To meet the latest trends in Internal Combustion engines regarding efficiency, emissions and durability, an integrated approach to engine development is required. This paper describes about a Robust, Reliable and an integrated approach used in design and development of an engine for high power density which can be adopted for both Off-highway application as well as Genset application.
The engine is developed to meet US - EPA Tier-III Emission Norms and MoEF (Genset Emission Norms for India formulated by Ministry of Environment and Forest) emission norms respectively. This paper discusses various technologies applied in developing this engine to achieve high power density, low exhaust emissions, and low noise and vibrations. This 4 valve per cylinder engine is created largely within a digital environment using the latest computer aided design (CAD) and computer aided engineering (CAE) techniques and simulation tools.
Advance features have been implemented in finalizing the layout for cylinder head and engine block. Crankshaft design and bearing design were given more attention. More focus was provided on combustion package like optimizing the bowl, injector location and dead volume optimization. Port Layout, Swirl Characteristics, Bolt design, Water pump design, Oil pump design, Manifold design, and EGR selection were the other areas of focus in this new engine development. Experimental validation of various components have been carried out wherever is possible since the Engine is under manufacturing stage.
Statistical database, Quality Tools like DFMEA, DFMA etc, Classical design Methods, Advanced CAD - CAE and Simulation tools helped us in developing this engine with minimum iterations in reduced cycle time. Major focuses has been given on Mechanical Design aspects and have been discussed in detail in this paper.