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An alternate cost effective material for rocker arm used in heavy commercial vehicles

VE Commercial Vehicles, Ltd.-Sonu Paroche, Kaarthic Kaundabalaraman, Suresh Kumar Kandreegula, Hemantkumar Rathi
  • Technical Paper
  • 2019-28-2550
To be published on 2019-11-21 by SAE International in United States
Rocker arm in internal combustion engine is very important part which transfer the cam motion and force to the valve. In heavy commercial vehicles, the engine components are design for an infinite life (considerable higher than other components). Recently industries are working for light weight and optimized cost material. Hence it is required to have an optimized cost effective design of rocker arm without affecting its performance. A rocker arm should meet the stiffness and strength requirement. The objective of this study is to find out the alternate material for rocker arm which can provide the similar strength & stiffness as conventional rocker arm material. To achieve the performance and cost target, alternate material cast iron has been evaluated for rocker arm. Cast iron is lighter than the forged steel rocker arm, also it has a good frictional characteristic. Further bush is eliminated from the rocker arm assembly due to self-lubricant property of the cast iron rocker arm. This is significant reduce in cost of material and assembly procedure. A 2-d simulation and finite element…
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Effect of Gasoline-Ethanol blends on GDI engine to reduce cost of vehicle ownership

Mahindra & Mahindra, Ltd.-Kartick Ramakrishnan, Padmavathi Ramadandi, Karthikeyan N Krishnan
  • Technical Paper
  • 2019-28-2379
To be published on 2019-11-21 by SAE International in United States
A major challenge for combustion development is to optimize the engine for improved fuel economy, reduce greenhouse gases. Stringent CAFÉ and emission norms require the customer to pay higher capital on vehicles. To offset the cost of ownership- cheaper and alternative energy sources are being explored. Ethanol blend with regular Gasoline and CNG are such alternative fuels. The study was carried on turbo-charged gasoline direct injection engine. The effect of ethanol on engine and vehicle performance is estimated and simulated numerically. The work is split into three stages: first the base 1D engine performance model was calibrated to match the experimental data. In parallel, vehicle level Simulink model was built and calibrated to match the NEDC cycle performance. Second, the thermal efficiency of the ethanol blend is calculated as a linear function of theoretical Otto cycle efficiency. The engine performance for varying compression ratio & ethanol gasoline blend is studied for vehicle level using a MATLAB code. Third, 1D code was run to simulate the high-speed exhaust temperature & low speed knock intensity, this is…
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Effect of Injector Cone Angle and NTP on Performance and Emissions of BS6 Engine

Mahindra Research Valley-Anbarasu Muthusamy, Vagesh Shangar Ramani, Pranav Kumar Sinha
  • Technical Paper
  • 2019-28-0108
Published 2019-10-11 by SAE International in United States
The combustion phenomenon of diesel engines has got a very major impact on the performance and exhaust emission levels. Several important factors like engine components design, combustion chamber design, Exhaust gas recirculation, exhaust after treatments systems, engine operating parameters etc. decide the quality of combustion. The role of fuel injector is crucial on achieving the desired engine performance and emissions. Efficient combustion depends on the quantity of fuel injected, penetration, atomization and optimum timing of injection. The nozzle through flow, cone angle, no of sprays and nozzle tip penetration are the factors which lead to the selection of perfect injector for a given engine. This paper focusses on the selection of the best fit injector suiting the BS6 application on evaluating the performance and emission characteristics. Injectors used were with varying cone angles and NTP. The nozzle tip protrusion of the injectors were varied by changing the sealing washer thickness. With all the above injector configurations, the performance and emission were thoroughly analysed at every level. Final confirmation of the configuration was selected based on…
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Automotive V-Ribbed Belt Drives and Test Methods

Belt Drive (Automotive) Systems Committee
  • Ground Vehicle Standard
  • J1596_201909
  • Current
Published 2019-09-24 by SAE International in United States

The following information covers engine accessory drive layout details and testing methods and includes test configurations, pulley diameters, power loads, and guidance for interpreting test data. This information has been prepared from existing literature, including standards and data supplied by both producers and users of V-ribbed belts.

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Compensating the Effects of Ice Crystal Icing on the Engine Performance by Control Methods

Central Institute of Aviation Motors-Oskar Gurevich, Sergei Smetanin, Mikhail Trifonov
Published 2019-09-16 by SAE International in United States
Aircraft equipment is operated in a wide range of external conditions, which, with a certain combination of environmental parameters, can lead to icing of the engine internal elements. Due to icing, the engine components performance characteristics change what leads to decrease in thrust, gas dynamic stability, durability, etc. Safe aircraft operation and its desired performance may be lost as a result of such external influence. Therefore, it is relevant to study the possibilities of reducing the icing effect with the help of a special engine control. The focus of this paper is to determine control methods of an aircraft gas turbine engine addressing this problem. The object of the study is a modern commercial turbofan with a bypass ratio of about 9. In this paper analysis of the effect of ice crystal icing on the engine components performance is conducted. To perform simulation of the engine performance under such impact, degraded components characteristics was introduced into physics-based turbofan model. Control algorithms for this model were developed applied to various regulated variables used in the setpoint…
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Validity of a Steady-State Friction Model for Determining CO2 Emissions in Transient Driving Cycles

IVK, University of Stuttgart-Michael Bargende
MAHLE International GmbH-Tobias Funk, Holger Ehnis, Reiner Kuenzel
  • Technical Paper
  • 2019-24-0054
Published 2019-09-09 by SAE International in United States
Due to its high benefit-cost ratio, decreasing mechanical friction losses in internal combustion engines represents one of the most effective and widely applicable solutions for improved engine efficiency. Especially the piston group - consisting of piston, rings and pin - shows significant potential for friction reduction, which can be evaluated through extensive experimental parameter studies. For each investigated variant, the steady-state friction measurements are fitted to an empirical polynomial model. In order to calculate the associated fuel consumption and CO2 emissions in transient driving cycles, the steady-state friction model is used in a map-based vehicle simulation. If transient engine operation entails friction phenomena that are not included in the steady-state model, the simulation could yield erroneous fuel consumption and CO2 predictions. This issue is gaining in importance with the current regulatory driving cycles, which aim to better reflect real-world driving conditions and thus contain more frequent and steep transient events. Therefore, the purpose of this study is to assess the extent to which it is valid to use a steady-state friction model for the determination…
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A Simplified Methodology for the Analysis of the Cylinder Liner Bore Distortion: Finite Element Analyses and Experimental Validations

Ferrari SpA-Luca Nicolò Mastrandrea
University of Modena and Reggio Emilia-Saverio Giulio Barbieri, Matteo Giacopini, Valerio Mangeruga, Luigi Bianco
Published 2019-09-09 by SAE International in United States
Advances in modern engines are becoming more and more challenging. The intense increase of thermal and mechanical loads, as a consequence of a higher power density, requires the improvement of the main couplings encountered between moving engine components. In this scenario, the cylinder liner/piston coupling plays a crucial role in terms of engine performance and durability, especially with regards to pollution emission and friction reduction. In this paper a numerical methodology is proposed, which aims at simplifying the Finite Element evaluation of the cylinder liner bore distortion in an eight-cylinder V-type four stroke turbocharged engine. Finite Element simulations are performed to obtain a virtual approval of the component geometry, in advance with respect to the component manufacturing. In particular, preliminary Finite Element analyses are developed which accurately follow the experimental procedure, where a single engine bank is coupled with a simplified test engine head. The Finite Element model is properly tuned in order to obtain the same cylinder liner distortion registered by experimental measurements. Further Finite Element analyses, both thermal and thermo-mechanical, are then performed…
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Temperature Measurements of the Piston Optical Window in a Research Compression Ignition Engine to Set-Up a 1d Model of Heat Transfer in Transient Conditions

Istituto Motori CNR-Ezio Mancaruso, Luigi Sequino, Bianca Maria Vaglieco
Published 2019-09-09 by SAE International in United States
The analysis of heat losses in internal combustion engines (ICEs) is fundamental to evaluate and to improve engine efficiency. Detailed and reliable heat transfer models are required for more complex 1d-3d combustion models. At the same time, the thermal status of engine components, like pistons, is needed for an efficient design. Measurements of piston temperature during ICEs operation represent an important and challenging result to get for the aforementioned purposes. In the present work, temperature measurements collected at different engine speeds and loads, both in motored and fired modes, have been performed and used to set-up a theoretical correlation and 1d model of heat transfer through the optical window of the piston. The in-cylinder gas and external ambient temperature, together with the thermodynamic and material properties are given. The model has been first calibrated in some selected operating conditions and then validated in the remaining. The aim of the 1d model is to simulate the transient of temperature during the engine warm up in motored, from the engine start up to the steady motored condition;…
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Intake Manifold Primary Trumpet Tuning Options for Fuel Flow Limited High Performance I.C.E.

Ferrari Gestione Sportiva-Angelo Rosetti, Corrado Iotti
University of Modena e Reggio Emilia-Giuseppe Cantore
Published 2019-09-09 by SAE International in United States
The 2014 change in Formula One regulations, from naturally aspirated to highly-downsized and heavily-boosted hybridized power units, led to a relevant increase of the internal combustion engine brake specific power output in comparison with former V-8 units. The newly designed “down-sized” engines are characterized by a fuel flow limitation and a relevant increase in the thermal loads acting on the engine components, in particular on those facing the combustion chamber. Furthermore, efficiency becomes an equivalent paradigm as performance. In the power unit layout, the air path is defined by the compressor, the intercooler and the piping from the intake plenum to the cylinder. Intake duct length is defined from intake plenum to valve seat and it is a key parameter for engine performance. In order to find the optimum length different design criteria can be applied: the so called “tuning”, the “un-tuning” or the “anti-tuning” are all valid possibilities, showing pros and cons. The scope of the paper is to study and present the possible different tuning options for the internal combustion engine (ICE) part…
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Test Cell Analytical Thrust Correction

EG-1E Gas Turbine Test Facilities and Equipment
  • Aerospace Standard
  • AIR5436A
  • Current
Published 2019-07-02 by SAE International in United States
This document describes a method to correct engine thrust, measured in an indoor test cell, for the aerodynamic effects caused by the secondary airflow induced in the test cell by the engine operating in an enclosed environment in close proximity to an exhaust duct. While it is not recommended to be used to replace test cell correlation, it does provide a means to verify an existing thrust correlation factor.
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