This document provides a detailed design review for an inline-4 cruiser motorcycle engine project. It includes summaries of the engine design, goals and objectives, market fit purpose, materials selection process, manufacturing methods selection, and contributions from the project team members. The engine is designed to meet all safety, emissions and noise regulations for the middle class motorcycle market in the USA. Key sections summarize the engine body, valvetrain, powertrain, and cooling and lubrication subsystems, including the relevant calculations, FEA analysis, materials selection, manufacturing methods, and Bill of Materials. Quality control testing plans and costs are also outlined.

1. 1
Sixy and We Know It
Detailed Design Review: December 4th, 2020
Team Lead
(Ray L)
Project Manager
(Julie W)
Research Lead
(Boxuan S)
Calculation Lead
(Junsei R)
CAD Lead
(Jim D)
Report Lead
(Serena C)
Research Assistant
(WIlson F)
CAD Assistant
(Tanios N)
Calculation Assistant
(Simon S)
Report Assistant
(Christina M)
Report Assistant
(Jake C)

2. Engine Summary:
● Inline-four, DOHC
● Total displacement: 1500.19cc
● Compression ratio: 10:1
● Liquid cooled
● Wet sump lubrication
2
Summary of Product

3. Goals and Objectives
Project Statement:
● Design an original inline 4 cruiser motorcycle engine for the middle class market in the USA
for the Spartan Motorcycle Company.
● This engine will comply with all safety, emissions, and noise regulations. The project
schedule will span from August 24th, 2020 to December 11th, 2020.
● Expect to produce 7500 units in the first year (2022), followed by 12000 units (2023), and
15000 units (2024).
3
Purpose (Market Fit):
● US motorcycle market size estimated at 7.85 billion USD in 2016
● Anticipated to grow at a CAGR of 3.7% over next 10 years
● Over 468,000 units sold in 2019, approximately 485,000 units expected in 2020
● Most cruisers have V-twin engines, so our inline 4 engine provides customers with an
alternative and reliable engine for a cruiser motorcycle

4. 4
Satisfaction of Design Requirements

5. 5

6. 6

7. 7
Materials Selection Process
Research and identify
common materials
currently used for
components in the
motorcycle industry
Determine important
material properties for the
component’s specific
function
Use Granta EduPack +
other resources to
compare materials with the
desired properties
Choose most favorable
material based on
manufacturing and
performance criteria. Apply
FEA to necessary
components
Before we dive into the different subsystems and
specifics of our manufacturing and material and
make vs buy decisions, we will first look into the
approach this team took to arrive to such decisions.

8. 8
Manufacturing Methods Selection
Using Edupack, Engineering
Handbook, and other
resources to find out what
processes are suitable for
particular materials.
Research and find out
the traditionally used
process from empirical
resources.
Depending on
performance requirement
and material, determine
the primary manufacturing
processes.
Determine any secondary
manufacturing processes.

9. 9
Buy vs Make Selection
Decide if part has many
dimensional choices available for
purchase or if it is of critical
importance to core function of the
engine that requires custom
dimensions.
For parts with several dimensional
options available, we will purchase
them (e.g. bolts, nuts, pumps, etc).
For parts with custom dimensions
and our critical to our engine, we
will make (e.g. engine block, piston
head, etc)
Do research on whether or not
purchased parts meet engine
performance and dimension
requirements. If not, we will make
the part.

10. 10
Engine Body

11. 11
Assembly Drawing

12. 12
Drawings of Engine Body: Engine Block

13. 13
Drawings of Engine Body: Cylinder Head (Preliminary)

14. 14
Drawings of Engine Body: Crankcase

15. 15
Engine Body Materials and Manufacturing

16. 16
Relevant FMEA for Engine Body
(S) (O) (D)

17. 17
Engine Body BOM
Part Number Designation:
Company Callout - Subassembly - #
Ex: SAWKI-EB-001 is for part #1 of engine block subassembly
*COTS = Commercial off the shelf
Make vs buy decision:
● Studs, washers, nuts, pins, and screws are purchased parts because
there are a variety of options available for these on the market that our
engine can be designed around
● Parts that the team has identified as core importance to the engine and
thus should be designed by us to produce a unique engine include engine
block, cylinder head, cylinder head cover, and etc

18. 18
Valvetrain

19. 19
Drawings of Valvetrain: Cylinder Head

20. 20
Drawings of Valvetrain: Subassembly

21. 21
Drawings of Valvetrain: Valve Assembly

22. 22
Drawings of Valvetrain: Exhaust & Intake Valves

23. 23
Drawings of Valvetrain: Camshafts

24. ~ Revised FOS:
- Intake Valve: 3.5
- Exhaust Valve: 3.8
24
Relevant FEA for Valvetrain

25. 25
Valvetrain Materials and Manufacturing

26. 26
Relevant FMEA for Valvetrain

27. 27
Valvetrain BOM
*COTS = Commercial off the shelf
● Buy:
○ Small parts with multiple dimensional options that we can fit our engine dimension to such as valve spring, valve guide seal, screws, keys, and
bearings.
● Make:
○ Camshafts and valve components since they are crucial parts that can be designed by our team to make a unique engine

28. 28
Valvetrain Calculations: Discharge Coefficient and Lift
Using exhaust valve and port design b (chart on the
right) for analysis:

29. 29
Valvetrain Calculations: Mass Flow

30. 30
Powertrain

31. 31
Drawings of Powertrain: Subassembly

32. 32
Drawings of Powertrain: Crankshaft

33. 33
Drawings of Powertrain: Conrod

34. 34
Drawings of Powertrain: Piston

35. ~ Revised FOS: 3.25
35
Powertrain FEA: Piston

36. ~ Revised FOS: 3
~ 2 slots of shear stress
concentration due to clearance
between piston and conrod.
36
Powertrain FEA: Wrist Pin

37. ~ Revised FOS: 6.23
37
Powertrain FEA: Conrod

38. Revised FOS: 3
38
Powertrain FEA: Crankshaft

39. 39
Powertrain Materials and Manufacturing

40. 40
Relevant FMEA for Powertrain

41. 41
Powertrain BOM
*COTS = Commercial off the shelf
● Buy:
○ Small parts with multiple dimensional options that we can fit our engine dimension to such as screws, keys, nuts, bearings, sprockets, and
piston rings
● Make:
○ Crankshaft, connecting rod, piston, and wrist pin are parts that will undergo a lot of load, so the team decided to design them to make sure
performance requirements of the engine are met

42. 42
Powertrain Calculations: Non-Ideal Cycle

43. 44
Cooling and Lubrication

44. Red: Coolant path Yellow: Oil path
45
Model of Cooling and Lubrication

45. 46
Cylinder Head Oil Path

46. 47
Lubrication Materials and Manufacturing

47. 48
Relevant FMEA for Cooling and Lubrication

48. 49
Lubrication and Cooling BOM
*COTS = Commercial off the shelf
● Buy:
○ Small parts with multiple dimensional options that we can fit our
engine dimension to such oil and cooling components
● Make:
○ Gaskets since they will have to fit to our engine which has custom
dimensions for core components to create a proper seal
○ Oil pan since it will be designed to have an outer dimension that
matches our engine to create a seal to prevent lubrication
leakage

49. 50
Cooling & Lubrication: Lubrication Calculations

50. 51
Cooling and Lubrication: Cooling Calculations
Parameters Value with Unit
Gas Temperature 1474 K
Inner Cylinder Wall Temperature 976 K
Coolant Temperature 366 K
Outside Surface Temperature of
Engine Block
315 K
Mass Flow 0.55 kg/s
The minimum temperature to sustain burns : 318 K
Volumetric Flow Rate of Coolant at 6500 RPM : 11.86
gpm

51. Coolant Pump
● Part #: WP136S
● Supplier: Meziere
● Satisfies volumetric flow rate of 8.35 GPM
52
Coolant and Lubricant Pump Selection
Oil Pump
● Part #: M16422012
● Supplier: Marco
● Subject to change as current volumetric flow
rate of 8507.41 mm^3/s is incorrect

52. 53
Other: Fuel Efficiency
65 mph 5000 Rpm: 36.05 MPG > 35 MPG (required value)
Mair (mass of air) 0.000505 kg
AFR (air to fuel ratio) 14.7
Density of octane 2.86 kg/gal

53. ● For AFR of 14.7 our engine will produce 158.3 g/km of CO and 29.64
g/km of NOx at 5000rpm.
● To meet the federal requirement, we have chosen Universal Catalytic
Converter 51355 from MagnaFlow.
54
Other: Emissions

54. 55
Theory of Operations

55. 56
Quality Control and Testing
Destructive Testings Non-Destructive Testings
Fatigue
Fracture and
Mechanical
Residual Stress
Measurement
Aggressive
Environment
Coordinate-
Measuring
Machine
Visual Testing
Magnetic
Particle/Liquid
Penetrant
Vibration
Analysis
Test Cell Decibel Meter
First Year
Purchased Parts 1 in 500 1 in 500 1 in 500 1 in 500 N/A All 1 in 500 N/A N/A N/A
Manufactured
Parts
Critical 1 in 50 1 in 50 1 in 50 1 in 50 All All All N/A N/A N/A
Non-Critical 1 in 100 1 in 100 1 in 100 1 in 100 1 in 100 All 1 in 100 N/A N/A N/A
Assembled Engine N/A N/A N/A N/A N/A All N/A 1 in 100 1 in 100 1 in 100
Second
Year
Purchased Parts 1 in 1000 1 in 1000 1 in 1000 1 in 1000 N/A All 1 in 1000 N/A N/A N/A
Manufactured
Parts
Critical 1 in 100 1 in 100 1 in 100 1 in 100 1 in100 All 1 in 100 N/A N/A N/A
Non-Critical 1 in 200 1 in 200 1 in 200 1 in 200 1 in 500 All 1 in 500 N/A N/A N/A
Assembled Engine N/A N/A N/A N/A N/A All N/A 1 in 200 1 in 200 1 in 200
Third Year
Purchased Parts 1 in 1000 1 in 1000 1 in 1000 1 in 1000 N/A All 1 in 1000 N/A N/A N/A
Manufactured
Parts
Critical 1 in 200 1 in 200 1 in 200 1 in 200 1 in 200 All 1 in 200 N/A N/A N/A
Non-Critical 1 in 500 1 in 500 1 in 500 1 in 500 1 in 1000 All 1 in 1000 N/A N/A N/A
Assembled Engine N/A N/A N/A N/A N/A All N/A 1 in 500 1 in 500 1 in 500
There is a decrease in testing rate because:
1. Increasing production, and
2. More consistent quality as we
produce more.
However, a part’s testing rate will return to first-
year standard if the part fails any testings.
Critical Parts: Connecting Rods, Cylinder Sleeve, Crankshaft, Piston Head, Intake Valves, Exhaust Valves, Wrist Pins, Camshafts.
Non-critical Parts: All the manufactured parts not listed in critical parts.

56. 57
Cost Estimate
Manufacturing Cost:
● Overhead cost ($/hr) = 100
● Labor ($/hr) = 21.73
● Focused on primary and secondary
processes
Purchased Cost:
● Accounted for an estimated 20% markup
retail price
*Cost subject to change as we finalize CAD. If
cost requirement is not met, a root cause
analysis and next steps will be provided in the
Final Report.
Manufacturing Cost ($) Material Cost ($) Purchased Cost ($) Total Cost per Engine ($)
Original 6984.46 181.71 3526.05 10692.22
Extra Cost for Manufacturing
and Purchased defects
349.22 9.09 70.52 428.83
Extra Cost for Destructive
Testing
63.11 34.59 7.05 104.76
Sum 7396.80 225.39 3603.63 11225.81
Scrap Rate (%)
Make 5
Buy 2

57. 58
Team Member Contribution Matrix
Link to more detailed contribution table:
https://docs.google.com/spreadsheets/d/1bHFtE6ZA2H7I4eMlNsfK5eIKP53iDOgBUCVewqBMyfs/edit#gid=0

58. 59
Team Member Contribution Chart

59. 60
Thank You!
Questions? Feedback?

60. ● Scope
○ https://docs.google.com/document/d/1uYN3Kzk68p5pE0NjM6FMkMz3LxVFO8zqk1yzyUqNCaE/edit?usp=sharing
● Full Derived Requirements
○ https://docs.google.com/spreadsheets/d/1sMIHcQhcnjza3Yr3R7RntVngGTOD-mHwropvHfzkw0M/edit?usp=sharing
● Abbreviated Derived Requirements
○ https://docs.google.com/spreadsheets/d/1ohSYr8MiRrmH7aRShHGncW_HOBIPjGjHCIL0h-wLFB8/edit#gid=78626143
● Pugh Charts
○ https://docs.google.com/spreadsheets/d/18ELRqXrPOghy-d9uP6Rad8a3WH-p9Xcz0kamU0qsRhI/edit?usp=sharing
● PDS _ Pricing Policy
○ https://docs.google.com/spreadsheets/d/1ED7uESZL6-nspWkAcAZFDGAuGvYXRb_KWy1KndVXfVY/edit?usp=sharing
● Gantt Chart
○ https://docs.google.com/spreadsheets/d/1WUQXCFwA4uwXKh9erpvrv2VRez4WSzKVEj9jpNCmJ4w/edit?usp=sharing
● Bill of Materials
○ https://docs.google.com/spreadsheets/d/15V80KvX34m_qI1ohdNmOaIdU7w35qXYGIlH_kxIg_NA/edit#gid=0
● Material and Manufacturing Justification
○ https://docs.google.com/spreadsheets/d/16AFzN7gmQR57AN-oiaFdzXS8Y27kMWFZ-knbgTNbsdg/edit#gid=0
● FMEA
○ https://docs.google.com/spreadsheets/d/1F9aQfaNuH3c6Wg3EVwDwbaet28BUIdUvyf1i6TW0lv8/edit#gid=0
61
Links

61. ● Theory of Operations
○ https://docs.google.com/document/d/1dHuip1QgGM-Jskde5y2eMqmoUGNA9r9hDGsRY7w6d1Q/edit
● Emissions and Fuel Efficiency
○ https://docs.google.com/spreadsheets/d/1jP_jdJ3sziOsTPAV5oynLPkkyucf3oJXzxk_eeX97mc/edit#gid=0
● Cooling and Lubrication
○ https://docs.google.com/spreadsheets/d/1lue-VBOdPQOK7iepezoYVlwi5MUEjrPtXmrfUPIG-DQ/edit#gid=218397271
● Labor Cost
○ https://www.bls.gov/iag/tgs/iagauto.htm
62
Links