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(Course Overview)
Class Structure
Course Goals
Contribute to future developments in automotive technology through design of engine components
Course Topics
1. Introduction Design philosophy, an overview of engine design, Applications of Computer aided Design (CAD) and Finite Element Analysis (FEA) in Engine Design. History of automobile engines, Classification of engines, Principle of engine operation (SI & CI). Engine support mountings. (8hrs) (2Q) 2. Design of Cylinders Block and Cylinder liners, details of water jacket, dry and wet liners, Design of Cylinder head, Cylinder arrangement. (4hrs) (1Q). 3. Design of Piston Assembly, piston rings, piston pin - stress analysis, methods of manufacture, heat treatment, piston ring selection, limits of fit for pins. (4hrs) (1Q). 4. Design of Connecting rod assembly (small end- Big end- Shank) (4hrs) (1Q). 5. Design of Crank shaft, firing order, balancing and torsional vibration analysis, vibration dampers. (4hrs) (1Q). 6. Design of Flywheel; Camshaft - drives of cams, materials, Types. (4hrs) (1Q). 7. Design of Valve and valve mechanism, types of valve operating mechanisms, valve springs, guides, push rods, rocker arms, tappets, valve timing diagrams. (4hrs) (1Q)
REFERENCE BOOKS
1. Shigley J.E. Mechanical Engineering Design McGraw Hill, 2003. 2. Garrett T.K., Newton K. and Steeds W. The Motor Vehicle Reed Educational and Professional Publishing, 2001. 3. Kolchin A., Demidov V. Design of Automotive Engines Mir Publishers, 1984. 4. Willard W. Pulkrabek Engineering Fundamentals of the Internal Combustion Engine Prentice Hall, 1997. 5. Richard D. Atkins An Introduction to Engine Testing and Development SAE International, USA, 2009.
Lecture (1)
1. 2. 3. Design philosophy What is Design? How to design? Design Process Design process For Automotive Applications of CAD/CAM/CAE Finite Element Analysis (FEA) in Engine Design.
Design Philosophy
What is Engineering? Engineering is not usually considered a science. Science is about discovering the natural. Engineering is creating the artificial. Engineers apply the principles of science and mathematics to develop solutions to problems. The main philosophy behind all of the engineering and engineering design activities is to serve the people, society and mankind. This is why the engineering design is defined as an activity to satisfy a need. A need is real only if it is defined and identified by a human.
What is Design?
Design is a interaction between what we want to achieve and how we want to satisfy them.
Design is a process of converting information that characterize the needs and requirements for a product into knowledge about the product.
Engineering design is creative at the beginning, and significance of creativity decreases towards the end of the process, Engineering design is iterative during the whole design process.
Scientific Principles and Technology Design Process Evaluation
Design Information
Feedback
Work
Product
How to Design?
What does the customer want?
Looks, safety, price, feeling, speed, Design, Efficiency, Features, Performance, Handling, Size, Extra service, Capacity, User reviews, Quality
How to Design?
What do you want to achieve and how?
Give people a vision about your car The car specifications
Engine, weight, efficiency, acceleration, topspeed, capacity
How to Design?
car classification:
Supermini Small family car Large family car Executive car Roadster Small Off-Roader Large Off-Roader
Explore
Research what others have done. Discover what materials are available.
Design
Use your knowledge and creativity to come up with many solutions. Choose one idea and draw or make a model of it.
Create
Make your solution.
Try It Out
Test your solution.
Make It Better
Evaluate how the solution worked and think of how to improve your design.
Design review
Review and redesign focuses on achieving the performance, producibility, reliability and cost (As compared to what) objectives. Competitive benchmarking Reverse Engineering of competitors products Early bird gets the profit
CAD/CAM/CAE
Computer-Aided Design (CAD) is the technology concerned with the use of computer systems to assist in the creation, modification, analysis, and optimization of a Design. Computer-Aided Manufacturing (CAM) is the technology concerned with the use of computer systems to plan, manage, and control manufacturing operations. Computer-Aided Engineering (CAE) is the technology concerned with the use of computer systems to analyze CAD geometry, allowing the designer to simulate and study how the product will behave.
Pro/ENGINEER
One of the CAD/CAM/CAE industrys leading suppliers of software tools from Parametric Technology Corp. (PTC) A pioneer of the new feature-based, parametrically driven design paradigm in late 1980s, now industrial standard. A system used to automate the development of a mechanical product from its conceptual design through production. Offering integrated software technologies to reduce time to market, improve engineering process, and optimize product quality. One of the fastest growing companies in the mechanical design automation market Improved users interface in recent release.
Unigraphics- NX
A full spectrum design modeling, analysis, simulation, and manufacturing CAD/CAE/CAM software from Unigraphics Solutions One of the older and well-established CAD/CAE system. A software of choice for a wide variety of applications, especially in automotive and aerospace product development.
CATIA
A process-centric CAD/CAM software solution marketed exclusively by IBM and developed by Dassault Systems A system used to design and manufacture many complex 3D products. Today, 7 out of every 10 airplanes and 4 out of every 10 cars are designed using CATIA-CADAM Solutions, making it the de facto standard for these markets. A software of choice for a wide variety of applications ranging from consumer goods and machinery to plant design and shipbuilding. 300,000 CATIA users worldwide, nearly half in English language markets
Applications in FEA
Questions?