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Summary
Summary
The mechanical engineering curriculum in most universities includes at least one elective course on the subject of reciprocating piston engines. The majority of these courses today emphasize the application of thermodynamics to engine ef?ciency, performance, combustion, and emissions. There are several very good textbooks that support education in these aspects of engine development. However, in most companies engaged in engine development there are far more engineers working in the areas of design and mechanical development. University studies should include opportunities that prepare engineers desiring to work in these aspects of engine development as well. My colleagues and I have undertaken the development of a series of graduate courses in engine design and mechanical development. In doing so it becomes quickly apparent that no suitable te- book exists in support of such courses. This book was written in the hopes of beginning to address the need for an engineering-based introductory text in engine design and mechanical development. It is of necessity an overview. Its focus is limited to reciprocating-piston internal-combustion engines - both diesel and spa- ignition engines. Emphasis is speci?cally on automobile engines, although much of the discussion applies to larger and smaller engines as well. A further intent of this book is to provide a concise reference volume on engine design and mechanical development processes for engineers serving the engine industry. It is intended to provide basic information and most of the chapters include recent references to guide more in-depth study.
Table of Contents
1 The internal-combustion engine: an introduction |
1.1 Heat engines and internal combustion engines |
1.2 The reciprocating piston engine |
1.3 Engine operating cycles |
1.4 Supercharging and turbocharging |
1.5 Production engine examples |
1.6 Basic measures |
1.7 Recommendations for further reading |
2 Engine maps, customers, and markets |
2.1 Engine mapping |
2.2 Automobile, motorcycle, and light-truck applications |
2.3 Heavy-truck applications |
2.4 Off-highway applications |
2.5 Recommendations for further reading |
3 Engine validation and durability |
3.1 Developing a durable engine |
3.2 Fatigue analysis |
3.3 Friction, lubrication, and wear |
3.4 Further wear and failure mechanisms |
3.5 Recommendations for further reading |
4 Engine development process |
5 Determining displacement |
5.1 The engine as an air pump |
5.2 Estimating displacement |
5.3 Engine uprating and critical dimensions |
6 Engine configuration and balance |
6.1 Determining the number and layout of cylinders |
6.2 Vibration fundamentals reviewed |
6.3 Rotating forces and dynamic couples |
6.4 Reciprocating forces |
6.5 Balancing the forces in multicylinder engines |
6.6 Gas pressure forces |
Bore-to-stroke ratio optimization |
6.8 Recommendation for further reading |
7 Cylinder block and head materials and manufacturing |
7.1 Block and head materials |
7.2 Block and head casting processes |
7.3 A look at block and head casting |
7.4 Block and head machining processes |
7.5 Recommendations for further reading |
8 Block layout and design decisions |
8.1 Initial block layout |
8.2 Crankcase design decisions |
8.3 Cylinder design decisions |
8.4 Camshaft placement decisions |
9 Cylinder head layout design |
9.1 Initial head layout |
9.2 Combustion chamber design decisions |
9.3 Valve, port, and manifold design |
9.4 Head casting layout |
9.5 Cylinder head cooling |
9.6 Oil deck design |
10 Block and head development |
10.1 Durability validation |
10.2 High-cycle loading and the cylinder block |
10.3 Modal analysis and noise |
10.4 Low-cycle mechanical loads |
10.5 Block and head mating and the head gasket |
10.6 Cylinder head loading |
10.7 Thermal loads and analysis |
10.8 Recommendations for further reading |
11 Engine bearing design |
11.1 Hydrodynamic bearing operation |
11.2 Split-bearing design and lubrication |
11.3 Bearing loads |
11.4 Classical bearing sizing |
11.5 Dynamic bearing sizing |
11.6 Bearing material selection |
11.7 Bearing system validation |
11.8 Recommendations for further reading |
12 Engine lubrication |
12.1 Engine lubricants |
12.2 Lubrication circuits and systems |
12.3 Oil pumps |
12.4 Oil pans, sumps, and windage |
12.5 Filtration and cooling |
12.6 Lubrication system performance analysis |
12.7 Recommendations for further reading |
13 Engine cooling13.1 Engine cooling circuits |
13.2 Cooling-jacket optimization |
13.3 Water pump design |
13.4 The cooling system |
13.5 Venting and deaeration |
13.6 Recommendations for further reading |
14 Gaskets and seals |
14.1 Gasketed-joint fundamentals |
14.2 Engine cover design |
14.3 Clamping load parameters |
14.4 Bolt torque and sealing load control |
14.5 Shaft seal design |
14.6 Recommendations for further reading |
15 Pistons and rings |
15.1 Piston construction |
15.2 Piston crown and ring land development |
15.3 Piston pin boss development |
15.4 Piston skirt development |
15.5 Piston ring construction |
15.6 Dynamic operation of the piston rings |
15.7 Cylinder wall machining |
15.8 Recommendations for further reading |
16 Crankshafts and connecting rods |
16.1 Crankshaft construction and manufacturing |
16.2 Crankshaft fillet development |
16.3 Torsional vibration and dampeners |
16.4 Crankshaft nose development |
16.5 Crankshaft flange and flywheel development |
16.6 Connecting-rod construction and development |
16.7 Recommendations for further reading |
17 Camshafts and the valve train |
17.1 Valve train overview |
17.2 Dynamic system evaluation and cam lobe development |
17.3 Camshaft durability |
17.4 Valve train development |
17.5 Drive system development |
17.6 Future trends in valve train design |
17.7 Recommendations for further reading |
Subject index |
Contents |