Browse Topic: Engine mechanical components

Items (14,946)
This study investigates the feasibility of a novel internal combustion engine (ICE) architecture, termed the membrane engine, in which the conventional piston is replaced by a flexible elastic membrane. Although the concept appears in several patent documents proposing reduced friction, improved sealing, and lower heat losses, no empirical data has been published to support these claims. To the authors’ knowledge, this work presents the first membrane engine built and experimentally tested. The primary aim is to verify whether such an engine can operate as a functional ICE, regardless of its current efficiency or performance level. To support concept validation, a simplified mathematical model was developed to describe the membrane’s deformation and its effect on combustion chamber volume. Unlike conventional piston engines, the membrane introduces a pressure-dependent geometry, enabling a variable compression ratio. The model is not intended to predict performance but to assist in
Allmägi, RolandIlves, Risto
Recent literature has highlighted significant heat transfer losses and elevated particle formation in direct-injection hydrogen engines, particularly when compared to hydrocarbon fuels such as methane. These challenges are attributed to hydrogen’s unique physicochemical properties, notably its short flame quenching distance and high diffusivity, as well as the interaction between the hydrogen jet and lubricated cylinder surfaces, which promotes lubricant entrainment into the combustion chamber. Consequently, a fundamental understanding of these entrainment mechanisms is a prerequisite for developing engineering strategies to enhance thermal efficiency and mitigate particle formation. The reported study investigates gaseous jet–air interaction in a confined volume to elucidate the influence of injector geometry on jet propagation and air entrainment. Three distinct jet configurations were examined: the wide hollow-cone, the narrow hollow-cone, and the round jets. The jet evolution and
Ben David Holtzer, Ben BinyaminTartakovsky, Leonid
Turbocharging is a common and simple method to utilize the exhaust heat of an internal combustion engine. However, conventional turbocharging exhibits the drawback of exhaust gas backpressure and thus increased residual gas mass in the cylinder. A promising concept to increase optimum efficiency is found in the TwinAV concept, which assigns divided exhaust valve cam timing and exhaust manifold configuration. This concept is hypothesized to reduce the static backpressure in the gas exchange loop and the residual exhaust gas amount in the gas exchange phase. In this article, a 1D simulation model was adapted to an existing 4-cylinder gasoline TC engine. Subsequently, the engine concept was applied to this engine model, whereas the focus was to achieve an engine layout for the entire engine speed range applicable for use in passenger vehicles. The results were compared at the full RPM range. Also, a load variation was conducted and benchmarked. The found results show an additional
Gotter, AndreasGotter, Alexander
Controlling the source vibrations in internal combustion engines is a crucial approach to minimizing the vibration levels experienced by the driver. The driver's subjective perception of vibration is primarily dictated by the vehicle's low-frequency response (<100 Hz). In an IC engine used in agricultural tractor applications, the primary sources of vibration include (a) 1st order inertial force, (b) couples generated by rotating and reciprocating components such as the piston assembly, connecting rod, and crankshaft, and (c) in-cylinder combustion. In this study, an order ranking analysis was conducted on a single-cylinder, air-cooled, naturally aspirated tractor engine within the driver’s operating range to identify the dominant contributors to source vibrations. The 1st order inertial force was observed to be the dominant contributor to the engine's vibration levels. Subsequently, an attempt was made to mitigate the unbalanced forces by implementing counterweight-based balancing
Bhuntel, AjayRajput, SurendraRawat, Ashish
Air suction in a naturally aspirated engine is a crucial influencing parameter to dictate the specific fuel consumption and emissions. For a multi-cylinder engine, a turbocharger can well address this issue. However, due to the lack of availability of continuous exhaust energy pulses, in a single or two-cylinder engine, the usage of turbocharger is not recommended. A supercharger solution comes handy in this regard for a single or two-cylinder engine. In this exercise, we explore the possibility of the usage of a positive displacement type supercharger, to enhance the air flow rate of a single cylinder, naturally aspirated, diesel engine for genset application, operating at 1500 rpm. The supercharger parametric 3D CAD model has been prepared in Creo, with three design parameters i.e. (a) Generating radius, (b) depth of blower and (c) clearance between lobes & lobe and casing. The optimum roots blower design is expected to fulfil the target boost pressure, power consumption and
Satre, Santosh DadasahebMukherjee, NaliniRajput, SurendraNene, Devendra
In a conventional powertrain driven by Internal combustion (IC) engines, various sensors are used to monitor engine performance and emissions. Along with physical sensors, virtual sensors or modelled values of key parameters play an important role for enabling various diagnostics strategies and engine monitoring. Conventional strategies for modelling incorporate the use of regression models, map-based models and physics-based models which have few drawbacks in terms of accuracy and model calibrations efforts. Data driven models or neural networks have fairly better accuracy and reliability for estimating complex parameters. Representing the neural network with a mathematics-based model would help to eliminate drawbacks associated with conventional modelling approach. The proposed methodology uses artificial intelligence technique called artificial neural network (ANN) for estimation of temperature at turbine inlet (TTI) in typical diesel engine. The data driven model is built in Python
Jagtap, Virendra ShashikantShejwal, SanketMitra, Partha
In today’s fast paced and competitive automotive market, meeting the customer’s expectation is the key to any OEM. This has led to development of downsized high performance engines with refinement as an important deliverable. However developing such high output engines do come with challenges of refinement, especially higher torsional vibrations leading to transmission noise issues. Hence, it becomes important to isolate the transmission system from these high torsional vibration input. To address this, one of the most common method is to adopt Dual Mass flywheel (DMF) as this component dampens torsional vibrations and isolates the transmission unit from the same. While Dual Mass Flywheel assemblies do great job in protecting the transmission units by not allowing the oscillations to pass through them, they do have their own natural resonance frequency band close to the engine idle (low) engine speeds, which must be avoided for a continuous operation otherwise it may lead to Dual Mass
Raiker, Rajanviswanatha, Hosur CJadhav, AashishJain, OjaseJadhav, Marisha
Engine noise mitigation is paramount in powertrain development for enhanced performance and occupant comfort. Identifying NVH problems at the prototype stage leads to costly and time-consuming redesigns and modifications, potentially delaying the product launch. NVH simulations facilitate identification of noise and vibration sources, informing design modifications prior to physical prototyping. Early detection and resolution of NVH problems through simulation can significantly shorten the overall development cycle and multiple physical prototypes and costly redesigns. During NVH simulations, predicting and optimizing valvetrain and timing drive noise necessitates transfer of bearing, valve spring, and contact forces to NVH simulation models. Traditional simulations, involved continuous force data export and NVH model evaluation for each design variant, pose efficiency challenges. In this paper, an approach for preliminary assessment of dB level reductions across design iterations is
Rai, AnkurDeshpande, Ajay MahadeoYadav, Rakesh
This paper presents the design, structural analysis, structural test validation and risk assessment done by Cummins to evaluate the structural integrity of Light Duty engine cylinder head for a Medium Wheelbase (MWB) pick-up truck. Initially, Cummins used the 2.5L and 3.0L (4-cylinder) engines that have standard power ratings based on existing requirements, but rising market demands for more power, fuel efficiency, lower cost and weight, and future emission compliance led to customer requirements for 15% uprate for 2.5L and 22% uprate for 3.0L from the same base engine. The increase in power requirement possesses challenges on critical components, especially cylinder heads in terms of thermal and structural limits. Multiple analysis led design iterations were performed using cutting edge CAE software such as Ansys, Dassault Systems fe-safe, and PTC Creo to ensure the structural integrity of the cylinder head under high thermal and mechanical loads, and to keep design margins within
Pathak, Arun JyotiAdiverekar, VaidehiSingh, RahulBiyani, Mayur
Meeting the stringent emissions norms of CEV stage V for medium BMEP engines, CI engines present significant challenges, particularly concerning cold startability. Low ambient temperatures and pressures intensify the cold start difficulties which are characterized by prolonged cranking, incidences of misfiring, compromised transient response and overall engine performance. This paper highlights the strategies and technologies employed to enhance cold start and transient performance of medium BMEP engines under such demanding environmental conditions. Investigations were conducted up to an altitude of 4500m and ambient temperatures as low as-20°C, utilizing only air heater at intake manifold as the sole cold start aid. This cost effective approach is integrated with an optimized combustion chamber design, along with minimal pilot injection timing and quantity to facilitate smooth ignition and stable combustion during cold start. The paper also explore the techniques to improve the
Saxena, HarshitLokare, PrasadSanthosh, AjithGandhi, NareshShinde, Prashant
Modern automotive powertrains are increasingly adopting engine downsizing and down speeding to meet stringent emission regulations and improving fuel efficiency However, these changes result in higher torsional vibrations excitation amplitudes and NVH (Noise, Vibration, and Harshness) refinement more challenging. With growing customer expectations for premium driving experiences conventional clutch is no longer sufficient. To meet the NVH performance targets of the vehicle Dual Mass Flywheels (DMFs) are used In DMF due to lower stiffness and inertia separation there is a greater advantage on torsional filtration in normal drive and idle condition. But the torsional resonance frequency of the connected DMF is lower than the idle RPM. Engine startup is a key drawback with DMF equipped vehicles. The proper tuning of starter motor performance & DMF stiffness is required to cross the resonance zone faster otherwise it will lead to DMF to stay in the resonance zone for a longer time leading
Jayachandran, Suresh KumarVijayaragavan, ThirupathiM, DevamanalanKanagaraj, PothirajAhire, ManojVellandi, Vikraman
Turbochargers play a crucial role in modern engines by increasing power output and fuel efficiency through intake air compression, thereby improving volumetric efficiency by allowing more air mass into the combustion chamber. However, this process also raises the intake air temperature, which can reduce charge density, lead to detonation, and create emissions challenges—such as smoke limits in diesel engines and knock in gasoline spark-ignited (GSL) engines. To mitigate this, intercoolers are used to cool the compressed air. Due to packaging constraints, intercoolers are typically long and boxy, limiting their effectiveness, especially at low vehicle speeds where ram air flow is minimal. This study investigates the use of auxiliary fans to enhance intercooler performance. Two methodologies were adopted: 1D simulation using GT-Suite and experimental testing on a vehicle under different fan configurations—no fan, single fan, and dual fans (positioned near the intercooler inlet and outlet
Patra, SomnathHibare, NikhilGanesan, ThanigaivelGharte, Jignesh Rajendra
Validation of hydrogen-fuelled internal combustion engine (H2 ICE) is critical to assess its feasibility as sustainable transportation with zero carbon emissions. This experimental analysis conducted on Ashok Leyland’s 6cylinder 2V engine to evaluate the engine performance & durability with hydrogen fuel. Combustion behaviour of hydrogen ICE needs to be closely monitored during continuous operation of validation testing, due to its unique properties compared to other conventional fuels. During engine run, a pre-ignition source can cause knock event leading to instant failure of critical parts like piston assembly, spark plug, liner, valves & cylinder head. Also, hotspots inside IMF leads to backfire affecting the air intake & fuel injection assembly. This study emphasizes the significance of precise instrumentation of thermocouples across engine on cylinder head, intake manifold & exhaust manifold, to detect performance detoriation and combustion abnormalities causing knocking
Vasudevan, SindhujaJ, Narayana ReddyBolar, Yogesh GaneshPandey, SunilN, HarishN R, VaratharajKarthikeyan, KKumar D, Kishore
Customers in off-highway industry are increasingly seeking high-performance capabilities for their tractors due to increasing penetration of mechanisation and labour scarcity. One effective solution to achieve enhanced performance is turbocharging of engines, while meeting emission and highly dynamic transient response of tractor field applications. The process of selecting and validating a suitable turbocharger for tractor field application suitability is significantly time and resources consuming activity due to extensive testbed and field trials. This study focuses on the selection of turbocharger for tractor engines through analytical calculations to freeze key parameters like lambda, boost pressure ratio & temperature within boundaries of exhaust temperature and turbo efficiency maps to deliver best field transient performance and fuel consumption. The selected parameters are further validated under real-world transient operating conditions, involving tractors and their implements
Kumar, Harish KumarRawat, SaurabhDogra, DaljitSinghSingh, SachleenSingh, Amarinder
Condition-based monitoring (CBM) has emerged as a transformative approach in predictive maintenance, enabling the proactive identification of potential component failures. It offers numerous advantages like Cost Savings, Increased Equipment Lifespan, RCA of failed parts, Optimized Resource Utilization, Reduced Disruptions, Enhanced Reliability and Safety and many more making it a vital approach for effective maintenance and operational efficiency. This paper presents a comprehensive methodology for monitoring and analyzing vibration trends to predict and prevent the breakdown of critical components in IC Engine in its testing phase. The good part here is that this methodology is not just limited to IC Engine but can be applied across wide range of industries and mechanical systems as from the literature and past vibration data, it was observed that before any such failure engine vibration increases. If the engine is stopped at that moment, it can be preserved, allowing for further
Gupta, GauravVerma, Vivek
The structural integrity and fatigue life of engine connecting rods are critical to ensuring reliability and performance in internal combustion (IC) engines. Traditional Finite Element Analysis (FEA) methods for stress and life prediction are computationally expensive, requiring extensive simulation time for varying loading conditions. This study proposes an Advanced AI-driven approach using Graph Neural Networks (GNNs) which is subset of Geometric deep learning (GDL) to predict stress distribution and fatigue life of a connecting rod based on historical simulation data. The methodology involves training on past high-fidelity FEA results, enabling the model to learn spatial stress patterns and fatigue behavior across different design variations and loading conditions. Unlike traditional models, GNNs effectively captures the geometric and topological dependencies inherent in the connecting rod structure, providing robust predictions with minimal computational overhead. Experimental
Pathan, Mohammed ShakilK, KarthikeyanPilla, SashankaS Kangde, Suhas
Modal analysis is performed to determine the natural frequencies and mode shapes of a structure or system. It helps engineers understand how a system vibrates and how external forces, such as mechanical loads, might excite unwanted resonances. To check the stresses due to vibration inputs, certain G levels are assumed, and stresses are scaled to those vibration levels. This gives an understanding of the stresses of components with respect to its EFR limit and design margins are calculated. But, assumed acceleration levels in pre-prototype stage level can over predict or under predict the design margins. A quick modal analysis correlation technique can be used by using test measured accelerations conducted at prototype stage of the program. In this work, a modal analysis correlation technique is used to perform risk assessment of intake manifold. The intake manifold failed due to high vibration levels which were not captured from high cycle fatigue analysis with assumed G-level. In the
Bale, Shrikant BhaskarBawache, Krushna
Automotive driveline design plays an important role in defining a vehicle’s Noise, Vibration and Harshness (NVH) characteristics. Driveline system, responsible for torque transfer from the engine/transmission to the wheels, is exposed to a wide spectrum of vibrational excitations. The industry’s shift toward turbocharged engines with fewer cylinders while maintaining the equivalent torque and power has led to increased low-frequency torsional vibrations. This paper presents some key design considerations to drive the NVH design of a driveline system using linear dynamic FE simulations. Using an E-W All-Wheel Drive driveline architecture with independent suspension as a case study, the influence of various subsystem modes on driveline NVH performance is examined. The paper further explores the strategies for vibration isolation, motion control, and mode management to identify the optimal bushing rates and its location. Furthermore, it examines the ideal bushing specifications for
Joshi, Atul KamalakarraoSubramanian, MANOJ
The work demonstrating a novel approach to the optimization of crankshaft design for heavy-duty commercial vehicle engines, specifically targeting non-automotive applications with elevated power ratings. The research focuses on a 6-cylinder, 5.6-litre diesel engine, originally rated at 160 kVA and upgraded to 200 kVA, where the challenge was to enhance the crank-train system’s robustness within existing packaging constraints. By fundamentally altering the crankshaft’s geometry and structural parameters, the new design achieves higher load-bearing capacity while inherently mitigating torsional vibrations, thereby eliminating the need for viscous dampers traditionally used in place of rubber dampers. Advanced simulation tools, notably AVL Excite, employed to iterate and evaluate the balance between crankshaft balance ratio, weight, and torsional behavior. The optimized design then validated through both simulation and physical vibration trials, with sixth-order angular displacement
Khandelwal, MehaKaundabalaraman, KaarthicRathi, Hemantkumar
The stringent emission norms over the past few years have driven the need to use low-carbon fuels and after treatment technology. Natural gas is a suitable alternative to diesel heavy-duty engines for power generation and transportation sectors. Stoichiometric combustion offers the advantages of complete combustion and low carbon dioxide emissions. Turbocharging and cooled exhaust gas recirculation (EGR) technology enhances the power density along with reduced exhaust emissions. However, there are several constraints in the operation of natural gas spark ignition engine such as exhaust gas temperature limit of 780 °C, sufficient before turbine pressure for EGR drivability, boost pressure, peak cylinder pressure limit and knocking. These limits coulld restrict the engine BMEP (brake mean effective pressure). In the present study, tests were conducted on a V12, 24 liters, heavy duty natural gas fuelled spark ignition engine (600 HP) with different EGR and turbocharger configurations to
Khaladkar, OmkarMarwaha, Akshey
The pressing global need for de-fossilization of the transport sector, especially within the heavy-duty segment, has intensified the exploration of alternative clean fuels. In this context, methanol gained traction due to their renewable production pathways, carbon-neutrality, and are being highly promoted by the Indian government to reduce CO2 emissions. Dual direct injection compression ignition (DDICI) is an effective combustion strategy to use methanol in heavy-duty engines, which combines the advantage of high-efficiency compression ignition with the clean-burning potential of methanol. In contrast to spark-ignited premixed methanol engines, this strategy involves a diffusion combustion of the methanol flame, thereby eliminating knocking and enabling running with high compression ratios. This experimental and numerical study presents a comprehensive investigation into the DDICI strategy using methanol as primary fuel and diesel as a pilot for ignition assistance. The work
Singh, InderpalDhongde, AvnishRaut PhD, AnkitGüdden, ArneEmran, AshrafBerry, Sushil
Emissions regulations, such as Euro VI, drives the Automotive industry to innovate continuously in Engine development. One significant challenge is the engine oil pumping from the crankcase into the combustion chamber, where it participates in combustion, which contributes to increased Particulate Numbers and fails to meet Euro VI emission compliance. This issue is most noticeable during engine idling and motoring conditions. During this time, a higher negative pressure difference develops between the intake manifold, which is acting above the combustion chamber and the engine crankcase. This pressure difference drives oil-laden blow-by aerosols past piston rings during the intake stroke and through the valve stem seals, allowing oil into the combustion chamber. The impact of the pressure difference between the intake manifold and crankcase was studied by varying the crankcase pressure through crankcase ventilation system. The results confirm that oil entry into the combustion chamber
R, Mahesh BharathiBondfale, ShubhamJeyaprakasan, Dharoon Gautham
In this study, a novel dual-fuel combustion strategy is investigated, employing late pilot injection in diesel–methane engines to improve performance and reduce emissions. The engine was first tested with conventional diesel and methane, exploring a wide range of pilot injection timings, injection pressures, and intake boost pressures. Subsequently, experiments were repeated using a methane/hydrogen blend to assess the influence of hydrogen addition. Results show that, when using only methane, delayed pilot injections have minimal effects on engine performance. In naturally aspirated operation, unburned hydrocarbons and carbon monoxide are reduced, while in supercharged conditions, emissions increase; however, they remain within acceptable limits. Nitrogen oxides and particulate matter reach their lowest levels with delayed injection. Introducing hydrogen reduces engine performance and hydrocarbons and carbon monoxide emissions; notably, it suppresses the typical nitrogen oxides
Carlucci, Antonio PaoloStrafella, LucianoFicarella, Antonio
Fused filament fabrication (FFF) 3D printing has proven to be an affordable method for producing customized and lightweight parts and an accessible method to validate new composite materials. As a rapid prototyping method, it can be used to manufacture and replace defective and/or damaged parts in places with limited infrastructure or logistical support. However, the layer-by-layer deposition inherent to the FFF process introduces anisotropy and residual stresses, which can compromise part performance under high temperatures or vibrational loads. This article aims to analyze the failure of a 3D printed intake runner and address the problems found. The analyzed part was 3D printed in acrylonitrile butadiene styrene (ABS), which had a high volumetric contraction during the printing process. Although ABS exhibits a high heat deflection temperature (HDT) compared to other polymers, prolonged exposure to elevated temperatures during operation led to unintentional embrittlement, reducing
Oliveira, Vinícius deHoriuchi, Lucas NaoMagalhaes, GabrielAlcantara, Nathan deGonçalves, Ana PaulaSouza, MarianaPolkowski, Rodrigo
Growing interest in cleaner energy has spurred progress in engine technology, focusing on greater efficiency and lower emissions. Methane-based fuels, like compressed natural gas (CNG), have become an alternative for spark-ignition engines, especially in Brazil. Among performance strategies, dethrottled operation stands out by reducing intake restrictions and minimizing pumping losses, a major inefficiency in conventional spark ignition engines. This improves thermal efficiency and reduces both fuel consumption and emissions. This study experimentally examines the performance and combustion of a CNG-powered Hyundai HR 2.5 16V engine, converted from diesel to spark ignition with natural gas, comparing factory (omega) and custom (reentrant) piston geometries under both conventional and dethrottled modes. The research evaluates how piston design affects combustion stability, efficiency, and emissions across different load strategies. Tests were conducted at 7, 8, and 9 bar loads, as well
Silva, Cristian Douglas Rosa daGarlet, Roberto AntonioDapper, Jackson MayerFagundez, Jean Lucca SouzaLanzanova, Thompson Diórdinis MetzkaMartins, Mario Eduardo Santos
This study investigates a method for determining the indicated power of a combustion engine. To accomplish this, it was necessary to obtain the combustion pressure curve for each cylinder as a function of the crankshaft’s angular position, along with the geometric data of the connecting rod and crank mechanism. The combustion pressure was used to calculate the work transferred from the gas to the engine piston. Pressure measurements were obtained using a piezoelectric pressure transducer, which operates on the piezoelectric effect: a quartz crystal subjected to pressure generates an electrical signal. This signal is then converted into a proportional and linear signal that can be analyzed by a data acquisition system. Once acquired, the data were evaluated using a log P–log V diagram to verify quality and ensure the measurements accurately represented the physical phenomenon. The pressure versus volume (P–V) diagrams were generated, and the area under these curves during the
da Silva, Nerivaldo RodriguesGlauco, Caio
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