This content is not included in your SAE MOBILUS subscription, or you are not logged in.
Design / Analysis and Development of Cylinder Head for High Performance 3 Cylinder CRDi Euro-V Diesel Engine for a High Combustion Pressure of 200 Bar
ISSN: 0148-7191, e-ISSN: 2688-3627
Published October 05, 2010 by SAE International in United States
This content contains downloadable datasetsAnnotation ability available
This work is a part of program on “Development of High Performance DI, 3 Cylinder CRDI Diesel Engine to meet Euro-IV/V Emission Norms focused on automotive passenger car application purpose. This is a 3 Cylinder, TCIC engine designed for combustion pressure of 160 bar max for first stage which is being upgraded to 200 bar max in the second stage.
Cylinder Head design is a part of complicated configuration whose construction and principal dimensions are dependent on the size of inlet and exhaust valves, fuel injectors positioning and mounting, port layout and swirl and shape of combustion chambers. The cylinder head of a direct-injection diesel engine has to perform many functions. It has to bring charge air to the cylinder and exhaust gas from the cylinder, with minimum pumping loss and required swirl and other properties of charge motion. This paper describes about the Robust, Reliable and an integrated approach used in design and development of a cylinder head for a high power density engine, which can be adopted for automotive application.
Design of Head is carried out within several design, assembly and manufacturing constraints such as to maintain a specific cylinder centre distance, four valve layout, internal EGR passage, CGI material, incorporation of various accessories, viz. manifolds, thermostat housing, cam carrier, glow plugs integrated with pressure transducer, etc. Major focuses have been given on cylinder head layout, bolt Pattern, port layoutting, water jacket core optimization for flow and strength while going for the design. In addition, approach involved in design, development, testing and optimization of the ports had been discussed. Statistical database, quality tools like DFMEA, DFMA etc, classical design Methods, advanced CAD - CAE and simulation tools helped us in developing this cylinder head with minimum iterations in reduced cycle time.
Experimental validation of above mentioned design parameters is carried out as a part of design verification and validation. Results are elaborated to show the effectiveness of an integrated approach used for this development program.
CitationDharan R, B., Ramdasi, S., and Marathe, N., "Design / Analysis and Development of Cylinder Head for High Performance 3 Cylinder CRDi Euro-V Diesel Engine for a High Combustion Pressure of 200 Bar," SAE Technical Paper 2010-01-1975, 2010, https://doi.org/10.4271/2010-01-1975.
Data Sets - Support Documents
|[Unnamed Dataset 1]|
|[Unnamed Dataset 2]|
- Gale, N.F., “Diesel Engine Cylinder Head Design: The Compromises and the Techniques,” SAE Technical Paper 900133, 1990, doi:10.4271/900133.
- Dawson, Steve, et al, “CGI - A New Material for Highly Stressed Cylinder Block and Cylinder Head”, International Motor Symposium, 2007.
- Guesser, Wilson Luiz, “Compact Graphited Iron - A New Material for Diesel Engine Cylinder Block” Brazilian MRS Meet 2003.
- Hamm, T., Rebbert, M., Ecker, H.-J., and Grafen, M., “Cylinder Head Design for High Peak Firing Pressures,” SAE Int. J. Engines 1(1):749-755, 2008, doi:10.4271/2008-01-1196.
- Bates, M.C. and Heikal, M.R., “A Knowledge-Based Model for Multi-Valve Diesel Engine Inlet Port Design,” SAE Technical Paper 2002-01-1747, 2002, doi:10.4271/2002-01-1747.
- Osterwisch, C., DeJack, M., and Smolnikar, M., “CAE Process for Developing Cylinder Head Design Including Statistical Correlation and Shape Optimization,” SAE Technical Paper 2010-01-0494, 2010, doi:10.4271/2010-01-0494.
- Mikami, S., Ogino, K., and Sorazawa, M., “Development of Evaluation Method for Low-Cycle Fatigue Breakdown on HSDI Diesel Cylinder Head,” SAE Technical Paper 2010-01-0695, 2010, doi:10.4271/2010-01-0695.
- Özdemir, Ö., Ebrinç, A., and Ünüvar, B., “Casting Porosity Elimination in CGI Cylinder Head,” SAE Technical Paper 2009-01-0219, 2009, doi:10.4271/2009-01-0219.
- Mattarelli, E., Borghi, M., Balestrazzi, D., and Fontanesi, S., “The Influence of Swirl Control Strategies on the Intake Flow in Four Valve HSDI Diesel Engines,” SAE Technical Paper 2004-01-0112, 2004, doi:10.4271/2004-01-0112.
- Kawashima, J.-I., Ogawa, H., and Tsuru, Y., “Research on a Variable Swirl Intake Port for 4-Valve High-Speed DI Diesel Engines,” SAE Technical Paper 982680, 1998, doi:10.4271/982680.
- Li, Y., Li, L., Xu, J., Gong, X. et al., “Effects of Combination and Orientation of Intake Ports on Swirl Motion in Four-Valve DI Diesel Engines,” SAE Technical Paper 2000-01-1823, 2000, doi:10.4271/2000-01-1823.
- Mehta,Pramod S., Chaturvedi, Abhay, “Modeling of Intake Port Swirl”,Proceedings of the XIII National Conference on I.C.Engines &Combustion Indian Institute of Science, Banglore. January 18-20,1994, Pages 157-163
- Fasolo, B., Doisy, A.-M., Dupont, A., and Lavoisier, F., “Combustion System Optimization of a New 2 Liter Diesel Engine for EURO IV,” SAE Technical Paper 2005-01-0652, 2005, doi:10.4271/2005-01-0652.
- Challen, B. and Baranescu, R.,”Diesel Engine Reference Book,” SAE International, Warrendale, PA, ISBN 0-7680-0403-9, 1999.
- Heywood,,“Internal Combustion Engine Fundamentals”, Edition 1988, pages 342-353.
- “Diesel Engine Reference Book”, Lilly, LCR.
- “Internal Combustion Engine in Theory and Practice” Taylor,C.F.
- ASM Handbook, “Specification for Compacted Graphite Iron Castings”, ASTM A 842, 1985
- AVL- FIRE USERS GUIDE
- ARAI DESIGN REFERENCE MANUALS