ice d&d 2009 proceedings

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I. C. Engine Design & Development

3 Day Certificate Courseon

from 18 to 20 Jan. 09th th

ARAI, Pune(The Automotive Research Association of India)

at

WESTERNSECTION

Jointly Organised by

ARAI Campus

Pune, INDIA

Concurrent with SIAT 2009

21 - 23 January 2009st rd

I.C

.E

NGIN

EDESIG

N&

DEVELOPM

ENT


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About SAE

SAE International is a professional engineering society,whose membership represents practically everyengineering and scientific discipline. Its memberscombine their specialized abilities to further advance theresearch, development, design, manufacture and

utilization of vehicles, which operate on land, water, airand space. Over 1,00,000+ engineers and scientist, whoare SAE members, develop technical information on allforms of self-propelled vehicles including automobiles,trucks and buses, off-highway equipment, aircraft,aerospacevehicles, marine, railand transit systems.

Engineering leaders round the world in the field ofvehicle engineering belong to SAE because of the valueit offers them. Networking with the other leaders is amajor attraction of every SAE event. SAE books,standards, technical papers and special publications

offer the most complete resources for anyone interestedin the latest technological advances. Much of thisinformation is now available electronically throughSAEswebsite.

To know more about SAE International, please visit

SAEINDIA has started operating in India from 2002 asan affiliate of SAE International. Presently there are fivesections: West, South, North, East and Bangalore, with

about 3000 regular members and 15000 studentmembers.

To know more about SAEINDIA, please visit

SAEINDIA Western Section, the firstSection establishedin 1996, is operating with its-headquarters at ARAI-Pune. It regularly conducts technical workshops,seminars, toptechs and symposia. It has about 35collegiate chapters in and around Ahmadabad, AlwarAurangabad, Bharuch, I sl am pu r,

Nanded, Navi Mumbai,Pandharpur, Pillani,

andYatmal

,

www.sae.org

www.saeindia.org

Gwalior, Indore,Mumbai, Nagpur, Nashik,

Pune, Sangli, Shegaon, Surat,Vallabh VidyaNagar

SAEINDIA Office Bearers 2008 - 2009

M. S. Kumar President

R. Dayal Senior Vice President

S.R. Marathe Vice President

Dr. Aravind S Bharadwaj Vice President

Dr. K. C. Vora Secretary

Mr. Rajesh Singh Treasurer

Dr. G. Nagarajan Joint Secretary

S. Maitra Joint Treasurer

Dr. Pawan Goenka Immediate Past President

Dr. M. K. Gajendra Babu Member

Dr. K. Kumar Member

Dr. R. Mahadevan Member

R. Mukundan Member

Dr. Arun Kumar Jaura Member

S. Govindarajan Member

K. N. Krishnamurthy Member

S. Selvamani Member

Dr. David. L. Schutt Exec.Vice President, SAE International

Mr. Murli M Iyer Global Development Manager,

SAE International

WESTERN SECTION

Activities of SAEINDIA


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Three Da y Cer t i f ica t e Course

on

I. C. Engine Design & Development

at

ARAI, Pune(The Automotive Research Association of India)

From 18th to 20th January 2009

Jo i n t l y Orga n i zed by :

Western Section

&

The Automotive Research Association of India


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

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Mr. Shrikant R. Marathe

Director ARAI, PuneVice President - SAEINDIA

FOREWORD

SAEINDIA organizes series of Conferences, Seminars, Lectures, Workshops, Toptechs andCertificate Courses on number of advanced topics related to automotive technology. This forumprovides a platform for experts and engineering professionals to meet and discuss latest technologiesand 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 advancedtechniques related to product design, development and testing are introduced, they would be readyto 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 onI. C. Engine Design & Development, so that the delegates can assimilate and develop a strategyfor future design & development based on application and their targets. As per the wishes of theU. S. faculty, Dr. K. C. Vora of ARAI, Pune has been inducted as a speaker to indigenize this courseand convert it into SAEINDIA Professional Development Program (PDP).

It is essential to gain an in-depth understanding of the development process of the engine, rightfrom customer requirements to design validation. This 3 Day Certificate Course on I. C. EngineDesign & Development, arranged jointly by ARAI, Pune and SAEINDIA Western Section is anendeavor 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 andmy sincere thanks to the speakers for their excellent contribution in introducing the delegates to thisadvanced topic.

Date: Jan 15, 2009 Shrikant Marathe


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Mr. N. V. MaratheDeputy Director,

Head of Department,Engine Development Lab, ARAI, Pune

PREFACEIndia 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 automotiveand 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/vehiclerequirements 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 structuralcomponents / 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, fatiguelife, 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 contentsof 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 encouragementand 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


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ORGANISING COMMITTEE

Mr. N. V. Marathe

Dr. K. C. Vora

Mr. R. D. Talele Mr. A. V. Marathe

Mr. Parag Mengaji Mr. N. A. Sakle

Mr. Bharani Dharan Mr. Prasad Bhatt

Mr. Y. K. Upadhayay Mr. G. V. Sangle

Mr. M. A. Palse Mr. J. D. Banerji

Mr. H. S. Rasane Mrs. Anjali Dharap

Mr. Vilas Tanpure Mr. B. Y. Deshmukh

Mr. R. B. Yadav Mr. M. R. Sarkale

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ABOUT SPEAKERS

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Dr. S. M. Shahed

Dr. Shahed is Corporate Fellow at Honeywell TurboTechnologies. He has worked for more than 35 years indeveloping emissions control technology for engines. His work at Honeywell involves developing and applyingadvanced boosting technology to reduce emissions andimprove fuel economy of automobiles. He has served asthe faculty at the University of California, Berkeley and Texas.

He has worked extensively in R&D at Cummins and servedas a consultant to automotive companies worldwide as a partof his work at SWRI. He is a Fellow of SAE and was Presidentof SAE International, USA in 2002

E-mail :[email protected]

Dr. Kevin Hoag

Prof. Hoag is Associate Director at the University ofWisconsin Engine Research Center and Program Directorwith the Dept. of Engineering Professional Development.His work with engines began as a mechanic, where his primaryfocus was engine overhaul. He has more than 25 years ofengineering experience in engine development, the majorityof which was with Cummins, where he held a variety ofleadership roles in engine performance and mechanical

development. He holds bachelors and masters degrees inMechanical Engineering from the University of Wisconsin.He is the author of two books, Skill Development forEngineers (IEE Press, 2001) and Vehicular Engine Design(Springer-Verlag, 2005).

E-mail : [email protected]


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ABOUT SPEAKERS

Mr. Roy Primus

Mr. Primus is Principal Engineer at the General Electric GlobalResearch Center. Over his 30+ year career, he has managed awide spectrum of analytical & experimental work with dieseland spark ignition engine combustion, emissions, performance,fluid mechanics, heat transfer, thermodynamic system modelingand air handling system assessment. Prior to joining GE in2002, Roy worked for Cummins. He pioneered the use ofsecond law analysis for assessment of diesel engine systemsand established the visual thermodynamics framework fordepicting design space of engine systems. Roy is a Fellow ofSAE and holds a BS degree in mathematics and MS degree inmechanical engineering from Rose-Hulman Institute ofTechnology.


Dr. Kamalkishore Vora

Dr. Vora is Sr. Assistant Director at ARAI, Pune and headsARAI Academy & Library with effect from 1st Jan 2009. Withhis Ph.D. from IIT Bombay, presently, he is working on Design& Development of a high performance common rail dieselengine. Over his 20+ year career, he has worked with WalchandNagar Industries, Emitec, ARAI and M&M. He Has specializedin the field of Engine R&D, Automotive Education andTechnology Development. He is instrumental in starting ARAIPost Graduate Academy, which conducts M.Tech. Course inAutomotive Engineering. Dr. Vora is trained at Ford Motors,General Motors, United States Environmental Protection

Agency in USA and Emitec in Germany. He has been visitingProfessor 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 wasthe Convener of BAJA SAEINDIA 2007 held at Pithampurfrom 21st to 23rd Dec 2007 and now the Secretary of BAJASAEINDIA 2009.


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PROGRAMME for 3 day SAE Certificate Course onI. C. Engine Design & Development

Day One 18-01-2009Start End Subject Lead Duration

9:00 9:30 Introduction Shahed 30

9:30 10:15 Engine Layout and Configuration Kevin 45

10:15 11:45 Cylinder Head Kevin 90

11:45 12:15 Tea/Coffee Break 30

12:15 12:30 Welcome Address and Interaction with S. R. MaratheSpeakers & Delegates N. V. Marathe 30

12.30 13.30 Lunch Break 45

13:30 14:30 Overall Engine System Parameters Shahed 60

14:30 15:30 Camshaft and Valve train Roy 60


16:00 17:00 Crankshaft Kamal 60

17:00 17:20 Summarize Team 20

17:20 End 500

Day Two 19-01-2009

Start End Subject Lead Duration

9:00 11:00 Cylinder Block Kevin 120


11:30 13:00 Pistons Kamal 90

13:00 13:45 Fuel Injection Roy 45

13:45 14:30 Lunch Break 45

14:30 15:30 Rings and Cylinder Wall Roy 60


16:00 17:30 Air Induction Shahed 90

17:30 End 510

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Day Three 20-01-2009

Start End Subject Lead Duration

9:00 10:30 Bearings Kevin 9010:30 11:00 Engine Cooling Kamal 30


11:30 12:30 Engine Cooling (Contd) Kamal 60

12:30 13:00 Lunch Break 30

13:00 13:30 Sensors and Controls Roy 30

13:30 14:45 Lube System Kamal 75


15:15 16:30 Summary/Feedback Team 60

16:30 17:00 Closing Ceremony Local Host 30

17:00 End 465

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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

CONTENTS

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INTRODUCTION


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Overall Engine System Parameters


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Engine Layout & Configuration


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The Cylinder Block


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The Cylinder Head


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The Cranktrain


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The Power Cylinder - Piston


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The Power Cylinder - Piston Rings & Cylinder Wall


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Camshaft & Valve Train


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Fuel Injection System


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Air Induction System


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The Cooling System


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Engine Lubrication - Bearings


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Sensors & Controls


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Inlet port flow study

Turbo machinery a

The Automotive Research Association of IndiaThe Automotive Research Association of India

Website : www.araiindia.com

P. B. No. 832 Pune - 411 004.Survey No. 102, Vetal Hill, Off Paud Road,

+91-20-3023 1430, +91-20-2543 [email protected],

,

Kothrud, Pune - 411 038, INDIA

Tel. : Fax :

E-mail :

Website : www.araiindia.com

For more details, please contact :, Dy. Director & Head,

Engine Development Laboratory,Mr. N. V. Marathe


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ice d&d 2009 proceedings

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