Ice D&D 2009 Proceedings

I. C.
ENGINE DESIGN & DEVELOPMENT
Concurrent with SIAT 2009 st rd 21 - 23 January 2009
ARAI Campus Pune, INDIA
3 Day Certificate Course

on
I. C. Engine Design & Development

at
ARAI, Pune
(The Automotive Research Association of India)
from 18 to 20 Jan. 09
Jointly Organised by
th
th
WESTERN SECTION
About SAE
SAE International is a professional engineering society, whose membership represents practically every engineering and scientific discipline. Its members combine their specialized abilities to further advance the research, development, design, manufacture and utilization of vehicles, which operate on land, water, air and space. Over 1,00,000+ engineers and scientist, who are SAE members, develop technical information on all forms of self-propelled vehicles including automobiles, trucks and buses, off-highway equipment, aircraft, aerospace vehicles, marine, rail and transit systems. Engineering leaders round the world in the field of vehicle engineering belong to SAE because of the value it offers them. Networking with the other leaders is a major attraction of every SAE event. SAE books, standards, technical papers and special publications offer the most complete resources for anyone interested in the latest technological advances. Much of this information is now available electronically through SAEs website.
WESTERN SECTION
To know more about SAE International, please visit www.sae.org SAEINDIA has started operating in India from 2002 as an affiliate of SAE International. Presently there are five sections: West, South, North, East and Bangalore, with about 3000 regular members and 15000 student members. SAEINDIA Western Section, the first Section established in 1996, is operating with its-headquarters at ARAIPune. It regularly conducts technical workshops, seminars, toptechs and symposia. It has about 35 collegiate chapters in and around Ahmadabad, Alwar, Aurangabad, Bharuch, Gwalior, Islampur, Indore, Mumbai, Nagpur, Nanded, Nashik, Navi Mumbai, Pandharpur, Pillani, Pune, Sangli, Shegaon, Surat, Vallabh Vidya Nagar and Yatmal To know more about SAEINDIA, please visit www.saeindia.org
Activities of SAEINDIA
SAEINDIA Office Bearers 2008 - 2009

M. S. Kumar Dr. Pawan Goenka R. Dayal S.R. Marathe Dr. K. C. Vora Mr. Rajesh Singh Dr. G. Nagarajan S. Maitra President Immediate Past President Senior Vice President Vice President Secretary Treasurer Joint Secretary Joint Treasurer Dr. K. Kumar Dr. R. Mahadevan R. Mukundan S. Govindarajan K. N. Krishnamurthy S. Selvamani Dr. David. L. Schutt Mr. Murli M Iyer Member Member Member Member Member Member Exec.Vice President, SAE International Global Development Manager, SAE International
Dr. Arun Kumar Jaura Member
Dr. Aravind S Bharadwaj Vice President
Dr. M. K. Gajendra Babu Member
Three Day Certificate Course on
I. C. Engine Design & Development

at
ARAI, Pune
(The Automotive Research Association of India) From 18th to 20th January 2009
Jointly Organized by:
The Automotive Research Association of India
&
Western Section
{1}
Three Day SAE Certificate Course on I. C. Engine Design & Development
{2}
Mr. Shrikant R. Marathe

Director ARAI, Pune Vice President - SAEINDIA
FOREWORD
SAEINDIA organizes series of Conferences, Seminars, Lectures, Workshops, Toptechs and Certificate Courses on number of advanced topics related to automotive technology. This forum provides a platform for experts and engineering professionals to meet and discuss latest technologies and its relevance to Indian Automotive Industry. It has been felt that it is necessary to educate and train engineering professionals of the Indian Automotive Industry, so that whenever advanced techniques related to product design, development and testing are introduced, they would be ready to absorb it and effectively use it for its application. With a vision to design and develop I.C. Engines in India on a large scale, we have invited Dr. S.M. Shahed, Prof. Kevin Hoag and Mr. Roy Primus from U.S.A. to conduct a Certificate Course on I. C. Engine Design & Development, so that the delegates can assimilate and develop a strategy for future design & development based on application and their targets. As per the wishes of the U. S. faculty, Dr. K. C. Vora of ARAI, Pune has been inducted as a speaker to indigenize this course and convert it into SAEINDIA Professional Development Program (PDP). It is essential to gain an in-depth understanding of the development process of the engine, right from customer requirements to design validation. This 3 Day Certificate Course on I. C. Engine Design & Development, arranged jointly by ARAI, Pune and SAEINDIA Western Section is an endeavor to give an in-depth analysis of the current scenario of Engine Design & Development with appropriate case studies for automotive applications. I congratulate the organizing team, who has worked hard in arranging this Certificate Course and my sincere thanks to the speakers for their excellent contribution in introducing the delegates to this advanced topic. Date: Jan 15, 2009 Shrikant Marathe
{3}
{4}
Mr. N. V. Marathe
Deputy Director, Head of Department, Engine Development Lab, ARAI, Pune
PREFACE
India is now at the forefront in Automotive Design & Development. Many Engineering Services are being offered to automotive companies in India and abroad. In coming years, Indian automotive and component industry will be required to design automotive systems with proper computational techniques and analysis. The heart of the automobile is the engine and there is tremendous potential for design & development of high performance fuel-efficient engines. This 3 Day Certificate Course on I. C. Engine Design & Development is proposed to impart a comprehensive practical hands-on training to engine design and development engineers. It will present techniques for the use of customer/vehicle requirements to set the engine specifications and selection of major parameters. The latest trends in design and development will be discussed. Some of the highlights include major structural components / subsystems like cylinder block, cylinder head, crank-train, valve train, drives, bearings, fuel injection, air induction, exhaust, cooling and lubrication systems. I am confident that the course material developed by the four prominent speakers will serve as a useful guide to the participants while dealing with engine design and development programmes. I understand that the subjects like functional requirements including balancing, noise & vibration, design goals, theoretical basis for design, design tools, illustration of the effect of design parameters, some discussions of materials and processes, an outline of Failure Modes and Effects Analysis (FMEA), description of proof of design tests including mechanical functionality, stress limits, fatigue life, thermal stress, etc. are going to be discussed with the help of case studies. The Power-Point presentations for the course work are included in this proceeding. The contents of the proceeding are also introduced in the form of CD-ROM. I am grateful to Shri S. R. Marathe, Director-ARAI & Chairman-SAEIWS for his encouragement and support for organising this course. Dr. Vora and his organising team have contributed a lot, without which this course would not have existed. Hope to have a fruitful technological deliberation. Date: January 12, 2009 N. V. Marathe
{5}
ORGANISING COMMITTEE
Mr. N. V. Marathe Dr. K. C. Vora
Mr. R. D. Talele Mr. Parag Mengaji Mr. Bharani Dharan Mr. Y. K. Upadhayay Mr. M. A. Palse Mr. H. S. Rasane Mr. Vilas Tanpure Mr. R. B. Yadav Mr. A. V. Marathe Mr. N. A. Sakle Mr. Prasad Bhatt Mr. G. V. Sangle Mr. J. D. Banerji Mrs. Anjali Dharap Mr. B. Y. Deshmukh Mr. M. R. Sarkale
{6}
ABOUT SPEAKERS
Dr. S. M. Shahed Dr. Shahed is Corporate Fellow at Honeywell Turbo Technologies. He has worked for more than 35 years in developing emissions control technology for engines. His work at Honeywell involves developing and applying advanced boosting technology to reduce emissions and improve fuel economy of automobiles. He has served as the faculty at the University of California, Berkeley and Texas. He has worked extensively in R&D at Cummins and served as a consultant to automotive companies worldwide as a part of his work at SWRI. He is a Fellow of SAE and was President of SAE International, USA in 2002 E-mail : sm.shahed@honeywell.com
Dr. Kevin Hoag Prof. Hoag is Associate Director at the University of Wisconsin Engine Research Center and Program Director with the Dept. of Engineering Professional Development. His work with engines began as a mechanic, where his primary focus was engine overhaul. He has more than 25 years of engineering experience in engine development, the majority of which was with Cummins, where he held a variety of leadership roles in engine performance and mechanical development. He holds bachelors and masters degrees in Mechanical Engineering from the University of Wisconsin. He is the author of two books, Skill Development for Engineers (IEE Press, 2001) and Vehicular Engine Design (Springer-Verlag, 2005). E-mail : hoag@wisc.edu
{7}
ABOUT SPEAKERS
Mr. Roy Primus Mr. Primus is Principal Engineer at the General Electric Global Research Center. Over his 30+ year career, he has managed a wide spectrum of analytical & experimental work with diesel and spark ignition engine combustion, emissions, performance, fluid mechanics, heat transfer, thermodynamic system modeling and air handling system assessment. Prior to joining GE in 2002, Roy worked for Cummins. He pioneered the use of second law analysis for assessment of diesel engine systems and established the visual thermodynamics framework for depicting design space of engine systems. Roy is a Fellow of SAE and holds a BS degree in mathematics and MS degree in mechanical engineering from Rose-Hulman Institute of Technology. E-mail : primus@research.ge.com Dr. Kamalkishore Vora Dr. Vora is Sr. Assistant Director at ARAI, Pune and heads ARAI Academy & Library with effect from 1st Jan 2009. With his Ph.D. from IIT Bombay, presently, he is working on Design & Development of a high performance common rail diesel engine. Over his 20+ year career, he has worked with Walchand Nagar Industries, Emitec, ARAI and M&M. He Has specialized in the field of Engine R&D, Automotive Education and Technology Development. He is instrumental in starting ARAI Post Graduate Academy, which conducts M.Tech. Course in Automotive Engineering. Dr. Vora is trained at Ford Motors, General Motors, United States Environmental Protection Agency in USA and Emitec in Germany. He has been visiting Professor in various Engineering Colleges of Pune & Nashik. He is the Secretary of the Society of Automotive Engineers (SAE) India and Co-ordinator of SAE India Western Section, under which he conducts series of Conferences, Seminars, Workshops, Courses and various students activities. He was the Convener of BAJA SAEINDIA 2007 held at Pithampur from 21st to 23rd Dec 2007 and now the Secretary of BAJA SAEINDIA 2009. E-mail : vora.pga@araiindia.com
{8}
PROGRAMME for 3 day SAE Certificate Course on I. C. Engine Design & Development
Day One 18-01-2009
Start 9:00 9:30 10:15 11:45 12:15 12.30 13:30 14:30 15:30 16:00 17:00 17:20 End 9:30 10:15 11:45 12:15 12:30 13.30 14:30 15:30 16:00 17:00 17:20 Subject Introduction Engine Layout and Configuration Cylinder Head Tea/Coffee Break Welcome Address and Interaction with Speakers & Delegates Lunch Break Overall Engine System Parameters Camshaft and Valve train Tea/Coffee Break Crankshaft Summarize End Kamal Team Shahed Roy S. R. Marathe N. V. Marathe Lead Shahed Kevin Kevin Duration 30 45 90 30 30 45 60 60 30 60 20 500
Day Two 19-01-2009

Start 9:00 11:00 11:30 13:00 13:45 14:30 15:30 16:00 17:30 End 11:00 11:30 13:00 13:45 14:30 15:30 16:00 17:30 Subject Cylinder Block Tea/Coffee Break Pistons Fuel Injection Lunch Break Rings and Cylinder Wall Tea/Coffee Break Air Induction End Shahed Roy Kamal Roy Lead Kevin Duration 120 30 90 45 45 60 30 90 510
{9}
Day Three 20-01-2009

Start 9:00 10:30 11:00 11:30 12:30 13:00 13:30 14:45 15:15 16:30 17:00 End 10:30 11:00 11:30 12:30 13:00 13:30 14:45 15:15 16:30 17:00 Subject Bearings Engine Cooling Tea/Coffee Break Engine Cooling (Contd) Lunch Break Sensors and Controls Lube System Tea/Coffee Break Summary/Feedback Closing Ceremony End Team Local Host Roy Kamal Kamal Lead Kevin Kamal Duration 90 30 30 60 30 30 75 30 60 30 465
{ 10 }
CONTENTS
About Speakers .........................................................................................7 Programme for Three Days Course ..................................................................9 Introduction ........................................................................................... 13 Overall Engine System Parameters ............................................................... 15 Engine Layout & Configuration ..................................................................... 21 The Cylinder Block ................................................................................... 27 The Cylinder Head.................................................................................... 37 The Cranktrain ........................................................................................ 45 The Power Cylinder - Piston ........................................................................ 53 The Power Cylinder - Piston Rings & Cylinder Wall ............................................ 63 Camshaft & Valve Train ............................................................................. 71 Fuel Injection System ................................................................................ 79 Air Induction System ................................................................................. 83 The Cooling System .................................................................................. 93 Engine Lubrication - Bearings .....................................................................103 The Lubrication System ............................................................................111 Sensors & Controls..................................................................................119
{ 11 }
{ 12 }
INTRODUCTION
{ 13 }
{ 14 }
Overall Engine System Parameters
{ 15 }
{ 16 }
{ 17 }
{ 18 }
{ 19 }
{ 20 }
Engine Layout & Configuration
{ 21 }
{ 22 }
{ 23 }
{ 24 }
{ 25 }
{ 26 }
The Cylinder Block
{ 27 }
{ 28 }
{ 29 }
{ 30 }
{ 31 }
{ 32 }
{ 33 }
{ 34 }
{ 35 }
{ 36 }
The Cylinder Head
{ 37 }
{ 38 }
{ 39 }
{ 40 }
{ 41 }
{ 42 }
{ 43 }
{ 44 }
The Cranktrain
{ 45 }
{ 46 }
{ 47 }
{ 48 }
{ 49 }
{ 50 }
{ 51 }
{ 52 }
The Power Cylinder - Piston
{ 53 }
{ 54 }
{ 55 }
{ 56 }
{ 57 }
{ 58 }
{ 59 }
{ 60 }
{ 61 }
{ 62 }
The Power Cylinder - Piston Rings & Cylinder Wall
{ 63 }
{ 64 }
{ 65 }
{ 66 }
{ 67 }
{ 68 }
{ 69 }
{ 70 }
Camshaft & Valve Train
{ 71 }
{ 72 }
{ 73 }
{ 74 }
{ 75 }
{ 76 }
{ 77 }
{ 78 }
Fuel Injection System
{ 79 }
{ 80 }
{ 81 }
{ 82 }
Air Induction System
{ 83 }
{ 84 }
{ 85 }
{ 86 }
{ 87 }
{ 88 }
{ 89 }
{ 90 }
{ 91 }
{ 92 }
The Cooling System
{ 93 }
{ 94 }
{ 95 }
{ 96 }
{ 97 }
{ 98 }
{ 99 }
{ 100 }
{ 101 }
{ 102 }
Engine Lubrication - Bearings
{ 103 }
{ 104 }
{ 105 }
{ 106 }
{ 107 }
{ 108 }
{ 109 }
{ 110 }
The Lubrication System
{ 111 }
{ 112 }
{ 113 }
{ 114 }
{ 115 }
{ 116 }
{ 117 }
{ 118 }
Sensors & Controls
{ 119 }
{ 120 }
{ 121 }
1250 1000
Force (N)
750 500 250
120
240
360
480
600
720
For more details, please contact : Mr. N. V. Marathe, Dy. Director & Head, Engine Development Laboratory, P. B. No. 832, Pune - 411 004. Survey No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune - 411 038, INDIA Tel. : +91-20-3023 1430, Fax : +91-20-2543 4190 E-mail : nvmarathe.edl@araiindia.com, Website : www.araiindia.com
Inlet port flow study
Turbo machinery analysis
The ARAI established in 1966 as a co-operative industrial research centre by the Automotive industry and Government of India. It has grown substantially to become a prime research, development and testing institute in India, bringing complete automotive technology under one roof.
Pr o g re
Through Re s
It is working in harmony and in complete confidence with its Members, Customers and the Government of India. It has increased activities globally while continuing to offer the finest service to our clients. ARAI is proud to be the first automotive R&D institute in India with ISO 9001/14001 Certifications and also with NABL Accreditation. R&D DIVISION: Automotive Electronics Department (AED) Alternate Fuel Laboratory (AFL) Engine Development Laboratory (EDL) NVH & CAE Laboratory (NVH) Structural Dynamics Laboratory (SDL) Passive Safety Laboratory (PSL) TESTING & CERTIFICATION DIVISION: Automotive Material Laboratory (AML) Emission Certification Laboratory (ECL) Vehicle Evaluation Laboratory (VEL) Safety and Homologation Laboratory (SHL) Calibration & Metrology Laboratory (CAL & MET) SERVICE DIVISION: Directors Technical Secretariat (DTS) Apex Central Cell (APX) Information and Technology Management (ITM) Plant & Services (PAS) Single Window System (SWS) Post Graduate Academy (PGA) Central Library (LIB) The Automotive Research Association of India Postal Address : P. B. No.832, Pune - 411004 Regd. Office : S.No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038 (India) Tel.: + 91 20 30231111 Fax : + 91 20 25434190
Automotive Technology, R & D and Certification
www.araiindia.com
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I. C.

ENGINE DESIGN & DEVELOPMENT

Concurrent with SIAT 2009 st rd 21 - 23 January 2009

ARAI Campus Pune, INDIA

3 Day Certificate Course

I. C. Engine Design & Development

SAEINDIA Office Bearers 2008 - 2009

Dr. Arun Kumar Jaura Member

Dr. Aravind S Bharadwaj Vice President

Dr. M. K. Gajendra Babu Member

Three Day Certificate Course on

I. C. Engine Design & Development

Jointly Organized by:

The Automotive Research Association of India

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Mr. Shrikant R. Marathe

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Day Two 19-01-2009

Day Three 20-01-2009

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Overall Engine System Parameters

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Engine Layout & Configuration

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

The Cylinder Block

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

The Cylinder Head

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development

Three Day SAE Certificate Course on I. C. Engine Design & Development