Design and Development of High Performance Diesel Engine Block for High Power Density Engines with an Integrated Approach 2010-01-1973

This work is a part of program on “Development of High Power Density DI, Diesel Engine to Meet US EPA - Tier III Emission norms for off highway and Genset application purpose. This is a 4 Cylinder, TCIC engine delivering 165 Hp @ 2500 rpm. BMEP at max torque comes to be 18 bar giving max cylinder firing pressure of 160 bar.

Engine block is a most vital component which has to serve various functions all together. Also design of block for such a high BMEP levels, demands to give a different design strategy required for development of High Performance Engines. In order to reduce overall production cost, several constraints are imposed on design of new block. Design of block is carried out within several design, assembly and manufacturing constraints such as maintain a specific cylinder centre distance, integral oil cooler in the engine block, re-location of camshaft and FIE positions, incorporation of various accessories viz. steering pump, Air Compressor etc. These constraints brought a need to develop a complete new engine block from concept. Having cylinder head layout and power train components as base, the engine block is built around it.

This paper portrays the complete perspective and design methodology used during design process. Integration of classical methods, FE analysis and experimental work for validation is presented. FE analysis is mainly carried out for understanding bore deformation, stress flow path and cylinder head gasket pressure distribution. Modal analysis technique on simulation basis is used for fixing ribbing pattern to get desired sound pressure levels in a frequency domain. Tools like DFMA, DFMEA are used along with value engineering concepts to make an efficient and cost effective product development process.