CAD System for Cylinder Head Used in High-Speed and Heavy-Power Diesel Engine

A CAD system for the cylinder head is developed. As an integrated system, it can be used in 3 D modeling, 2 D drawing and finite element structural analysis and optimization. The key problems in system designing are introduced. Design flow, system structure and how to solve the key problems are focused on. All of those would form the base for more research on how to use the modern CAD technology to design complex engine parts. And it is also a good example of using the modern CAD technology.

Excavator Energy-saving Efficiency Based on Diesel Engine Cylinder Deactivation Technology

The hydraulic excavator energy-saving research mainly embodies the following three measures： to improve the performance of diesel engine and hydraulic component, to improve the hydraulic system, and to improve the power matching of diesel-hydraulic system-actuator. Although the above measures have certain energy-saving effect, but because the hydraulic excavator load changes frequently and fluctuates dramatically, so the diesel engine often works in high-speed and light load condition, and the fuel consumption is higher. Therefore, in order to improve the economy of diesel engine in light load, and reduce the fuel consumption of hydraulic excavator, energy management concept is proposed based on diesel engine cylinder deactivation technology. By comparing the universal characteristic under diesel normal and deactivated cylinder condition, the mechanism that fuel consumption can be reduced significantly by adopting cylinder deactivation technology under part of loads condition can be clarified. The simulation models for hydraulic system and diesel engine are established by using AMESim software, and fuel combustion consumption by using cylinder-deactivation-technology is studied through digital simulation approach. In this way, the zone of cylinder deactivation is specified. The testing system for the excavator with this technology is set up based on simulated results, and the results show that the diesel engine can still work at high efficiency with part of loads after adopting this technology; fuel consumption is dropped down to 11% and 13% under economic and heavy-load mode respectively under the condition of driving requirements. The research provides references to the energy-saving study of the hydraulic excavators.

Compacted graphite iron-A material solution for modern diesel engine cylinder blocks and heads

The demands for improved fuel economy,performance and emissions continue to pose challenges for engine designers and the materials they choose. This is particularly true for modern diesel engines,where the primary path to achieving improved engine performance and emissions is to increase the Peak Firing Pressure in the combustion chamber. The resulting increase in thermal and mechanical loading has required a change from conventional grey cast iron to Compacted Graphite Iron (CGI) in order to satisfy durability requirements without increasing the size or the weight of the engines. With at least 75% higher tensile strength,45% higher stiffness and approximately double the fatigue strength of conventional grey cast iron,CGI satisfies durability requirements and also provides the dimensional stability required to meet emissions legislation throughout the life of the engine. Currently,there are no CGI diesel engines running on the roads in North America. This is set to change considerably as new commercial vehicle and pick-up SUV diesel engines are launched with CGI cylinder blocks in 2008 and 2009. These initial programs will provide over 2 million CGI diesel engines when ramped to mature volume,potentially accounting for 10%-15% of the North American passenger vehicle fleet within the next four years.

Analysis of Oil Consumption in Cylinder of Diesel Engine for Optimization of Piston Rings

The performance and particulate emission of a diesel engine are affected by the consumption of lubricating oil. Most studies on oil consumption mechanism of the cylinder have been done by using the experimental method, however they are very costly. Therefore, it is very necessary to study oil consumption mechanism of the cylinder and obtain the accurate results by the calculation method. Firstly, four main modes of lubricating oil consumption in cylinder are analyzed and then the oil consumption rate under common working conditions are calculated for the four modes based on an engine. Then, the factors that affect the lubricating oil consumption such as working conditions, the second ring closed gap, the elastic force of the piston rings are also investigated for the four modes. The calculation results show that most of the lubricating oil is consumed by evaporation on the liner surface. Besides, there are three other findings： （1） The oil evaporation from the liner is determined by the working condition of an engine; （2） The increase of the ring closed gap reduces the oil blow through the top ring end gap but increases blow-by; （3） With the increase of the elastic force of the ring, both the left oil film thickness and the oil throw-off at the top ring decrease. The oil scraping of the piston top edge is consequently reduced while the friction loss between the rings and the liner increases. A neural network prediction model of the lubricating oil consumption in cylinder is established based on the BP neural network theory, and then the model is trained and validated. The main piston rings parameters which affect the oil consumption are optimized by using the BP neural network prediction model and the prediction accuracy of this BP neural network is within 8%, which is acceptable for normal engineering applications. The oil consumption is also measured experimentally. The relative errors of the calculated and experimental values are less than 10%, verifying the validity of the simulation results. Applying the established simulation model and the validated BP network model is able to generate numerical results with sufficient accuracy, which significantly reduces experimental work and provides guidance for the optimal design of the piston rings diesel engines.

Optimizing the Exhaust System of Marine Diesel Engines to Improve Low-speed Performances and Cylinder Working Conditions

Proper design of exhaust systems in marine high-power turbocharged diesel engines can contribute to improve the low-speed performance of these engines and make the working conditions of the cylinders more uniform.Here a high-power marine 16-cylinder V-type turbocharged diesel engine is simulated using the GT-Power software.The results reveal the differences induced by different exhaust system structures,such as an 8-cylinder-inpipe exhaust system with single/double superchargers and a 4-cylinder-in-pipe exhaust system with a single supercharger.After a comparative analysis,the 8-cylinder type with double superchargers is determined to be the optimal solution,and the structure of the exhaust system is further optimized.The simulations show that the optimized maximum exhaust temperature difference among cylinders is reduced by 66%.Finally,the simulation results and the optimized performance of the designed exhaust system are verified through experiments.

Optimization Study on a Single-cylinder Compressed Air Engine

The current research of compressed air engine（CAE） mainly focused on simulations and system integrations. However, energy efficiency and output torque of the CAE is limited, which restricts its application and popularization. In this paper, the working principles of CAE are briefly introduced. To set a foundation for the study on the optimization of the CAE, the basic mathematical model of working processes is set up. A pressure-compensated valve which can reduce the inertia force of the valve is proposed. To verify the mathematical model, the prototype with the newly designed pressure-compensated intake valve is built and the experiment is carried out, simulation and experimental results of the CAE are conducted, and pressures inside the cylinder and output torque of the CAE are obtained. Orthogonal design and grey relation analysis are utilized to optimize structural parameters. The experimental and optimized results show that, first of all, pressure inside the cylinder has the same changing tendency in both simulation curve and experimental curve. Secondly, the highest average output torque is obtained at the highest intake pressure and the lowest rotate speed. Thirdly, the optimization of the single-cylinder CAE can improve the working efficiency from an original 21.95% to 50.1%, an overall increase of 28.15%, and the average output torque increases also increases from 22.047 5 N · m to 22.439 N · m. This research designs a single-cylinder CAE with pressure-compensated intake valve, and proposes a structural parameters design method which improves the single-cylinder CAE performance.

Combustion condition of diesel engine by cylinder pressure oriented to control

According to demand of electronic control and combustion process measurement in diesel engine, cylinder pressure difference method was introduced to study combustion condition. Combustion parameters such as intensity, phase and heat-releasing rate were used to describe combustion condition. Combustion commencement angle, maximal burst pressure and its angle, and bar-center point in pressure difference curve were selected as character parameters to demonstrate overall combustion charater. The 4100 diesel engine was simulated with GT-POWER software, relation of pressure character index with injection timing and injection quantity was resolved by simulation and measurement of pressure data, and varying trend of each pressure character index with diesel engine emission NOx based on experimental data was analyzed. The results indicated that pressure character index had direct relationship with injection fuel timing and engine output parameter, and pressure character index could be used as combustion condition flag.

Finite Element Analysis of Fretting Behavior Between an Engine Cylinder Block and a Main Bearing Cap

The finite element analysis of the fretting behavior between a cylinder block and a main bearing cap is presented. The stresses, relative fretting slip, frettin g friction work parameter W and crack initiation location parameter Gon the fretting contact surface of the cylinder block are obtained and analyzed. It shows that the fretting fatigue problem of the cylinder block can be quantitat ively explained by WorG. The effects of pretightening force, friction factor and material combination of the cylinder block and the main bearing cap are studied. The computational results indicate that the fretting fatigue of the cylinder block can be allayed by increasing the elastic modulus of the cylinder block, but not by changing the other two factors.

Cylinder Pressure Prediction of An HCCI Engine Using Deep Learning

Engine tests are both costly and time consuming in developing a new internal combustion engine.Therefore,it is of great importance to predict engine characteristics with high accuracy using artificial intelligence.Thus,it is possible to reduce engine testing costs and speed up the engine development process.Deep Learning is an effective artificial intelligence method that shows high performance in many research areas through its ability to learn high-level hidden features in data samples.The present paper describes a method to predict the cylinder pressure of a Homogeneous Charge Compression Ignition(HCCI)engine for various excess air coefficients by using Deep Neural Network,which is one of the Deep Learning methods and is based on the Artificial Neural Network(ANN).The Deep Learning results were compared with the ANN and experimental results.The results show that the difference between experimental and the Deep Neural Network(DNN)results were less than 1%.The best results were obtained by Deep Learning method.The cylinder pressure was predicted with a maximum accuracy of 97.83%of the experimental value by using ANN.On the other hand,the accuracy value was increased up to 99.84%using DNN.These results show that the DNN method can be used effectively to predict cylinder pressures of internal combustion engines.

Heavy Duty Natural Gas Single Cylinder Research Engine Installation, Commissioning, and Baseline Testing

Natural Gas (NG) Internal Combustion Engines (ICE) are a promising alternative to diesel engines for on-road heavy-duty applications to reduce greenhouse gas and harmful pollutant emissions. NG engines have not been widely adopted due to the lower thermal efficiency compared with diesel engine counterparts. To develop the base knowledge required to reach the desired efficiency, a Single Cylinder Engine (SCE) is the most effective platform to acquire reliable and repeatable data. A SCE test cell was developed using a Cummins 15-liter six-cylinder heavy-duty engine block modified to fire one cylinder (2.5-liter displacement). A Woodward Large Engine Control Module (LECM) is integrated to permit implementation of real-time advanced combustion control. Intake and exhaust characteristics, fuel composition, and exhaust gas recirculated substitution rate (EGR) are fully adjustable. A high-speed data acquisition system acquires in-cylinder, intake, and exhaust pressure for combustion analysis. The baseline testing shows reliable and consistent results for engine thermal efficiency, indicated mean effective pressure (IMEP), and coefficient of variance of the IMEP over a wide range of operating conditions while achieving effective control of all engine control and operation variables. This test cell will be used to conduct a research program to develop new and innovative control algorithms and CFD optimized combustion chamber designs, allowing ultra-high efficiency and low emissions for NG ICE heavy-duty on-road applications.

Study on Oil Film Model of Electronic Fuel Injection Motorcycle Engine Cylinder

Based on the principles of heat transfer,an oil film model in the engine cylinder was established.Under the condition of cold state,the influence of factors such as engine fuel injection,fuel drop point,cylinder inner wall temperature,and inlet fluid on the oil film is comprehensively considered to establish an oil film quality prediction model.Based on the measurement of the compensation oil quantity in the transition conditions,the variation of the oil film during the transition is analyzed.The experimental results show that the velocity of the air-flow in the intake port and the temperature and pressure on the wall of the intake port are the main factors affecting the oil film in the cylinder.Based on the abovementioned experimental and theoretical studies,an oil film distribution model for each cycle of the transition condition was established based on the engine inlet oil film model.The experimental measurement curve and model prediction curve for the fuel compensation per cycle in the transition condition from 10%load to 30%load.The model established can be in good agreement with the experimental results and meet the fuel compensation trend in the transition condition.While realizing the fuel compensation for the transient conditions,this work is definitely helpful to achieve accurate control of the air-fuel ratio.

AStudyofProbabilisticBalancingQualityofaMulti┐CylinderEngine

This paper presents a method which uses a random model and adopts the Monte Carlo simulation method to analyze the randomness of the actual balancing quality of a multi cylinder engine.The uncertainties considered in the analysis are the reciprocating mass,rotating mass,connecting rod length,crank radius and crank phase angle of individual crank mechanisms.According to the calculated results with respect to inertia forces and couples,the regularities of probabilistic balancing quality are discussed in detail,and some views are offered.

Performance Characteristics of Single Cylinder Diesel Engine under Different Operating Conditions

Recently, it is predicted that the fossil fuels will be sufficient for a few decades at the present extraction rates. So, the performance studies of the internal combustion engines play an important role to achieve the best operating point at different weather temperatures. In the present study, the effects of the inlet air temperatures on the engine performance characteristics were studied at different cooling loads. Several experiments were carried out on a single cylinder diesel engine （SCDI）. The performance characteristics of SCDI included： brake power, specific fuel consumption, brake thermal efficiency and exhaust emissions （carbon dioxide, CO2, carbon monoxide CO, and hydrocarbon HC）. The findings show that the inlet air temperature and cooling conditions have appreciable effect on the performance characteristics of the SCDI especially at low cooling rate. It can be concluded that the high cooling rate leads to the enhancement in the brake thermal efficiency, the b.s.f.c, and the emitted COz, CO, and HC. On the other hand the high cooling rate leads to the decrease in the volumetric efficiency. So, a compromising between the inlet air temperature and the cooling rate should be recommended for the engine best performance.

Erratum to:“An Approximate Method for Calculating the Fluid Force and Response of A Circular Cylinder at Lock-in” [China Ocean Engineering,22(3),2008,371-384]

Because of my carelessness,Eq.（1）in the paper "An approximate method for calculating the fluid force and response of a circular cylinder at lock-in"(China Ocean Engineering,22（3）,2008,pp.373)should be f’-1.0/U’-5.0=f’;-1.0/5.75f’;-5.0,not f’=U’/5.75. My apology is hereby given.

A New Method for Computing Radiation Heat Flow of In-Cylinder Soot of Diesel Engines

A concise formula for computing radiation heat flow of in-cylinder soot is presented, based on the assumptions that in-cylinder heat transfer of diesel engines is a quasi-equilibrium process and in-cylinder soot particles are spherical. That in this formula there consist neither constants needing adjustments nor variables related to engine types or operating conditions makes it universal and easy to use. Also it can be seen from the formula that radiation heat transfer is proportional to the quotient of in-cylinder soot mass over the average radius of primary particles. Besides, with the help of different algorithms it can be used for predicting cylinders＇ global as well as local radiation heat flows. As a demonstrative application on its global facet, a three-dimension simulation study about the soot-radiation-related heat flow in the combustion chamber of a diesel engine is carried out. Results show that the range of the soot-radiation-related heat flow computed by this formula agrees well with other researcher＇s earlier theoretic reasoning and experimental measurements.

Numerical Simulation of Emission Characteristics for Single-Cylinder Diesel Engine

First, the geometry model and the calculation mesh of single-cylinder direct injection diesel engine are built, using ESE module of the 3D simulation software AVL FIRE v2014 [1]. Then, by setting appropriate boundary condition, initial condition and calculating step length, and selecting spray, the burning emissions on model and on the basis of adjusting the parameters, a scientific and reasonable simulation platform is built. Emission characteristics of single-cylinder diesel engines in oxygen-enriched, oxygen-enriched + EGR (inlet adding CO2), and separately using EGR would be studied. It is concluded that EGR synergy oxygen-enriched combustion is beneficial to exhaust treatment and 21% CO2 + 23% oxygen content is the optimal matching to improve diesel engine exhaust emissions.

基于Pro/Engineer的薄壁套加工变形仿真与验证实验

利用Pro/Engineer-Mechanica软件,针对薄壁套车削时受夹紧力和切削力影响的变形进行了有限元分析。通过对不同装夹方式和切削参数加工的模拟分析与对比,优化了工艺方案。切削试验结果表明:仿真模拟数据与实际测量数据具有较高的一致性。因此,这种分析方法可作为薄壁套类零件工艺方案制定的一种定量分析手段,改变了凭经验或通过试切调整确定工件装夹方式和切削参数的传统方法。

Mathematical modeling and analysis of thermodynamic processes in a twin-rotor piston engine

In order to study the major performance indicators of the twin-rotor piston engine(TRPE), Matlab/simulink was used to simulate the mathematical models of its thermodynamic processes. With consideration of the characteristics of the working processes in the TRPE, corresponding differential equations were established and then simplified by period features of the TRPE. Finally, the major boundary conditions were figured out. The changing trends of mass, pressure and temperature of working fuel in the working chamber during a complete engine cycle were presented. The simulation results are consistent with the trends of an actual working cycle in the TRPE, which indicates that the method of simulation is feasible. As the pressure in the working chamber is calculated, all the performance parameters of the TRPE can be obtained. The major performance indicators, such as the indicated mean effective pressure, power to weight ratio and the volume power, are also acquired. Compared with three different types of conventional engines, the TRPE has a bigger utilization ratio of cylinder volume, a higher power to weight ratio and a more compact structure. This indicates that TRPE is superior to conventional engines.

Influence of Internal Combustion Engine Parameters on Gas Leakage through the Piston Rings Area

In this work, the influence of internal combustion engine parameters (cylinder-piston clearance, piston head height, the first segment position, gap of the first piston ring and gap of the second piston ring, piston rings’ axial clearance, intake valve debit coefficient) gas leakage from the combustion chamber through the piston rings’ area was investigated. This influence was studied by making an initial forming operation over gas leakage in the analyzed area.

Numerical Investigation of the Effects of Rate-Shaped Main Injection on Combustion and Emission in an OPOC Two-Stroke Diesel Engine

The effects of various split injection strategies on the opposed-piston opposed-cylinder(OPOC)diesel engine combustion and emission characteristics have been studied numerically using AVL-Fire CFD tools.The five rate-shaped main injections were used in split injection strategies.The results show that ignition delay from a rectangular injection rate is the shortest.Maximum pressure of the trapezoid injection rate is the largest.And the NOx emission of the rectangular injection rate is the largest.Meanwhile,the soot emission of the trapezoid injection rate is the least among the five injection rates.