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The Automotive Market in the United States is moving in the direction of more Light Trucks and fewer Small Cars. The customers for these vehicles have not changed, only their purchase decisions. Cummins has studied the requirements of this emerging market. Design and development of an engine system that will meet these customer needs has started. The engine system is a difficult one, since the combined requirements of a very fuel-efficient commercial diesel, and the performance and sociability requirements of a gasoline engine are needed. Results of early testing are presented which show that the diesel is possibly a good solution.

AISI-4140H steel has been used as articulated piston crown material in heavy-duty engines. With the driving force for reducing manufacturing cost, microalloyed steel (MAS) was identified as a low-cost material to replace 4140H steel. In order to determine the feasibility of using MAS to replace 4140H steel, a test program was initiated to fully evaluate the material properties of MAS and to compare them to those of the baseline 4140H steel. The physical and mechanical properties of both materials from room temperature to 550°C were evaluated. The effect of long term thermal exposure on the material properties was also studied. Some engine tests were also conducted to evaluate the performance of the articulated pistons made with both materials. The inherently lower strength of MAS as compared to 4140H steel, requires a total re-design of the piston for the utilization of MAS as a low-cost replacement material for 4140H steel.

Design and development of the Cummins Signature 600, a new high horsepower dual overhead cam truck diesel engine, has been completed. The Signature 600 product system includes an all-new engine, controls, fuel system, and business information systems. During product definition, particular emphasis was placed on target markets, customer input to design, engineering and manufacturing processes, concurrent engineering and extensive mechanical and thermal analyses. Cummins Signature 600 fulfills the needs of Owner-Operator and Premium Fleet linehaul trucking businesses.

A new method for detecting the low power conditions on electronically-controlled diesel engines used in on-road vehicles has been developed. The advantage of this method is that it uses readily available diagnostic tools and engine installed sensors with no necessity for a dynamometer test. Without removing the engine, it gives an estimate of the real engine power which is accurate to 5%.

Inter-ring gas pressure and piston ring motion are considered important for the control of oil consumption, particulate emissions, and reduced friction. For this reason, inter-ring gas pressure was measured on a diesel engine. Two different ring pack configurations were tested (positive and negative twist second rings). A significant difference in measured inter-ring pressure was observed. The measurements were compared to the predictions of a cylinder kit model with favorable results. Predictions showed that the observed difference between measured inter-ring pressures is caused by a significant difference in ring motion. The reasons for these differences are explained in this paper.

The paper presents the latest research results on the piston ring free shape. A new free shape measurement method with optical gauging was developed. Three numerical models to compute the contact force distribution of piston ring were developed using finite element analysis (FEA). These numerical methods have been compared each other, and validated with the experimental results of ring deformation in a ring gage. The contact force distribution of a piston ring at working condition was also studied. It consists of the ring thermal boundary conditions (RTBC) validation, 3-D FEA thermal analysis and thermal contact force computation based on validated wire-cable element model. The RTBC for heavy duty diesel engine has been validated for the first time using a CUMMINS L10 engine test. Three different free shapes have been tested. The wear band measurements of tested rings all show tremendous improvements over the standard top ring.

Measurements have been made to determine the effect of piston crown surface properties on combustion. Back-to-back engine tests were conducted to compare surface modified pistons to a production piston. Each modified piston was found to prolong combustion duration. Porous coatings and a non porous, roughened piston were observed to increase fuel consumption. Increase in fuel consumption was determined to be the result of increased heat release duration. The data show surface roughness alone affects the duration of heat release. The shift in magnitude of the centroid of heat release was similar to the shift observed in insulated engine experiments.

Recent engine design trends towards increasing power, reducing weight, advancing of injection timing and increasing of injection rate and pressure could result in increased incidence of liner pitting. Liner pitting due to coolant cavitation is a complex function of many engine design parameters and operating conditions as described in reference [1]*. Traditionally, liner cavitation problems were not detected early in the development cycle. Traditional liner vibration and coolant pressure measurements in conjunction with a numerous amount of expensive engine endurance tests were then needed to resolve cavitation problems. A method newly developed by the author and described in reference [2] for cavitation intensity measurements was successfully utilized to map out engine operating condition and develop limit curves. This method could also be applied in a non intrusive fashion.

Cavitation corrosion is a very complex phenomenon that is governed by a formidable amount of factors and parameters. The phenomenon is a multi-disciplinary one which involves several aspects of physical sciences and engineering. This process is a slow progressive phenomenon with its detrimental effects being felt after severe damage has already occurred. A real time detection method for the severity of fluid cavitation and bubble collapse is described. The results are correlated to dynamic instantaneous pressure fluctuation measurements. The method is fast, reliable, and less restrictive of the sensing location. It has been tested and verified through a specially designed cavitation test rig and instrumentation setup. The method can be used for cavitation studies on ultrasonic bench rig tests and for cavitation measurements on running engines. The method was used to shed some light on characteristic cavitation differences between water and glycol which is used in engine coolants.

Previous work on the cooling jackets of the Cummins L10 engine revealed flow separation, and low coolant velocities in several critical regions of the cylinder head. The current study involved the use of detailed cooling jacket temperature measurements, and finite element heat transfer analysis to attempt the identification of regions of pure convection, nucleate boiling, and film boiling. Although difficult to detect with certainty, both the measurements and analysis pointed strongly to the presence of nucleate boiling in several regions. Little or no evidence of film boiling was seen, even under very high operating loads. It was thus concluded that the regions of seemingly inadequate coolant flow remained quite effective in controlling cylinder head temperatures. The Cummins L10 upon which this study has focused is an in-line six cylinder, four-stroke direct injection diesel engine, with a displacement of 10 liters.

Testing procedures to evaluate new coolant pump seal face materials and new coolant pump seal designs were evaluated. Rig testing of materials and seals followed by engine dynamometer testing enabled changes in the seal materials or design to be validated prior to field testing and limited production. These procedures were used to test and implement a coolant pump seal face material change to silicon carbide versus carbon. The change resulted in higher reliability for the coolant pump seal and reduced warranty cost for the engine.

Detailed thermal analysis was conducted on several advanced cylinder head, liner, and piston concepts, for low heat rejection diesel engines. The analysis was used to define an optimized engine configuration. Results pointed to the strategic use of oil cooling and insulation in the cylinder head, an oil cooled cylinder liner, and an insulated piston, with separate insulation behind the compression rings. Such a configuration reduced in-cylinder heat rejection by 30 percent, while durability would be expected to be maintained or improved from today's production levels.

The influence of bowl offset on motored mean flow and turbulence in a direct injection diesel engine has been examined with the aid of a multi-dimensional flow code. Results are presented for three piston geometries. The bowl geometry of each piston was the same, while the offset between the bowl and the cylinder axis was varied from 0.0 to 9.6% of the bore. The swirl ratio at intake valve closing was also varied from 2.60 to 4.27. It was found that the angular momentum of the air at TDC was decreased by less than 8% when the bowl was offset. Nevertheless, the mean (squish and swirl) flows were strongly affected by the offset. In addition, the distribution of turbulent kinetic energy (predicted by the k-e model) was modified. Moderate increases (10% or less) in mass averaged turbulence intensity at TDC with offset were observed. However, the TDC turbulent diffusivity was changed less than 3% due to a slight decrease in turbulent length scale with increasing offset.

A number of turbocharging systems have been proposed for improving the drivability of diesel engines for heavy duty trucks. The systems studied here included resonant intake, wastegate, and variable geometry turbocharging. By imposing a fixed power, torque rise, and engine speed range, it was possible to evaluate the fuel economy impact of each approach. First Law and Second Law balances are included to illustrate the differences in the systems. It was found that variable geometry turbocharging provided the best fuel economy.

Lucas Industries Noise Centre has introduced a combustion noise meter which is designed to predict the contribution of the combustion process to overall diesel engine noise. The performance of the meter is evaluated using Cummins B series engines in naturally-aspirated and turbocharged form. Combustion noise levels predicted by the meter are compared to levels determined using traditional techniques. The effects of several engine operating parameters on combustion noise are investigated under both steady state and accelerating conditions. The meter reliably predicts changes in combustion noise levels, and is a useful tool for performance development engineers. Combustion noise is shown to be related to the maximum rate of pressure rise at the onset of combustion, but combustion noise is not reliably related to maximum cylinder pressures.

Diesel engine manufacturers have traditionally done most engine noise development work under steady: state operating conditions. However, truck driveby noise tests are acceleration tests, and engines exhibit different noise behavior under accelerating conditions. Acceleration noise can be affected by engine performance parameters which may have no influence on steady state noise levels. In this study, a test cell simulation of the truck driveby procedure has been developed and evaluated. Test cell simulation and truck driveby results are compared for a naturally-aspirated and a turbocharged engine. This simulation procedure has been shown to predict reliably results measured in vehicles. As a result, the simulation can be used to evaluate engine modifications during the development process without requiring a vehicle installation.

Cummins Engine Company is developing a low heat rejection 450 kW engine under contract for the US Army Tank & Automotive Command. This paper discusses progress made toward achieving the program goals of 6.6 kcal/kW-min brake specific heat rejection and 200 g/kW-hr brake specific fuel consumption. Methodology for measuring heat rejection on a low heat rejection engine is presented. Design improvements of the base engine are discussed along with their effect on improving fuel consumption. Performance test data is assessed in terms of the first law energy balance and cooling load distribution. The heat rejection data provides insights on the performance of insulating components and two cooling system designs. Diesel cycle simulations are compared to the test data and are used to predict the effect of ceramic insulation on engine heat rejection.

RAPID CORROSIVE WEAR OF COPPER ALLOYS caused by a friction reducing additive was encountered in field tests of experimental lubricants. This oil soluble molybdenum, sulphur, and phosphorous containing additive subsequently was used in several commercial heavy duty diesel lubricants although the additive manufacturer did not recommend it for such applications. Numerous engine failures occurred due to the aggressiveness of this additive toward copper. Standard laboratory engine test methods or standard bench test methods did not predict the severe field problem. A new laboratory engine test method has been shown to duplicate the field failures. Bench test methods to duplicate the field failures are discussed. The mode of failure is shown and described.

Joint development of the adiabatic engine by Cummins Engine Company and the U. S. Army began with a feasibility analysis ten years ago. The effort was initially driven by the expectation of substantial performance improvement, a reduction in cooling system size, and several additional benefits. Program emphasis turned quickly to experimentation with the goal of demonstrating the feasibility of the adiabatic engine in working hardware. Several significant achievements were realized as have been reported earlier. Further development of the adiabatic engine is expected to be more evolutionary, paced by available technology in the areas of materials and tribology. Analysis capability necessary for insulated engine development has been found to be inadequate. Additional effort has gone into the development and validation of insulated engine analysis tools, both for cycle simulation and structural modeling.

Some results of a systematic study of the effects of fuel and chamber gas properties on the transient evaporating spray mixing process are presented. The study uses an existing two-dimensional stochastic thick spray model. The results show that the combustion process in typical heavy duty, quiescent, DI diesel engines can be mixing limited rather than vaporization limited. In addition, the results show that the mixing process of a transient evaporating spray is characterized by the combined effects of fuel evaporation and its turbulent mixing with the surrounding air. In general, increasing the evaporation rate alone does not necessarily increase the fuel-air mixing rate. Furthermore, two dimensionless parameters have been used to quantify the relative effects of fuel and chamber gas properties on the transient spray evaporation process. Finally, through detailed comparisons between spray and gas jet results, the transient evaporating spray mixing process is better understood.