Development of high speed diesel engine
JAIKIRAT SINGH
Abstract:
High speed 600 V12 twin charged ,
direct fuel injection ,4 valve DOHC
mid longitudinal engine, 5,964 cc ,
direct multi point fuel injection ,
603.46 BHP/ 450 kW . 101.2 bhp /
liter torque figures of about 859.4
Nm . The stroke value is 150 mm and
the bore value is 225 mm. The
engine weight is reduced by
replacing all engine components
from cast steel to magnesium parts
which offer better strength to weight
ratio. The air intake is changed to
carbon fibre from the regular plastic
or aluminium pipes. All engine
mountings are taken off and stripped
down and is bolted directly to the
monocouque shell. It is further
reduced by using special light weight
turbos with lighter bearings and
using a prototype material which has
higher heat dissipating properties.
The unnecessary cover
for the valve train and cam shaft
covers are replaced by aluminium
nickel alloy metal. The usual racing
manifolds made of stainless is
replaced by a denser light metal
which is used on space shuttles saves
weight and does not deform under
high engine exhaust gasses. This
significantly high powered engine is
the first of its kind light weight-high
output engine.
As standards for durability and
automobile
designs become more complex, steel
simply can't deliver on higher
performance expectations. Light
weight magnesium requires far less
energy during the entire die cast
production process and designs can
be far more elaborate without
sacrificing strength. Tolerances are
tighter and the fit and finish in the
final product is vastly superior
Introduction:
The engine built serves the
importance for the Le mans racing
where the engine needs to have
higher output at lower speeds and
faster acceleration relative to the
endurance required to last 24 hours
of constant running at high speeds.
motive to win the next le mans and
take the world by storm with the
high output diesel engine was the
main motivation to build this
prototype engine .
Large scale modifications have been
done to the existing engine
technology . from replacing bolts to
changing engine firing .
Magnesium is 33% lighter than
aluminum, 60% lighter than
titanium, and 75% lighter than
steel. Yet for many applications it's
stronger per unit volume than all
three of those structural metals
Magnesium weighs 1.5 times less
than aluminium when both are
taken in equal volume. Magnesium
offers great versatility. It can be run
in both hot (conventional and
multi-slide machines) and cold
chamber die cast machines. This
makes is suitable for castings that
are small in size (less than an
ounce) to very large (up to sixteen
pounds or larger).
General overview :
OBJECTIVES OF DEVELOPMENT
AND
TECHNOLOGIES USED
To ensure that the v12 engine
achieved simultaneous
improvement of output, fuel
consumption, and reliability, while
meeting Category 2 regulations, the
following were set as primary
development objectives:
(1) increasing the performance of
the diesel engine.
(2) Decreasing the fuel
consumption or in other words
increasing fuel economy.
(3) increasing the durability and
reliability of the vehicle as it has to
Sustain harsh conditions from
extreme hot to extreme cold so the
engine should give same
performance in all the terrains.
ENGINE SPECIFICATIONS
Configuration: 600 V12
Location: Mid longitudinally
mounted
Construction: Engine block made up
of light weight magnesium steel
alloys.
Displacement: 5964 cc
Valve train: 4 valve DOHC
Fuel feed: Multi point injection
Lubrication: Dry sump
Aspiration: Twin charger (
supercharger + turbo charger )
Power: 450 Kw .
Torque: 860 Nm
Compression ratio: 26:1
BHP/Liter: 102hp/liter
Rpm redline: 5100
Stroke: 150 mm
Role of Bore/Stroke
Ratio
In order to getting high rpms
the effect of bore/stroke ratio
should be taken in
Bore: 225 mm
D/L: 1.5
Cooling system: Liquid cooled
Ignition system: Electronically
controlled
Advantages of using V12engine:
V12 engines have minimal
vibrations because they are
two 6 straight sixes which are
balanced by a single crankshaft
and are balanced by Vs. I m
using 600 angle between the Vs
so that the engine is much
more compact.
The power delivery in case of v
12s are the smoothest and it
gives a smooth ride as we are
using a diesel engine.
.
consideration because ,there are
various advantages of this type
of design , as the bore is bigger
than the stroke then the piston
speed will be relatively low and
as a result of which there will be
less stress on the crankshaft and
 the combustion process will
be more effective if we take
multi point injection system
and as we are using enhanced
swirl technology so we will
get better flame propagation
which helps the engine to
reach higher rpms. As we
have larger bore we can
easily fit in 4 valve
technology and we can have
larger valves for better air
intake and hence increasing
the rpm of the engine.
CERMET COATING ON INTERIOR
SURFACES OF PISTON CYLINDER
To enhance performance and
wear resistance in order to
reduce friction, all the inner
surfaces are rubbed by the
gas seals which are coated
with chrome and carbide
based cermets(Composite of
ceramic and sintered metals)
also the inner lining of the
cylinder are coated with
cermet in order to reduce
wear and tear and have
higher heat resistance.
Swirl technology:
I have invented a new kind of
swirl technology in which there
will be grooves present in the
cylinder above the top dead
center which will be in the
shape of helix help the air to
have better swirl so that the
complete combustion process
takes place giving the engine
much better performance and
As the engine speed increases
so there is less time to burn the
fuel and injection process
should also be spontaneous so
this kind of swirl technology
helps when the engine is
running at higher rpms.
ECU
Fuel pump and injector sensors
: it manages the injections
timing for each cylinder , ie; the
ECU sends signals to the
injector depending on the
timing and the amount of fuel
needed per degree of the crank
shaft
Variable coolant pressure
controller:
The ECU controls the input amount of air intake varies to
coolant pressure in relation to get a smooth and a fast ride.
the pressure needed by the
engine. i.e.; if the engine
temperature increases which
is detected by a thermostat, so
it will increase the pressure of MAGNESIUM ALLOY PARTS
the coolant which will help in
cooling the engine faster. A vast majority of magnesium
applications are covered by AZ91, a
Waste gate valves of twin diecasting alloy. This alloy has
charger : insufficient creep resistance for
many desirable applications at
temperatures above 130C.
The ECU controls the valve
position of the twin
chargers at different The characteristics of magnesium are:
speeds. i.e.; the ECU Lightest of all structural materials
controls the valve to open
33% lighter than aluminum
the supercharger valve at
75% lighter than steel
lower speeds closing the
High Strength to weight ratio
turbo charger valve and
Excellent dimensional stability
spots the supercharger
Large alloy section
valve at higher speeds and
High Impact resistance
only uses the turbo charger
Abundant material supply
at higher speeds
100% recyclable

Throttle sensor:

The ECU controls the

amount of air coming
through the turbo into the
cylinder by a variable flap
valve . its value varies upon
the engine curve at
different rpms and
different torques the
ACKNOWLEDGEMENT
The technologies employed in
this engine to improve the
engines output, fuel
consumption, and
durability/ reliability. It is a
valuable contribution and support
from the various members and
many outside organizations portals
on the internet that made the,
Technological developments
possible. We thank them all and,
with their continued assistance and
guidance, we will continue our
efforts to further upgrade and
improve our racing engines.
References
[1] Magnesium imp Wettbewerb,
EUROFORUM-Konferenz, Bonn,17
18.02, 1998. [1]B.L. Mordike, T. Ebert
Department of Material Science and
Engineering, Technical Uni6ersity of
Clausthal, Sachsenweg 8, 38678
Clausthal-Zellerfeld, Germany .
2 Braess, Zielkonflikte in der
Automobiltechnik, in: BMBF Workshop
Werkstoff- und produktionstechnische
Potentiale fursparsame, umweltvertragliche
und wettbewerbsfahige
Kraftfahrzeugskonzepte, Bonn, 31.0101.02,
1997.
3 K.U. Kainer, Potential von
Magnesium in der Karosserie
Moglichkeiten und
Entwicklungsbedarf, in: Stahl,
Aluminium und [4]B.L. Mordike, W. Henning,
Creep and high temperature propertiesof
magnesium based alloys,
 4 The New Generation of
High Speed DI Diesel
Engine with High Specific
Power and Durability
Published on: 1995-10-01 Authors:
V.Kordesch
10 Fast Prototyping of a Racing Diesel Engine
Control System
Published on : 2008-12-02
H. Waras,
Authors : Enrico Corti, Giulio Cazzoli ,Matteo
Rinaldi ,Luca Solier

5 The effect of structure

11 Diesel Engine Noise Reduction by Combustion
design on high speed automotive diesel
and Structural Modifications
engine noise
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Emissions in a High Speed DI Diesel Engine
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Yoshimura, Noboru 13 An example of Development of Automotive
Matsumura small high speed diesel engine. Published on1965-
02-01 Author: Shotaro Tanaka, Shinji Seki,
Hirokazu Nakamura

7 Developmental Work of High Speed 3.0

Litre Diesel Engine
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Nakata, Koji Yoshizu, Koichi Hatamura.

8 Dynamic Behaviour of a High Speed Direct

Injection Diesel Engine.
Published on: 1999-03-01
Authors: R. S. Wijetunge, C. J. Brace, J. G. Hawley,
N.D
Vaughan, R. W. Horrocks, G.
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9 A New High Speed Light Duty DI Diesel Engine

Published on: 1988-08-01
Authors: Otto Freudenschuss