This content is not included in
your SAE MOBILUS subscription, or you are not logged in.
Integration of Cylinder Head and Intake Manifold for Powertrain Downsizing and Light Weighting Using Simulations Tools
Technical Paper
2017-01-1723
ISSN: 0148-7191, e-ISSN: 2688-3627
This content contains downloadable datasets
Annotation ability available
Sector:
Language:
English
Abstract
As the commercial vehicle engine heads towards the next generation of stringent emissions and fuel economy targets, all aspects of the internal combustion engine are subject to close scrutiny. Inherently, ICE’s are very inefficient, with efficiency varying between 18 ~ 40%. This efficiency is a function of friction losses, pumping losses and wasted heat. Currently, automotive OEM’s globally are hard at work trying to attack these issues with various solutions to achieve incremental gains.
The leading trend is getting more power from less space, also known as downsizing. Due to the importance of downsizing, direct injection and other technologies, it is imperative to highlight another key area, where OEM’s are expanding their limits to gain those extra few kilometers per liter of fuel i.e. weight reduction. From an emissions perspective, it is estimated that every 50 kg of weight reduced from an average 1,500 kg vehicle cuts CO2 emissions by 4 ~ 5 grams.
The key areas of the powertrain on which OEM’s will focus their weight reduction efforts will be engine, transmission, exhaust, fuel system, casing, batteries and motors. VECV powertrain team has studied to reduce of about 25 kg in the integration of aluminum cylinder head and intake manifold for light duty commercial vehicles, enabling savings of about 2g of CO2.
To achieve same existing/proven cast iron cylinder head and intake manifold stiffness for new integral aluminum cylinder head with intake manifold stiffness with defined worst engine loading conditions. First, the existing cast iron has been analyzed for defined worst engine loading conditions to know about the stiffness at different known locations. The idea was to come with new design with the same stiffness arrived at the same locations as existing cast iron design.
Finite element structural simulation has been used to align the project time plan (design and development time of integration of cylinder head and intake manifold), considering all structural loads i.e. interferences, bolt pre-loads, temperatures, peak firing pressure and compare the stiffness’s with the current/proven cylinder head and intake manifold results. With this integral aluminum cylinder head with intake manifold design, it is estimated that cost savings of up to 30%, reduction in weight by 40% and better fatigue performance (25% - 30%) can be achieved. Hypermesh as a pre-processor and ANSYS as a FE solver are used in this study. The FE simulation tools have helped us in selecting the right parameters for the design and ensure first time right design at the development phase.
Authors
Topic
Citation
Kandreegula, S., Tikoliya, J., and Nishad, H., "Integration of Cylinder Head and Intake Manifold for Powertrain Downsizing and Light Weighting Using Simulations Tools," SAE Technical Paper 2017-01-1723, 2017, https://doi.org/10.4271/2017-01-1723.Data Sets - Support Documents
Title | Description | Download |
---|---|---|
Unnamed Dataset 1 | ||
Unnamed Dataset 2 | ||
Unnamed Dataset 3 |
Also In
References
- Integration of exhaust manifold with engine cylinder head towards size and weight reduction Neshan1 M.A. , Keshavarz A. , Khosravi K. The Journal of Engine Research 30 2013 55 65
- Trucks and Heavy-Duty Vehicles Technical Requirements and Gaps for Lightweight and Propulsion Materials U.S Department of Energy, Energy Efficiency & Renewable Energy, Vehicle Technologies Office February 2013
- Fraser , N and Blaxill , H Engine Downsizing and the Application of Gasoline Direct Injection to a High Specific Output Turbocharged Engine Fuel Economy and Engine Downsizing Seminar Proceedings May 2004
- Hancock , D. , Fraser , N. , Jeremy , M. , Sykes , R. et al. A New 3 Cylinder 1.2l Advanced Downsizing Technology Demonstrator Engine SAE Technical Paper 2008-01-0611 2008 10.4271/2008-01-0611
- Borrmann D. , Kuhlbach K. , Friendfeldt R. , Mehring J. , Fritsche R. Cylinder head with integrated exhaust manifold for downsizing concepts MTZ Journal 70 2009
- Kandreegula , S. , Singh , R. , and Tikoliya , J. Comparative Static Simulation Study of Aluminum Cylinder Head for Commercial Vehicles using Simulations Tools SAE Technical Paper 2016-01-2349 2016 10.4271/2016-01-2349
- Sadagopan , K. , Suresh Kumar , S. , T , A. , and Karunakaran , S. Design of Compact Aluminum Cylinder Head SAE Technical Paper 2015-26-0035 2015 10.4271/2015-26-0035
- Mendes , A. and Cardoso , A. Structural Analysis of the Aluminum Cylinder Head for a High-Speed Diesel Engine SAE Technical Paper 2007-01-2562 2007 10.4271/2007-01-2562
- Kandreegula , S. , Gupta , U. , and Vyas , S. Investigation of Gasket Sealing Behavior of Cylinder Head and Block under Engine Operating Conditions and Its Experimental Verification SAE Technical Paper 2015-26-0029 2015 10.4271/2015-26-0029