Highlights on Engine Cavity measurement using the negative extrusion technique.

1. 1
1808-009 Cavity measurements
Ra’uf Tailony
07/11/2017
Pneumatic cylinder (Exhaust)
Exhaust Seal
Volume= 5060.2 x103
mm3
Surface Area= 567.8 x103
mm2
Volume= 51 x103
mm3
Surface Area= 41.1 x103
mm2

2. 2
Ball Valve-Exhaust Seal
Engine exhaust cavity
Volume= 112.2 x103
mm3
Surface Area= 12.9 x103
mm2

3. 3
Engine intake cavity
Volume= 69.7 x103
mm3
Surface Area= 169 x103
mm2

4. 4
Intake cavity (RH)
Intake cavity (LH)
Volume= 68.8 x103
mm3
Surface Area= 12.4 x103
mm2
Volume= 47.7 x103
mm3

5. 5
Part Name Part # Quantity Volume [mm3
]
Exhaust Seal 00W1168170ta0016 6 306 x103
mm3
Pneumatic cylinder
(exhaust)
CDQ2B125TF-200DCMZ 1 5060.2 x103
mm3
intake Seal 00W1168165ta0023 12 667.2 X 103
mm3
Pneumatic cylinder
(intake)
CDQ2A100TF-200DCMZ 1 1634 X 103
mm3
Engine exhaust cavity -- 6 4183.2 X 103
mm3
Engine intake cavity
(RH+LH)
-- 6 pairs
(12 ports)
825.6 x103
mm3

6. 6
Single line exhaust volume
Total Volume= 892.2 x103
mm3

7. 7
Single line intake volume
Total Volume= 316.3 x103
mm3
(includes RH and LH ports)

8. 8
Volume Calculations Results
1.0 Exhaust side
PTC|Exhaust = 163.2 x103
mm3
VE|Exhaust + VC|Exhaust = 69.7 x103
mm3
= NVE
 NVE/(PTC+NVE) = 29% (should be >= 85%)
2.0 Intake side
PTC| Intake= (55.6+112.2) x103
mm3
= 167.8 x103
mm3
(VI|Intake + VC|Intake) |RH = 68.8 x103
mm3
= NVI|RH
(VI|Intake + VC|Intake) |LH = 47.7 x103
mm3
= NVI|LH
NVI|Total = 116.5 x103
mm3
■ Intake |RH percentage = NVI|RH/(PTC+NVI|RH)
= 68.8 x103
/(167.8 x103
+68.8 x103
)
= 29% (should be >= 85%)
■ Intake |LH percentage = NVI|LH/(PTC+NVI|LH)
= 47.7 x103
/(167.8 x103
+47.7 x103
)
= 22.1% (should be >= 85%)
■ Total Volume Percentage = NVI|Total/(PTC+NVI|Total)
= 40.9% (should be >= 85%)
Volume Correction Estimates
1.0 Exhaust volume correction
PTC|Exhaust= 163.2 x103
mm3
NVE = 69.7 x103
mm3
Customer Volume percentage
Volume percentage goal (Vp) = 92%
 PTC|Exhaust =
NVE−( NVE∗Vp)
Vp

9. 9
=
𝟔𝟗𝟕𝟎𝟎 – (𝟔𝟗𝟕𝟎𝟎 ∗ 𝟎.𝟗𝟐)
𝟎.𝟗𝟐
► PTC|Exhaust ≤ 60608.7 mm3
 Volume to be removed from current PTC assembly
PTC|@81% - PTC|@92% = 163200 – 60608.7
= 102591.3 mm3
■ Fix #1
Assuming PTC Radius = 9 mm
 Total PTC length should be ≤ (238 mm)
■ Fix #2
Assuming PTC Length = 300 mm
 Average PTC radius should be ≤ (8.02 mm)
2.0 Intake volume correction
PTC|Intake= 167.8 x103
mm3
NVI|RH = 68.8 x103
mm3
NVI|LH = 47.7 x103
mm3
Customer Volume percentage
Volume percentage goal (Vp) = 92%
2.1 Intake(RH) volume correction
 PTC|Intake RH =
𝐍𝐕𝐈|𝐑𝐇 −( 𝐍𝐕𝐈|𝐑𝐇 ∗ Vp)
Vp
=
𝟔𝟖𝟖𝟎𝟎 – (𝟔𝟖𝟖𝟎𝟎 ∗ 𝟎.𝟗𝟐)
𝟎.𝟗𝟐
► PTC|Intake RH ≤ 5982.6 mm3
V cylindrical =
π . r2
. l

10. 10
■ Fix #1
Assuming PTC Radius = 9 mm
Total PTC length should be ≤ (23.8 mm) !!!
■ Fix #2
Assuming PTC Length = 300 mm
 Average PTC radius should be ≤ (2.5 mm) !!!
2.2 Intake(LH) volume correction
 PTC|Intake RH =
𝐍𝐕𝐈|𝐑𝐇 −( 𝐍𝐕𝐈|𝐑𝐇 ∗ Vp)
Vp
=
𝟒𝟕𝟕𝟎𝟎 – (𝟒𝟕𝟕𝟎𝟎 ∗ 𝟎.𝟗𝟐)
𝟎.𝟗𝟐
► PTC|Intake RH ≤ 4147.8 mm3
■ Fix #1
Assuming PTC Radius = 9 mm
Total PTC length should be ≤ (16.3 mm) !!!
■ Fix #2
Assuming PTC Length = 300 mm
 Average PTC radius should be ≤ (2.09 mm) !!!

11. 11
Cavities Volume Comparison
Volumes [mm3
]
Cavity # Intake RH Intake LH Exhaust
1 68,699 49,013 69,087
2 66,138 46,401 69,597
3 68,042 49,290 69,173
4 68,715 49,069 67,631
5 68,913 49,082 67,532
6 65,568 47,178 69,250
123456

12. 12
Corrected PTC Dimentions
3.0 Exhaust PTC dimension
PTC|Exhaust= 163.2 x103
mm3
NVE = 99.7 x103
mm3
(30cc combustion volume added)
Customer Volume percentage
Volume percentage goal (Vp) = 87%
PTC diameter = 8 mm
 PTC|Exhaust =
NVE−( NVE∗Vp)
Vp
=
𝟗𝟗𝟕𝟎𝟎 – (𝟗𝟗𝟕𝟎𝟎 ∗ 𝟎.𝟖𝟕)
𝟎.𝟖𝟕
► PTC|Exhaust ≤ 14897.7 mm3
 Total PTC length should be ≤ (296.5 mm)
4.0 Intake PTC dimension
PTC|Intake= 167.8 x103
mm3
NVI|RH = 98.8 x103
mm3
(30cc combustion volume added)
NVI|LH = 77.7 x103
mm3
(30cc combustion volume added)
Customer Volume percentage
Volume percentage goal (Vp) = 87%
4.1 Intake(RH) PTC diemsion
PTC|Intake RH =
𝐍𝐕𝐈|𝐑𝐇 −( 𝐍𝐕𝐈|𝐑𝐇 ∗ Vp)
Vp
=
𝟗𝟖𝟖𝟎𝟎 – (𝟗𝟖𝟖𝟎𝟎 ∗ 𝟎.𝟖𝟕)
𝟎.𝟖𝟕

13. 13
► PTC|Intake RH ≤ 14763.2 mm3
 Total PTC length should be ≤ (293.8 mm)
4.2 Intake(LH) PTC dimension
PTC|Intake RH =
𝐍𝐕𝐈|𝐋𝐇 −( 𝐍𝐕𝐈|𝐋𝐇 ∗ Vp)
Vp
=
𝟕𝟕𝟕𝟎𝟎 – (𝟕𝟕𝟕𝟎𝟎 ∗ 𝟎.𝟖𝟕)
𝟎.𝟖𝟕
► PTC|Intake RH ≤ 11610.3 mm3
 Total PTC length should be ≤ (231.1 mm)
4.3 Intake(Total) PTC dimension
PTC|Intake Total =
𝐍𝐕𝐈|𝐓𝐨𝐭𝐚𝐥 −( 𝐍𝐕𝐈|𝐓𝐨𝐭𝐚𝐥 ∗ Vp)
2∗Vp
(Equation based on GM recent specs.)
=
𝟏𝟑𝟕𝟓𝟎𝟎 – (𝟏𝟑𝟕𝟓𝟎𝟎 ∗ 𝟎.𝟖𝟕)
𝟐∗𝟎.𝟖𝟕
► PTC|Intake Total ≤ 10272.9 mm3
 Total PTC length should be ≤ (204.47 mm)

14. 14
4.4 PTC dimensions including combustion volume
■ Assuming Combustion volume = 30cc
Inputs
V|Combustion = 30 x103
mm3
NVE = 99.7 x103
mm3
NVI|RH = 98.8 x103
mm3
NVI|LH = 77.7 x103
mm3
NVI|Total = 137.5 x103
mm3
Cavity PTC length [mm] PTC Diameter [mm]
Exhaust ≤ 296.5 8
Intake RH ≤ 293.8 8
Intake LH ≤ 231.1 8
Intake Total ≤ 204.5 8
■ Assuming Combustion volume = 60cc
Inputs
V|Combustion = 60 x103
mm3
NVE = 129.7 x103
mm3
NVI|RH = 128.8 x103
mm3
NVI|LH = 107.7 x103
mm3
NVI|Total = 167.5 x103
mm3
Cavity PTC length [mm] PTC Diameter [mm]
Exhaust ≤ 385.7 8
Intake RH ≤ 383.1 8
Intake LH ≤ 320.3 8
Intake Total ≤ 498.1 8

15. 15
■ Actual Combustion volume = 32cc
Inputs
V|Combustion = 32 x103
mm3
NVE = 101.7 x103
mm3
NVI|RH = 100.8 x103
mm3
NVI|LH = 79.7 x103
mm3
NVI|Total = 139.5 x103
mm3
Cavity PTC length [mm] PTC Diameter [mm]
Exhaust ≤ 357.2 8
Intake RH ≤ 354.1 8
Intake LH ≤ 279.9 8
Intake Total ≤ 490 8