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E-grāmata: Vehicular Engine Design

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  • Formāts: EPUB+DRM
  • Sērija : Powertrain
  • Izdošanas datums: 04-Aug-2015
  • Izdevniecība: Springer Verlag GmbH
  • Valoda: eng
  • ISBN-13: 9783709118597
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Vehicular Engine DesignPalielināt
  • Formāts: EPUB+DRM
  • Sērija : Powertrain
  • Izdošanas datums: 04-Aug-2015
  • Izdevniecība: Springer Verlag GmbH
  • Valoda: eng
  • ISBN-13: 9783709118597
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This book provides an introduction to the design and mechanical development of reciprocating piston engines for vehicular applications. Beginning from the determination of required displacement and performance, coverage moves into engine configuration and architecture. Critical layout dimensions and design trade-offs are then presented for pistons, crankshafts, engine blocks, camshafts, valves, and manifolds. Coverage continues with material strength and casting process selection for the cylinder block and cylinder heads. Each major engine component and sub-system is then taken up in turn, from lubrication system, to cooling system, to intake and exhaust systems, to NVH. For this second edition latest findings and design practices are included, with the addition of over sixty new pictures and many new equations.
1 The Internal Combustion Engine---An Introduction
1(16)
1.1 Heat Engines and Internal Combustion Engines
1(2)
1.2 The Reciprocating Piston Engine
3(2)
1.3 Engine Operating Cycles
5(2)
1.4 Supercharging and Turbocharging
7(1)
1.5 Production Engine Examples
8(1)
1.6 Basic Measures
9(6)
1.7 Recommendations for Further Reading
15(2)
References
15(2)
2 Engine Maps, Customers and Markets
17(14)
2.1 Engine Mapping
17(5)
2.2 Automobile, Motorcycle, and Light Truck Applications
22(3)
2.3 Heavy Truck Applications
25(2)
2.4 Off-Highway Applications
27(3)
2.5 Recommendations for Further Reading
30(1)
References
30(1)
3 Engine Validation and Reliability
31(20)
3.1 Developing a Reliable and Durable Engine
31(2)
3.2 Fatigue Analysis
33(9)
3.3 Friction, Lubrication, and Wear
42(6)
3.4 Further Wear and Failure Mechanisms
48(2)
3.5 Recommendations for Further Reading
50(1)
References
50(1)
4 The Engine Development Process
51(10)
5 Determining Displacement
61(8)
5.1 The Engine as an Air Pump
61(3)
5.2 Estimating Displacement
64(4)
5.3 Engine Up-rating and Critical Dimensions
68(1)
6 Engine Configuration and Balance
69(28)
6.1 Determining the Number and Layout of Cylinders
69(1)
6.2 Determining the Number of Cylinders
69(4)
6.3 Determining the Cylinder Bore-to-Stroke Ratio
73(6)
6.4 Vibration Fundamentals Reviewed
79(1)
6.5 Rotating Forces and Dynamic Couples
80(5)
6.6 Reciprocating Forces
85(3)
6.7 Balancing the Forces in Multi-Cylinder Engines
88(6)
6.8 Gas Pressure Forces
94(1)
6.9 Recommendations for Further Reading
95(2)
References
95(2)
7 Cylinder Block and Head Materials and Manufacturing
97(20)
7.1 Cylinder Block and Head Materials
97(6)
7.1.1 Gray Cast Iron
97(3)
7.1.2 Aluminum Alloys
100(2)
7.1.3 Magnesium Alloys
102(1)
7.2 Cylinder Block and Head Casting Processes
103(4)
7.2.1 Sand Casting
103(1)
7.2.2 Permanent Mold Casting
104(1)
7.2.3 High Pressure Die Casting
105(1)
7.2.4 Lost Foam Casting
105(1)
7.2.5 The Cosworth Casting Process
106(1)
7.3 Cylinder Block and Head Casting Design Considerations
107(4)
7.4 Cylinder Block and Head Machining Processes
111(3)
7.5 Recommendations for Further Reading
114(3)
References
114(3)
8 Cylinder Block Layout and Design Decisions
117(30)
8.1 Initial Block Layout, Function, and Terminology
117(3)
8.2 Main Block Features
120(3)
8.3 Main Block Design Dimensions
123(10)
8.3.1 Deck Height
125(3)
8.3.2 Vee Angle
128(1)
8.3.3 Cylinder Bore Spacing
128(4)
8.3.4 Other Block Dimensions
132(1)
8.4 Crankcase Bottom End
133(3)
8.5 Cylinder Design Decisions
136(7)
8.5.1 Integral Cylinder Liner
136(1)
8.5.2 Dry Cylinder Liner
137(1)
8.5.3 Wet Cylinder Liner
138(1)
8.5.4 Cylinder Cooling Passages
138(5)
8.6 Camshaft Placement Decisions
143(2)
8.7 Positive Crankcase Ventilation
145(1)
8.8 Recommendations for Further Reading
146(1)
References
146(1)
9 Cylinder Head Layout Design
147(30)
9.1 Initial Head Layout
147(2)
9.2 Combustion Chamber Design Decisions
149(6)
9.2.1 Spark-Ignition (SI) Combustion Chambers
149(3)
9.2.2 Direct-Injection Spark-Ignited (DISI) Combustion Chambers
152(1)
9.2.3 Diesel or Compression-Ignition (CI) Combustion Chambers
153(2)
9.3 Valve, Port and Manifold Design
155(14)
9.3.1 Intake Port Swirl
162(1)
9.3.2 Intake Port Tumble
163(1)
9.3.3 Intake Port and Intake Manifold Length
163(1)
9.3.4 Intake Port Surface Roughness and Flow Area
164(1)
9.3.5 Intake Port Heat Transfer
165(1)
9.3.6 Fuel Injector Placement, and Intake Manifold Design
165(2)
9.3.7 Exhaust Port Heat Transfer
167(1)
9.3.8 Exhaust Port and Exhaust Manifold Length
167(1)
9.3.9 Exhaust Port and Manifold Surface Roughness and Flow Area
168(1)
9.3.10 Exhaust Port and Exhaust Manifold Design
168(1)
9.4 Head Casting Layout
169(5)
9.5 Cylinder Head Cooling
174(1)
9.6 Oil Deck Design
175(1)
9.7 Recommendations for Further Reading
176(1)
References
176(1)
10 Block and Head Development
177(16)
10.1 Durability Validation
177(1)
10.2 High-Cycle Loading and the Cylinder Block
177(3)
10.3 Modal Analysis and Noise
180(3)
10.4 Low-Cycle Mechanical Loads
183(1)
10.5 Block and Head Mating and the Head Gasket
184(3)
10.6 Cylinder Head Loading
187(1)
10.7 Thermal Loads and Analysis
188(2)
10.8 Recommendations for Further Reading
190(3)
References
190(3)
11 Engine Bearing Design
193(22)
11.1 Hydrodynamic Bearing Operation
193(3)
11.2 Split Bearing Design and Lubrication
196(2)
11.3 Bearing Loads
198(4)
11.4 Classical Bearing Sizing
202(2)
11.5 Dynamic Bearing Sizing
204(3)
11.6 Bearing Material Selection
207(2)
11.7 Bearing System Validation
209(3)
11.8 Recommendations for Further Reading
212(3)
References
213(2)
12 Engine Lubrication
215(28)
12.1 Engine Lubricants
215(6)
12.2 Crankcase Deposits
221(2)
12.3 Lubrication Circuits and Systems
223(4)
12.4 Oil Pumps
227(3)
12.5 Oil Pans, Sumps, and Windage
230(3)
12.6 Filtration and Cooling
233(2)
12.7 Lubrication System Performance Analysis
235(5)
12.8 Recommendations for Further Reading
240(3)
References
241(2)
13 Engine Cooling
243(20)
13.1 Tracking the Energy Transfers
243(2)
13.2 Critical Issues in Temperature Control
245(2)
13.3 Engine Cooling Circuits
247(3)
13.4 Cooling Jacket Optimization
250(3)
13.5 Thermal Mapping
253(1)
13.6 Water Pump Design
254(3)
13.7 The Cooling System
257(1)
13.8 Venting and Deaeration
258(1)
13.9 Trends in Cooling System Requirements
259(1)
13.10 Air-Cooled Engines
260(1)
13.11 Recommendations for Further Reading
260(3)
References
261(2)
14 Gaskets and Seals
263(34)
14.1 Gasketed Joint Fundamentals
263(5)
14.2 The Gasket Operating Environment
268(1)
14.3 Flange Sealing Types
268(3)
14.4 Engine Cover Design
271(3)
14.5 Clamping Load Parameters
274(4)
14.6 Bolt Torque and Sealing Load Control
278(1)
14.7 Shaft Seal Design
279(2)
14.8 Example: Cylinder Head Gasket Joint Design
281(12)
14.8.1 Calculated External Applied Loads and Target Fastener Clampload
282(2)
14.8.2 Calculated Equivalent Stiffness and Load Factors
284(3)
14.8.3 Calculate Fastener and Abutment Deflection and Loading
287(2)
14.8.4 Calculate Thermal Affects
289(1)
14.8.5 Design Margins
290(3)
14.9 Test Methods for Gaskets
293(2)
14.10 Recommendations for Further Reading
295(2)
References
296(1)
15 Pistons and Rings
297(24)
15.1 Piston Construction
297(4)
15.2 Piston Crown and Ring Land Development
301(3)
15.3 Piston Pin Boss Development
304(3)
15.4 Piston Skirt Development
307(2)
15.5 Piston Ring Construction
309(1)
15.6 Dynamic Operation of the Piston Rings
310(5)
15.7 Cylinder Wall Machining
315(2)
15.8 Recommendations for Further Reading
317(4)
References
318(3)
16 Cranktrain (Crankshafts, Connecting Rods, and Flywheel)
321(40)
16.1 Definition of Cranktrain Function and Terminology
321(2)
16.2 Description of Common Cranktrain Configurations and Architectures
323(5)
16.2.1 Crankshaft Configurations
323(2)
16.2.2 Connecting Rod Configurations
325(3)
16.2.3 Flywheel Configurations
328(1)
16.3 Detailed Design of Crankshaft Geometry
328(4)
16.4 Crankshaft Natural Frequencies and Torsional Vibration
332(8)
16.5 Crankshaft Nose Development (Straight, Taper, Spline Fit)
340(4)
16.6 Crankshaft Flange Development
344(1)
16.7 Crankshaft Drillings
345(1)
16.8 Connecting Rod Development
346(6)
16.8.1 Connecting Rod Column Forces
346(2)
16.8.2 Connecting Rod Crankpin Bore Cylindricity
348(1)
16.8.3 Connecting Rod-to-Cap Alignment
349(1)
16.8.4 Connecting Rod Bushing Press Fit and Journal Bearing Crush
350(2)
16.8.5 Connecting Rod Computational Stress Analysis
352(1)
16.9 Flywheel Design Considerations
352(2)
16.10 Crankshaft and Connecting Rod Construction
354(2)
16.11 Analysis and Test
356(3)
16.12 Recommendations for Further Reading
359(2)
References
360(1)
17 Camshafts and the Valve Train
361(20)
17.1 Valve Train Overview
361(2)
17.2 Dynamic System Evaluation and Cam Lobe Development
363(4)
17.3 Camshaft Durability
367(4)
17.4 Valve Train Development
371(4)
17.5 Drive System Development
375(1)
17.6 Future Trends in Valve Train Design
376(2)
17.7 Recommendations for Further Reading
378(3)
References
379(2)
Index 381
Kevin Hoag is an Institute Engineer in the Engine, Vehicle and Emission Research Division at Southwest Research Institute. Prior to joining Southwest Research Mr. Hoag was Associate Director of the University of Wisconsin Engine Research Center and a program director with the Department of Engineering Professional Development. He has more than 35 years of experience in internal combustion engine development, 16 years of which were with Cummins Engine Company, prior to joining the university. He joined the University of Wisconsin in 1999, where he was active in research, consulting, course development and teaching in continuing engineering education. He continues to teach Engine Design, and Engine Performance and Combustion, in Wisconsins Master of Engineering in Engine Systems program. Mr. Hoag has been an active member in the Society of Automotive Engineers throughout his career. He was twice awarded Outstanding Younger Member and is a recipient of the Arch T. Colwell Award for technical publication pertaining to Second Law analysis of I.C. engines. He currently co-teaches SAEs Turbocharging Internal Combustion Engines course and serves as a session organizer on engine thermodynamics modeling. Mr. Hoag holds bachelors and masters degrees in mechanical engineering from the University of Wisconsin-Madison. He is the author of two books, and over 30 technical papers. He holds two patents pertaining to internal combustion engine development.

Brian Dondlinger is a Global Business Process Manager of Product Development at the Harley-Davidson Motor Company. He has sixteen years of experience in the motorcycle industry including roles in design, manufacturing and process development. He holds five patents pertaining to internal combustion engine design. 

Mr. Dondlinger holds bachelors and masters degrees in mechanical engineering from the University of Wisconsin-Madison and is a licensed Professional Engineer in the state of Wisconsin. While atUW-Madison, he competed in the SAE student design competition Baja SAE, and currently volunteers as a design judge for both Baja SAE and Formula SAE competitions. He has continued his love of racing by competing in Rally America and as an SFI certified Technical Inspector. He has taught continuing education seminars on Internal Combustion Engine Design and Mechanical Development.
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