Engine Cylinder Block Research Articles

Diesel Engine Cylinder Block Casting Process Optimization

This paper describes the traditional diesel engine cylinder block casting process on the basis, focusing on inline four-cylinder diesel engine cylinder block lost foam process design and optimization of application. Product pattern and pouring system model formed with expandable polystyrene beads, and assemble them into a model cluster, man can drying them after the model cluster dipping with the aid of manual or manipulator . Put the drying model cluster into the single sand box which with a negative pressure pumping system, a single dry sand rain-type sand system filling and compaction. Finally, to achieve the solidification of molten metal casting and forming under a certain vacuum.

Analysis of Fretting Behavior for Fasten Surface between Diesel Engine Cylinder Block and Main Bearing Cap

Fretting fatigue becomes a typical failure mode for engine cylinder block caused by the increasing of the gas pressure and rotating speed, but the mechanism of fretting fatigue under diesel engine load condition hasn’t been systematic studied. In this paper, the fretting behaviors are mainly discussed by using fretting friction work parameter W and crack initiation location parameter G.

707 エンジン外付け型の等価的図示平均有効圧センサの試作

707 エンジン外付け型の等価的図示平均有効圧センサの試作

Finite Element Analysis of Marine Diesel Engine Frame

Taking the marine low-speed high power diesel engine frame for example, created a three-dimension model through UG. By using the finite element software ANSYS investigated the body’s stress status and displacement which provides a valuable reference for the structural optimization of the cylinder block of diesel engine’s design.

Study on the Fretting Wear Failure in the Cylinder Block of a Diesel Engine

Fracture accidents often take place along the whole clapboard or block in cylinder block of diesel engine during its stand test. From the analysis of the macroscope fractography of the fracture plane and stress, it indicates that the failure of cylinder block was induced by the generation and extension of crack and local plastic deformation and the inching fretting fatigue are the main causes of crack initiation, while alternating cyclic load is the power of crack propagation. The paper represents some corresponding methods to prevent or avoid fracture accidents based on our profound research, and the study lays the reference and foundation for diesel engine design and testing.

Numerical and experimental study of engine cylinder block under mechanical and thermal loads: static and dynamic investigation

In this paper, the static behaviour of the Pride’s engine block under pressure and thermal loads in the course of combustion is analysed using the finite element method (FEM). For this purpose, the engine block with its full details including water-jackets, journal positions with oil slots and so on, is modelled and then the model is meshed. To ensure geometric modelling, the dynamic characteristics of the model were obtained by experimental modal analysis and the results compared with the ones obtained by the numerical (FEM) modal analysis. By imposing mechanical and thermal loads, stresses and strains were computed. The results were compared with the available experimental or theoretical-related works. The results show that thermal loads have the most significant effect on the cylinder block deformation. This deformation is higher in the lateral direction than the longitudinal one, and decreases from the top to the bottom of the cylinder block. In addition, the maximum stress is highest in cylinder no. 3. The results confirm the accuracy of the geometric modelling.

Experimental Investigation of Thermal Load in High Speed Direct Injection Diesel Engine Under the Control of Various Engine Performance Parameters

Multiple injection strategies are being widely utilized to reduce the vibration, noise, and particle emission in diesel engines. A considerable amount of research related to attempts to increase the maximum power and to reduce vibration, noise, and particulate matters has been done. However, investigations of various performance parameters in terms of the thermal load in high speed direct injection engines are rarely to be found despite the fact that the relationship between these parameters and the reliability of the engine is important for mass production. Hence, the thermal load imposed on the cylinder head and cylinder block of a four-cylinder diesel engine was investigated under the most severe test conditions, at the rated speed and with a full load, by changing the performance parameters such as the main injection timing, the fuel pressure in the common rail, the boost pressure, the exhaust gas recirculation, the fuel quantity of the pilot injection, the timing of the pilot injection, the fuel quantity of the postinjection, and the timing of postinjection. Experimental results showed that the main injection timing among other parameters was the parameter that influenced the thermal load most at the rated engine speed and under a full load condition.

A STRUCTURAL ANALYSIS AND TOPOLOGY OPTIMIZATION ON CYLINDER BLOCK OF HEAVY DUTY DIESEL ENGIN

The heavy duty diesel engine must have a large output for maintaining excellent mobility. In this study, a three-dimensional finite element model of a heavy-duty diesel engine was developed to conduct the stress analysis by using property of CGI. The compacted graphite iron (CGI) is a material currently under study for the engine demanded for high torque, durability, stiffness, and fatigue. The FE model of the heavy duty diesel engine section consisting of four half cylinders was selected. The heavy duty diesel engine section includes a cylinder block, a cylinder head, a gasket, a liner, a bearing cap, bearing and bolts. The loading conditions of engine are pre-fit load, assembly load, and gas load. A structural analysis on the result was performed in order to optimize on the cylinder block of the diesel engine.

Assessment of Surface Treatment on Fatigue Life of Cylinder Block for Linear Engine using Frequency Response Approach

Objectives: This study was focused on the finite element techniques to investigate the effect of surface treatment on the fatigue life of the vibrating cylinder block for new two-stroke free piston engine using random loading conditions. Motivation: An understanding of the effects related to the random loading is necessary to improve the ability of designers to accurately predict the fatigue behavior of the components in service. An internal combustion engine cylinder block is a high volume production component subjected to random loading. Problem statement: Proper optimization of this component that is critical to the engine fuel efficiency and more robustly pursued by the automotive industry in recent years. A detailed understanding of the applied loads and resulting stresses under in-service conditions is demanded. Approach: The finite element modeling and analysis were performed utilizing the computer aided design and finite element analysis codes respectively. In addition, the fatigue life prediction was carried out using finite element based fatigue analysis code. Aluminum alloys were considered as typical materials in this study. Results: The frequency response approach was applied to predict the fatigue life of cylinder block using different load histories. Based on the finite element results, it was observed that the fatigue life was significantly influenced for the nitriding treatment. The obtained results were indicated that the nitrided treatment produces longest life for all loading conditions. Conclusion: The nitriding process is one of the promising surface treatments to increase the fatigue life for aluminum alloys linear engine cylinder block.

Assessment of Surface Treatment on Fatigue Life of Cylinder Block for Linear Engine using Frequency Response Approach

Objectives: This study was focused on the finite element techniques to investigate the effect of surface treatment on the fatigue life of the vibrating cylinder block for new two-stroke free piston engine using random loading conditions. Motivation: An understanding of the effects related to the random loading is necessary to improve the ability of designers to accurately predict the fatigue behavior of the components in service. An internal combustion engine cylinder block is a high volume production component subjected to random loading. Problem statement: Proper optimization of this component that is critical to the engine fuel efficiency and more robustly pursued by the automotive industry in recent years. A detailed understanding of the applied loads and resulting stresses under in-service conditions is demanded. Approach: The finite element modeling and analysis were performed utilizing the computer aided design and finite element analysis codes respectively. In addition, the fatigue life prediction was carried out using finite element based fatigue analysis code. Aluminum alloys were considered as typical materials in this study. Results: The frequency response approach was applied to predict the fatigue life of cylinder block using different load histories. Based on the finite element results, it was observed that the fatigue life was significantly influenced for the nitriding treatment. The obtained results were indicated that the nitrided treatment produces longest life for all loading conditions. Conclusion: The nitriding process is one of the promising surface treatments to increase the fatigue life for aluminum alloys linear engine cylinder block.

On board recognition of different fuels in SI engines with the use of dimensional and non-dimensional vibration signal parameters

Gaseous fuels such as natural gas and propane butane mixtures are currently the most popular fuels for dual fuel internal combustion engines. Gaseous fuels are more resistant to knocking than conventional liquid fuels they mix better with air. There have been many published works on the use of gaseous fuels but the problem of the combustion noise, as a very important source of acoustic discomfort is not getting enough attention. Combustion noise occurs in a direct and indirect form. It is transmitted throughout the engine block as a vibration at a different spectrum of frequencies. In this study an attempt has been made to correlate the combustion noise with the operating parameters of an engine fueled with LPG, CNG and CNG-hydrogen mixtures as compared to petrol fueled engine. Signals of multiple resonance in the combustion chamber and corresponding vibration signals of the cylinder block of engine have been considered for one combustion cycle. A four cylinder, 1.6 dm3 spark-ignition engine converted to run on LPG, CNG and CNG-hydrogen mixtures has been tested in the project. A well known diagnostic parameter was used for comparison of the engine noise for its operation on gasoline and alternative fuels. A new non-dimensional indicator has also been proposed for the engine vibration estimation purposes the Increase Wavelet Ratio C’ab, precisely described in the paper.

Application of Monte Carlo Simulation for Free Piston Engine Cylinder Block Design

Application of Monte Carlo Simulation for Free Piston Engine Cylinder Block Design

Finite Element Analysis of Static Strain along the Fillet on Upper Deck of Diesel Engine Cylinder Block Produced by Tightening of Cylinder Head Bolts

The distribution of static strain along the fillet on an upper deck of cylinder block and its dependency on the depth of thread engagement for cylinder head bolts were evaluated for a diesel engine by the finite element method. Since the fillet on upper deck is one of the critical parts in the cylinder block that may be cracked by stress and strain concentration, the static strain along the fillet was focused on in this study. In the model, the static tightening force of cylinder head bolts balanced with the total force acting on the cylinder block. A uniform surface pressure calculated by the total force divided by the contact area was given to the upper deck. The following results were obtained.The static strain along the fillet was dependent on the circumferential direction of cylinder and its value was varied with the depth of thread engagement for cylinder head bolts. The optimum depth of thread engagement was determined to be about 100 mm from the viewpoints of the overall magnitude of strain, the circumferential fluctuation of strain, the change rate of strain against the depth of thread engagement, and the length of cylinder head bolt. The calculated circumferential distribution of the static strain and the tightening force were compared with the measurement results under the optimum depth of thread engagement condition. Both results agreed well and this fact suggests that the present analysis is useful for optimizing the structural design of cylinder block for diesel engines.

Influence of surface treatments on fatigue life of a two-stroke free piston linear engine component using random loading

This paper describes the finite element (FE) analysis technique to predict fatigue life using the narrow band frequency response approach. The life prediction results are useful for improving the component design methodology at the very early development stage. The approach is found to be suitable for a periodic loading but requires very large time records to accurately describe random loading processes. This paper is aimed at investigating the effects of surface treatments on the fatigue life of the free piston linear engine’s components. Finite element modelling and frequency response analysis were conducted using computer aided design and finite element analysis commercial codes, respectively. In addition, the fatigue life prediction was carried out using finite element based fatigue analysis commercial code. Narrow band approach was specially applied to predict the fatigue life of the free piston linear engine cylinder block. Significant variation as observed between the surface treatments and untreated cylinder block of free piston engine. The obtained results indicated that nitrided treatment yielded the longest life. This approach can determine premature products failure phenomena, and therefore can reduce time to market, improve product reliability and customer confidence.

Effects of surface finish and treatment on the fatigue behaviour of vibrating cylinder block using frequency response approach

This paper presents the effects of surface finish and treatment on the high cycle fatigue behaviour of vibrating cylinder block of a new two-stroke free piston engine at complex variable amplitude loading conditions using frequency response approach. Finite element modelling and frequency response analysis was conducted using finite element analysis software Package MSC.PATRAN/MSC.NASTRAN and fatigue life prediction was carried out using MSC.FATIGUE software. Based on the finite element results, different frequency response approach was applied to predict the cylinder block fatigue life. Results for different load histories and material combinations are also discussed. Results indicated great effects for all surface finish and treatment. It is concluded that polished and cast surface finish conditions give the highest and lowest cylinder block lives, respectively; and that Nitrided treatment leads to longest cylinder block life. The results were used to draw contour plots of fatigue life and damage in the worst or most damaging case.

AE mapping of engines for spatially located time series

This paper represents the first step towards using multiple acoustic emission (AE) sensors to produce spatially located time series signals for a running engine. By this it is meant the decomposition of a multi-source signal by acquiring it with an array of sensors and using source location to reconstitute the individual time series attributable to some or all of these signals. Internal combustion engines are a group of monitoring targets which would benefit from such an approach. A series of experiments has been carried out where AE from a standard source has been mapped for a large number of source–sensor pairs on a small diesel engine and on various cast iron blocks of simple geometry. The wave propagation on a typical diesel engine cylinder head or block is complex because of the heterogeneity of the cast iron and the complex geometry with variations in wall-thickness, boundaries and discontinuities. The AE signal distortion for a range of source–sensor pairs has been estimated using time–frequency analysis, and using a reference sensor placed close to the source. At this stage, the emphasis has been on determining a suitable processing scheme to recover a measure of the signal energy, which depends only on the distance of the source and not upon the path. Tentative recommendations are made on a suitable approach to sensor positioning and signal processing with reference to a limited set of data acquired from the running engine.

The laser-assisted iron oxide coating of cast Al auto engines

Cast A319 Al alloy, which is a popular choice for automobile engine cylinder block material, has been limited in that use by its poor tribological properties. Various techniques have been explored to address this problem, including the one addressed in this study, laser surface engineering (LSE.) Engine cylinders made of A319 Al alloy were LSE coated with FeO. The region of coating produced a refined microstructure compared to the cast substrate structure. Also, the FeO coating displayed superior wear performance compared to uncoated A319 Al under dry sliding wear conditions.

Time–frequency analysis of multiple resonances in combustion engine signals

This paper presents time–frequency analysis of multiple resonances in combustion chamber pressure signals and corresponding structure-born sound signals of the cylinder block of a combustion engine considering only one combustion cycle. Since the Wigner distribution proved itself as a good tool for these kinds of signals, the requirement which we imposed here was to produce a sum of the Wigner distributions of the signal components separately, but without cross-terms using only one signal realization. A distribution having this property can be achieved using the S-method. Based on this property of the method, we investigate a procedure to estimate the instantaneous frequencies that are functions of temperature within the combustion chamber and the energies of the components that are used for knock detection. The calculation delay is smaller than the duration of one combustion cycle. This can provide an efficient and accurate combustion control of spark-ignition car engines. The procedure is demonstrated on several simulated and experimental signals.

Surface hardening of a gray cast iron used for a diesel engine cylinder block using high-energy electron beam irradiation

This study investigates the effects of high-energy electron-beam (1.4 MeV) irradiation on surface hardening and microstructural modification in a gray cast iron currently used for a diesel engine cylinder block. The gray cast-iron samples were irradiated in air using an electron accelerator. Afterward, their microstructure, hardness, and wear properties were examined. The original microstructure, which contained graphite flakes in a pearlitic matrix, was changed to martensite, ledeburite, and retained austenite, along with complete or partial dissolution of the graphite. This microstructural modification occurred only when the surface was irradiated with an input-energy density over 1.1 kJ/cm2, and it greatly improved the surface hardness and wear resistance. In order to investigate the complex microstructures, thermal analysis and simulation testing were also carried out. The results indicated that the irradiated surface was heated to the austenite-temperature region and then quenched to room temperature, which was enough to obtain surface hardening through martensitic transformation. The thermal analysis results matched well with the microstructures of the thermally simulated samples.

9732829 Development of low-noise cylinder block of a diesel engine — Design and ITEM analysis utilizing full solid modeling Yoshiaki Moroguchi, Kazuhiro Nakashima, Manabu Yamamoto (Mitsubishi Motors Corporation)

9732829 Development of low-noise cylinder block of a diesel engine — Design and ITEM analysis utilizing full solid modeling Yoshiaki Moroguchi, Kazuhiro Nakashima, Manabu Yamamoto (Mitsubishi Motors Corporation)