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Internal Combustion Engine Design
- 1. Tillman Hatcher –my internal combustion engine design experience is listed: • Engine Design and Operating Parameters • Engine Classifications • Engine Operating Cycles • Engine Components • Spark-Ignition Engine Operation • Compression-Ignition Engine Operation • Stratified-Charge Engines 4/3/2012 Tillman Hatcher 1
- 2. • Important Engine Characteristics • Geometrical Properties of Reciprocating Engines • Brake Torque and Power • Indicated Work per Cycle • Mechanical Efficiency • Road-Load Power • Specific Fuel Consumption and Efficiency • Air/Fuel and Fuel/Air Ratios • Volumetric Efficiency • Engine Specific Weight and Specific Volume • Correction Factors for Power and Volumetric Efficiency • Specific Emissions and Emissions Index • Relationship between Performance Parameters • Engine Design and Performance Data • Thermochemistry of Fuel-Air Mixtures 4/3/2012 Tillman Hatcher 2
- 3. • Characterization of Flames • Ideal Gas Model • Composition of Air and Fuels • Combustion Stoichiometry • Energy and Enthalpy Balances • Heating Values • Adiabatic Combustion Processes • Combustion Efficiency of an Internal Combustion Engine • Entropy • Maximum Work from an Internal Combustion Engine and Efficiency • Chemical Equilibrium • Chemical Reaction Rates • Properties of Working Fluids • Unburned Mixture Composition • Gas Property Relationships 4/3/2012 Tillman Hatcher 3
- 4. • Unburned Mixture Charts • Burned Mixture Charts • Relationship Between Unburned and Burned Mixture Charts • Tables of Properties and Composition • Computer Routines for Property and Composition Calculations • Unburned Mixtures • Burned Mixtures • Transport Properties • Exhaust Gas Composition • Species Concentration Data • Equivalence Ratio Determination from Exhaust Gas Constituents • Effects of Fuel/Air Ratio Nonuniformity • Combustion Inefficiency • Thermodynamic Relations for Engine Processes • Cycle Analysis with Ideal Gas Working Fluid with Constant volume, and Constant pressure Constant 4/3/2012 Tillman Hatcher 4
- 5. • Constant-Volume Cycle • Limited and Constant Pressure Cycles • Cycle Comparison • Fuel-Air Cycle Analysis • SI Engine Cycle Simulation • CI Engine Cycle Simulation • Results of Cycle Calculations • Overexpanded Engine Cycles • Availability Analysis of Engine Processes • Availability Relationships • Entropy changes in Ideal Cycles • Available Analysis of Ideal Cycles • Effects of Equivalence ratio • Gas Exchange Processes • Comparison of Real Engine Cycles 4/3/2012 Tillman Hatcher 5
- 6. • Inlet and Exhaust Processes • Volumetric Efficiency • Quasi-Static Effects • Combined Quasi-Static and Dynamic Effects • Variation with Speed, and Valve Area, Lift, and Timing • Flow through Valves • Poppet Valve Geometry and Timing • Flow Rate and Discharge Coefficients • Residual Gas Fraction • Exhaust Gas Flow Rate and Temperature Variation • Scavenging • Flow through Ports • Supercharging and Turbocharging • Methods of Power Boosting • Basic Relationships 4/3/2012 Tillman Hatcher 6
- 7. • Compressors • Turbines • Wave-Compression Devices • SI Engine Fuel Metering and Manifold Phenomena • Spark-Ignition Engine Mixture Requirements • Carburetors • Carburetor Fundamentals • Fuel-Injection Systems • Multipoint Injection • Single-point Injection • Feedback Systems • Flow Past Throttle Plate • Flow in Intake manifolds • Design Requirements • Air-Flow Phenomena 4/3/2012 Tillman Hatcher 7
- 8. • Fuel-Flow Phenomena • Charge Motion within the Cylinder • Intake jet Flow • Mean Velocity and Turbulence Characteristics • Definitions • Application to Engine Velocity Data • Swirl • Swirl Measurement • Swirl Generation during Induction • Swirl Modification within the Cylinder • Squish • Prechamber Engine Flows • Crevice Flows and Blowby • Flows Generated by Piston-Cylinder Wall Interaction • Combustion in Spark-Ignition Engines 4/3/2012 Tillman Hatcher 8
- 9. • Essential Features of Process • Thermodynamic Analysis of SI Engine Combustion • Burned and Unburned Mixture States • Analysis of Cylinder Pressure Data • Combustion Process Characterization • Flame Structure and Speed • Experimental Observations • Flame Structure • Laminar Burning Speeds • Flame Propagation Relations • Cyclic Variations in Combustion, Partial Burning and Misfire • Observations and Definitions • Causes of Cycle by Cycle and Cylinder to Cylinder Variations • Partial Burning, Misfire, and Engine Stability • Spark ignition 4/3/2012 Tillman Hatcher 9
- 10. • Ignition Fundamentals • Conventional Ignition Systems • Alternative Ignition Approaches • Abnormal Combustion: Knock and Surface Ignition • Description of Phenomena • Knock Fundamentals • Fuel Factors • Combustion in Compression-Ignition Engines • Types of Diesel Combustion Systems • Direct-Injection Systems • Indirect-Injection Systems • Comparison of Different combustion Systems • Phenomenological Model of Compression-Ignition Engine Combustion • Photographic studies of engine combustion • Combustion of Direct-Injection, Multispray Systems 4/3/2012 Tillman Hatcher 10
- 11. • Application of Model to Other combustion Systems • Analysis of Cylinder Pressure Data • Combustion Efficiency • Direct-Injection Engines • Indirect-Injection Engines • Fuel Spray Behavior • Fuel Injection • Overall Spray Structure • Atomization • Spray Penetration • Droplet Size Distribution • Spray Evaporation • Ignition Delay • Definition and Discussion • Fuel Ignition Quality 4/3/2012 Tillman Hatcher 11
- 12. • Autoignition Fundamentals • Physical Factors Affecting Delay • Effect of Fuel Properties • Correlations for Ignition Delay in Engines • Mixing-controlled Combustion • Background • Spray and Flame Structure • Fuel-Air Mixing and Burning Rates • Pollutant Formation and Control • Nature and Extent of Problem • Nitrogen Oxides • Kinetics of NO Formation • Formation of NO² • NO Formation in Spark-Ignition Engines • NOx Formation in Compression-Ignition Engines 4/3/2012 Tillman Hatcher 12
- 13. • Carbon Monoxide • Unburned Hydrocarbon Emissions • Background • Flame Quenching and Oxidation Fundamentals • HC Emissions from Spark-Ignition Engines • Hydrocarbons Emissions Mechanisms in Diesel Engines • Particulate emissions • Spark-Ignition Engine Particulates • Characteristics of Diesel Particulates • Particulate Distribution within the Cylinder • Soot Formation Fundamentals • Soot Oxidation • Adsorption and Condensation • Exhaust Gas Treatment • Available Options 4/3/2012 Tillman Hatcher 13
- 14. • Catalytic Converters • Thermal Reactors • Particulate Traps • Engine Heat Transfer • Modes of Heat Transfer • Conduction • Convection • Radiation • Overall Heat-Transfer Process • Heat Transfer and Engine Energy Balance • Convective Heat Transfer • Dimensional Analysis • Correlations for Time-Average Heat Flux • Correlations for Instantaneous Spatial Average Coefficients • Correlations for Instantaneous Local Coefficients 4/3/2012 Tillman Hatcher 14
- 15. • Intake and Exhaust System Heat Transfer • Radiative Heat Transfer • Radiation from Gases • Flame Radiation • Prediction Formulas • Measurements and Instantaneous Heat-Transfer Rates • Measurement methods • Spark-Ignition Engine Measurements • Diesel Engine Measurements • Evaluation of Heat-Transfer Correlations • Boundary-Layer Behavior • Thermal Loading and Component Temperatures • Component Temperature Distributions • Effect of Engine Variables • Engine Friction and Lubrication 4/3/2012 Tillman Hatcher 15
- 16. • Background • Definitions • Friction Fundamentals • Lubricated Friction • Turbulent Dissipation • Total Friction • Measurement methods • Engine Friction Data • SI Engines • Diesel Engines • Engine Friction Components • Motored Engine Breakdown Tests • Pumping Friction • Piston Friction • Piston Assembly Friction 4/3/2012 Tillman Hatcher 16
- 17. • Crankshaft Bearing Friction • Valve Train Friction • Accessory Power Requirements • Lubrication • Lubrication Systems • Lubrication Requirements • Modeling Real Engine Flow and Combustion Processes • Purpose and Classification of Models • Governing Equations for Open Thermodynamic System • Conservation of Mass • Conservation of Energy • Intake and Exhaust Flow Models • Background • Quasi-Steady Flow Models • Filling and Emptying Methods 4/3/2012 Tillman Hatcher 17
- 18. • Gas Dynamics Models • Thermodynamic-Based In-Cylinder Models • Background and Overall Model Structure • SI Engine Models • Direct-Injection Engine Models • Prechamber Engine Models • Multicylinder and Complex Engine System Models • Second Law Analysis of Engine Systems Models • Fluid-Mechanic-Based Multidimensional Models • Basic Approach and Governing Equations • Turbulence Models • Numerical Methodology • Flow Field Predictions • Fuel Spray Modeling • Combustion Modeling 4/3/2012 Tillman Hatcher 18
- 19. • Engine Operating Characteristics • Engine Performance Parameters • Indicated and Brake Power and MEP • Variables that Affect CI Engine Performance, Efficiency, and Emissions • Spark timing • Mixture composition • Load and Speed • Compression Ratio • Design Objectives and Options • Factors that Control Combustion • Factors that Control Performance • Chamber Octane Requirement • Chamber Optimization Strategy • Fuel-Injection Parameters • Air-Swirl and Bowl-in-Piston Design 4/3/2012 Tillman Hatcher 19
- 20. • Supercharged and Turbocharged Engine Performance • Engine Performance Summary Data Collection • Transmission Angle • Limiting Positions of an Offset Slider Crank Linkages • Displacement Analysis and Computer Graphics • Quick Return Mechanisms • Linkage Interference • Mechanisms for Specific Applications • Computer-Controlled Units • Real time data capture and pursing into a graphical Excel File • Engine ECU programming • Exhaust After Treatment ECU programming • Cab ECU programming interface • Diagnostic software programming • Moving Coordinate Systems 4/3/2012 Tillman Hatcher 20
- 21. • Relative Velocity • Application of Analytical Vector Methods to Linkages • Graphical Analysis of Linkage Motion Utilizing Relative Velocity • Velocity Imaging • Velocity-Time Studies • Graphical Analysis of Sliding Contact Linkages • Cams and Cam Followers • Disk Cam Design for Basic Followers Types and Motions • Displacement, Velocity, Acceleration, and Jerk Analysis of Cam Follower Motion • Analytical Cam Design • Positive-Motion Cams • Cylinder Cams 4/3/2012 Tillman Hatcher 21