This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Design and Development of a Gasketless Cylinder Head / Block Interface for an Open Deck, Multi Cylinder, Highly Turbocharged Small Engine
Technical Paper
2006-32-0036
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Language:
English
Abstract
This paper describes the design and development of a gasketless interface, which was used successfully to couple an aluminium cylinder head to an open deck design cylinder block. The cylinder block was manufactured from aluminium, featuring shrink fit dry cast iron liners. Extensive CAE modelling was employed to implement the gasketless interface and thus avoid using a conventional metal or fiber based cylinder head gasket.
The engine was specifically designed and configured for the purpose, being a 430 cm3, highly turbocharged (TC) twin cylinder in-line arrangement with double overhead camshafts and four valves per cylinder. Most of the engine components were specially cast or machined from billets.
The new design removed the conventional head gasket and relied on the correct amount of face pressure generated by interference between the cylinder head and block to seal the interface. This had advantages in improving the structural integrity of the weak open deck design. Extensive FEM analysis determined the correct amount of interference needed for successful operation under all operating conditions.
Extensive thermal analysis concluded that removing the conventional gasket had the advantage of improving the heat path between the cylinder head and block, as the gasket behaves as an insulator. The possibility of gasket failure due to abnormal combustion is also eliminated.
The design proved successful in operation, withstanding knock amplitudes of 30 bar, in-cylinder pressures exceeding 100 bar and high combustion temperatures. The engine completed extensive static and transient testing with no interface problems after initial development, recording 25 bar brake mean effective pressure (BMEP) on pump gasoline.
Recommended Content
Authors
Topic
Citation
Attard, W., Watson, H., and Stryker, P., "Design and Development of a Gasketless Cylinder Head / Block Interface for an Open Deck, Multi Cylinder, Highly Turbocharged Small Engine," SAE Technical Paper 2006-32-0036, 2006, https://doi.org/10.4271/2006-32-0036.Data Sets - Support Documents
| Title | Description | Download |
|---|---|---|
| Unnamed Dataset 1 |
Also In
References
- CLOUGH, M.J. ‘Precision Cooling of a Four Valve per Cylinder Engine’ SAE paper 931123 1993
- POEPPERI, M. HEDRICH, G. HEUSLER, H. KOEHLER, D. MARIN, B. ROTHENBERGER, P. SCHARRER, O. ‘Adaptation of a Dual Continuous Variable Cam Phasing to a 4-Valve, 4-Cylinder Engine - Thermodynamic Benefits and Engine Hardware Requirements’ SAE paper 2006-01-0408 2006
- ROTHE, M. HEIDENREICH, T. SPICHER, U. SCHUBERT, A. ‘Knock Behaviour of SI Engines: Thermodynamic Analysis of Knock Onset Locations and Knock Intensities’ SAE paper 2006-01-0225 2006
- ATTARD, W ‘Design, Performance and Analysis of a Downsized Highly Turbocharged 0.45L Formula SAE Engine’ Mech. Eng. Dept., Univ. of Melbourne 2006
- ATTARD, W. WATSON, H.C. ‘Development of a 430cc Constant Power Engine for FSAE Competition’ SAE paper 2006-01-0745 2006
- KARAGOUNIS, T. STRAUS, ‘Development of a 90 bhp Turbocharged Engine for use in Formula SAE-A’ Mech.Eng. Dept, Univ. of Melbourne 2002
- ISHIGAKI, I. KITAGAWA, J. TANAKA, A. ‘New Evaluation Method of Metal Head Gasket’ SAE paper 930122 1993
- YAMAGUCHI, K. SATO, A. GOTO, E. FUJIKI, R. KAWAI, Y. NAKATA, K. ‘Development of a New Metal Cylinder Head Gasket’ SAE paper 980844 1998
- SCHNEIDER, E. BLOSSFELD, D. LECHMAN, D. HILL, R. REISING, F. BREVICK, J. ‘Effect of Cylinder Bore Out-of-Roundness on Piston Ring Rotation and Engine Oil Consumption SAE paper 930796 1993
- TAYLOR, C.F. ‘The Internal Combustion Engine in Theory and Practice’ 1 2 MIT Press 1977
- HEYWOOD, J. ‘Internal Combustion Engine Fundamentals’ McGraw Hill
- ROSENKRANZ, H.G. WATSON, H.C. BRYCE, W. LEWIS, A. ‘Driveability fuel consumption and emissions of 1.3 litre turbocharged spark ignition engine developed as a replacement for a 2 litre normally aspirated engine.’ Proc. I.Mech.E. C118 86 139 150 1986
- WATSON, H.C. MILKINS, E.E. ROBERTS, K. BRYCE, W. ‘Turbocharging for fuel efficiency SAE paper 830014 1983
- ATTARD, W. WATSON, H.C. KONIDARIS, S. ‘Highly Turbocharging a Restricted Two Cylinder Small Engine - Turbocharger Development’ SAE paper 07PFL-157 2007
- ATTARD, W. WATSON, H.C. KONIDARIS, S. ‘Highly Turbocharging a Restricted, Odd Fire, Two Cylinder Small Engine - Design, Lubrication, Tuning and Control’ SAE paper 06MSEC-38 2006
- ATTARD, W. WATSON, H.C. KONIDARIS, S. KHAN, M. ‘Comparing the Performance and Limitations of a Downsized Formula SAE engine in Normally Aspirated, Supercharged and Turbocharged Modes’ SAE paper 2006-32-0072 2006
- GORR, E. KERR, C. STEVENS, K. ARCHER, J. ‘Techniques for Manufacturing and Coating Liners of Small Engines’ SAE paper 2000-01-0904 2001
- RODRIGUES, M. PORTO, S. ‘Torque Plate Honing on Block Cylinder Bores’ SAE paper 931679 1993
- WOSCHNI, G. ‘A Universally Applicable Equation for the Instantaneous Heat Transfer Coefficient in the Internal Combustion Engine’ SAE paper 670931 1967
- MOREL, T. KERIBAR, R. ‘A Model for Predicting Spatially and Time Resolved Convective Heat Transfer in Bowl-in-Piston Combustion Chambers’ SAE paper 850204 1985
- CATON, J. HEYWOOD, J. ‘An Experimental and Analytical Study of Heat Transfer in an Engine Exhaust Port’ Int. J. Heat Mass Transfer 24 4 581 595 1981
- BANIASAD, S. KHALIL, E. SHEN, F. ‘Exhaust Valve Thermal Management and Robust Design Using Combustion and 3D Conjugate Heat Transfer Simulation with 6-Sigma Methodology’ SAE paper 2006-01-0889 2006
- CHANG, J. GURALP, O. FILIPI, Z. ASSANIS, D. KUO, T. NAJT, P. RASK, R. ‘New Heat Transfer Correlation for an HCCI Engine Derived from Measurements of Instantaneous Surface Heat Flux’ SAE paper 2004-01-2996 2004
- ALKIDAS, A. ‘Effects of Operational Parameters on Structural Temperatures and Coolant Heat Rejection of a S.I Engine’ SAE paper 931124 1993
- TOMANIK, E. SOBRINHO, R.M.S. ZECCHINELLI, R. ‘Influence of Top Ring Gap Types at Blow-By of Internal Combustion Engines’ SAE paper 931669 1993
- HAMORI, F. ‘Exploring the Limits of Hydrogen Assisted Jet Ignition’ Mech.Eng. Dept, Univ. of Melbourne 2006