and vice versa for the second stroke. Starting from the point at
which compressed fuel/air/oil mixture exists inside the piston, a spark is ignited from the spark
plug, hence combustion. Combustion produces large energy that pushes the piston downward
and exhaust gases are formed out of the combustion. Thus, the engine starts its first stroke in
which it delivers power using the Crankshaft and exhaust gases are liberated out of the cylinder
from the exhaust valve. A two-stroke engine is an internal combustion engine that completes the
process cycle in one revolution of the crankshaft (an up stroke and a down stroke of the piston.
1st stroke
The compressed fuel-air mixture ignites and thereby the piston is pressed down. At the
same time the intake port is covered by the piston. Now the new mixture in the crankcase
becomes pre-compressed. Shortly before the piston approaches the lower dead centre, the
exhaust port and the overflow conduit are uncovered. Being pressurized in the crankcase the
mixture rushes into the cylinder displacing the consumed mixture (exhaust now).
2nd stroke
The piston is moving up. The overflow conduit and the exhaust port are covered; the
mixture in the cylinder is compressed. At the same time new fuel-air mixture is sucked into the
crankcase. By means of a crank shaft the up and down motion is converted into a rotational
motion. As the piston proceeds downward, another valve is opened which is the fuel/air valve.
Air/fuel/oil mixtures come from the carburettor, where it was mixed, to rest in an adjacent fuel
Chamber. When the piston moves downward more and the cylinder has no more gases, fuel
1. The piston acts as the combustion chamber with the cylinder, and it also compresses the
air/fuel mixture and receives back the liberated energy and transfers it to the crankshaft.
2. The piston motion creates a vacuum in order to such the fuel/air mixture from the carburettor,
and pushes it from the crankcase (adjacent chamber) to the combustion chamber.
3. The sides of the piston are acting like the valves, covering and uncovering the intake and
exhaust ports drilled into the side of the cylinder wall.
1) Suction stroke: At the start of the suction stroke the piston is located at top dead centre
position. As it moves down, the inlet valve located in the cylinder head opens, while the
exhaust valve remains closed. From the inlet valve, air is drawn into the cylinder which
continues until the piston reaches bottom dead centre or the bottom most position inside
the cylinder. At this Point the suction stroke completes and the suction or inlet valve
closes.
2) Compression stroke: During the compression stroke the piston starts moving in upward
and compresses the air in the clearance volume. While in the case of spark ignition (SI)
engines, the compression ratio is about 6-10, the CI engine this ratio is about 16-20. This
4) Exhaust stroke: After the expansion stroke a number of residual gases are left in the cylinder
and need to be cleared from of the cylinder. During the exhaust stroke the exhaust valve opens
due to the difference between the atmospheric pressure and the pressure of exhaust gases inside
the cylinder. As the piston moves from the bottom to the top position the exhaust gases are swept
out of the cylinder. When the piston reaches the topmost position all the exhaust gases are
released. As the piston starts moving down, the inlet valves open and fresh air is drawn into the
cylinder.
In this way, the cycle of operation of the CI engine keeps on repeating without any hindrance.
Since large amounts of pressure are generated inside the CI engines these engines, there is a need
to have CI engines be sturdier than SI engines.
1.7 ADVANTAGES:
1.8..DISADVANTAGES
1.8.1 Two stroke
1. Scavenging problem
2. Fresh mixture is escaping with exhaust gases during exhaust stroke
3. Non stable at idling speed
1.9.4 Camshaft
Camshaft is frequently called “brain” of the engine. This is so because its job is to open and closed at
just the right time during engine rotation, so that the maximum power and efficient cleanout of exhaust
to be obtained. The camshaft drives the distributor to electrically synchronize spark ignition. Camshafts
do their work through eccentric "lobes" that actuate the components of the valve train. The camshaft
itself is forged from one piece of steel, on which the lobes are ground. On single-camshaft engines there
are twice as many lobes as there are cylinders, plus a lobe for fuel pump actuation and a drive gear for
the distributor. Driving the camshaft is the crankshaft, usually through a set of gears or a chain or belt.
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Crankshaft
Crankshaft is a large component with a complex geometry in the engine, which converts the
reciprocating displacement of the piston to a rotary motion with a four link mechanism. Since the
crankshaft experiences a large number of load cycles during its service life, fatigue performance
and durability of this component has to be considered in the design process. Design
developments have always been an important issue in the crankshaft production industry, in
order to manufacture a less expensive component with the minimum weight possible and proper
fatigue strength another functional requirements. These improvements result in lighter and
smaller engines with better fuel efficiency and higher power output.
The function of the crankshaft is to translate the linear reciprocating motion of a pistons into the
rotational motion required by the automobile. The crankshaft, connecting rod, and piston
constitute a four bar slider-crank mechanism, which converts the sliding motion of the pistoa
rotary motion. Since the rotation output is more practical and applicable for input to other
devices, the concept design of an engine is that the output would be rotation. In addition, the
linear displacement of an engine is not smooth, as the displacement is caused by the combustion
of gas in the combustion chamber. Therefore, the displacement has sudden shocks and using this
input for another device may cause damage to it. The concept of using crankshaft is to change
these sudden displacements to a smooth rotary output, which is the input to many devices such
as generators, pumps, and compressors.
The various forces acting on the shaft but failure takes place in two positions, bending and
twisting. Firstly, failure may occur at the position of maximum bending; this may be at the centre
of the crank or at either end. In such a condition the failure is due to bending and the pressure in
the cylinder is maximal. Second, the crank may fail due to twisting, so the connecting rod needs
Crankshaft experiences large forces from gas combustion. This force is applied to the top of the
piston and since the connecting rod connects the piston to the crankshaft, the force will be
transmitted to the crankshaft. The magnitude of the force depends on many factors which consist
of crank radius, connecting rod dimensions, and weight of the connecting rod, piston, piston
rings, and pin. Combustion and inertia forces acting on the crankshaft cause two types of
loading on the crankshaft structure; torsional load and bending load.
The crankshaft experiences a complex loading due to the motion of the connecting rod, which
transforms two sources of loading to the crankshaft. The main objective of this study was the
optimization of the forged steel crankshaft which requires accurate magnitude of the loading on
this component that consists of bending and torsion. The significance of torsion during a cycle
and its maximum compared to the total magnitude of loading should be investigated to see if it is
essential to consider torsion during loading or not.
An extensive literature review on crankshafts was performed Zoroufi and Fatemi et.al[1].
Their study presents a literature survey focused on fatigue performance evaluation and
comparisons of forged steel and ductile aluminium alloy crankshafts. Their survey included a
review of the effect of influential parameters such as residual stress on fatigue behaviour and
methods of inducing compressive residual stress in crankshafts. The common crankshaft material
and manufacturing process technologies in use were compared with regards to their durability
performance. This was followed by a discussion of durability assessment procedures used for
crankshafts, as well as bench testing. In their literature review, geometry optimization of
crankshafts, cost analysis and potential cost saving opportunities are also briefly discussed
3.2.1 Lubrication
In hot forging, in addition to lubrication effects, the effects of die chilling or heat transfer from
the host material to the colder dies must be considered. Therefore, values of the friction factor, or
coefficient of friction, obtained under certain forging conditions may not be applicable under
other conditions. For example, for a given lubricant, friction data obtained in hydraulic press
forging cannot be useful in mechanical press or hammer forging, even if the die and billet
temperatures.
CHAPTER 4
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MODELLING OF CRANKSHAFT
CATIA V6 runs only on Microsoft Windows and Mac OS with limited products.
CATIA V5 runs on Microsoft Windows (both 32-bit and 64-bit), and as ofRelease 18Service
Pack4 on Windows Vista 64.
CATIA V4 is supported for those Unixes and IBM MVS and VM/CMS mainframe
platforms up to release 1.7.
To start CATIA there may be icon on the desktop or you may have to look in start menu at the
bottom of leaf of the screen windows taskbar.
After selecting the part design module screen is as shown is below figure 1 in the screen there
will be three planes XY, YZ and ZX planes. The XY plans represent top or bottom view, the YZ
4.7.5 Draw the elongated hole of 20mm and the center distance 27mm
4.7.7 Now repeat the previous steps to form the first half of the crankshaft.
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In the present project a Modified crankshaft has been designed and Using catia v5 r20 software
design the crankshaft with standard measurements and observing the above design creating the
2D sketches using catia sketcher workbench then converting into 3D solid model using part
design. Complete model design using catia software with standard measurements
1.Zoroufi and fatemi et.al[1], focused on fatigue performance evaluation and comparsion
materials.
2.Altan, et.al[2]“Metal Forming Fundamentals and Applications,” American Society
for Metals, Metal Park, OH, USA.
3.Baxter, W. J., 1993, “Detection of Fatigue Damage in Crankshafts with the Gel
Electrode,” SAE Technical Paper No. 930409, Society of Automotive Engineers,
Warrendale, PA, USA.
4.Borges, A. C., Oliveira, L. C., and Neto, P. S., 2002, “Stress Distribution in a Crankshaft
Crank Using a Geometrically Restricted Finite Element Model,” SAE Technical Paper
No. 2002-01-2183, Society of Automotive Engineers, Warrendale, PA, USA.
5.Burrell, N. K., 1985, “Controlled Shot Peening of Automotive Components,” SAE
Technical Paper No. 850365, Society of Automotive Engineers, Warrendale, PA, USA.
6.Chien, W. Y., Pan, J., Close, D., and Ho, S., 2005, “Fatigue Analysis of Crankshaft
Sections Under Bending with Consideration of Residual Stresses,” International Journal
of Fatigue, Vol. 27, pp. 1-19.
7.Nallicheri et.al on material alternatives for the automotive crankshaft based on manufacturing
economics.