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In-cylinder fluid dynamics enhance performance and emission characteristics in internal combustion (IC) engines. Techniques such as helical ports, valve shrouding, masking, and modifications to piston profiles or vanes in ports are employed to achieve the desired in-cylinder flows in these engines. However, due to space constraints, modifications to the cylinder head are typically minimal. The literature suggests that introducing baffles into the combustion chamber of an IC engine can enhance in-cylinder flows, air-fuel mixing, and, subsequently, stratification. Studies have indicated that the height of the baffles plays a significant role in determining the level of improvement in in-cylinder flow and air-fuel mixing. Therefore, this study employs Computational fluid dynamics (CFD) analysis to investigate the impact of baffle height on in-cylinder flow and air-fuel mixing in a four-stroke, four-valve, spray-guided gasoline direct injection (GDI) engine.

The increasing demand for higher specific power, fuel economy, Operating Costs as well as meeting global emission norms have become the driving factors of today’s product development in the automotive market. Substitution of high-density materials and more precise adjustment of material parameters help in significant weight decrease, but it is accompanied by undesirable cost increase and manufacturing complexity. This becomes a challenge for every automotive engineer to balance the above parameters to make a highly competitive design. This work is a part of the Design and Development of 2.2 L, 4 Cylinder TCIC Diesel Engine for a whole new vehicle platform, concentrated on automotive passenger car operation. This paper explains the selection of a suitable cylinder head gasket technology for a lightweight engine that acts as a sealing interface between the cylinder block and cylinder head.

This paper discusses design and optimization process for the integration of exhaust manifold with turbocharger for a 3 cylinder diesel engine, simulation activities (CAE and CFD), and validation of manifold while upgrading to meet current BS6 emissions. Exhaust after-treatment system needs to be upgraded from a simple DOC (Diesel Oxidation Catalyst) to a complex DOC+sDPF (Selective catalytic reduction coated on Diesel Particulate Filter) to meet the BS6 emission norms for this engine. To avoid thermal losses and achieve a faster light-off temperature in the catalyst, the exhaust after-treatment (EATS) system needs to be placed close to the engine - exactly at the outlet of the turbocharger. This has given to challenges in packaging the EATS. The turbocharger in case of BS4 is placed near the 2nd cylinder of the engine, but this position will not allow placing the BS6 EATS.

Reducing the mechanical friction of internal combustion engines could play a major role in improving the brake specific fuel consumption (BSFC). Hence, it is important to reduce the friction at every component and sub-system level. In the present work, the oil pump friction of a 1.5 liter 4-cylinder diesel engine is optimized by reducing the oil pump displacement volume by 20%. This could be achieved by adopting an optimized oil supply concept which could reduce the oil leakage through the main bearings and connecting rod bearings. A 1-dimensional oil flow simulation was carried out to predict the oil flow distribution across the engine for different speeds. The results indicate that the oil leakage through the main bearings and connecting rod bearings contribute to ~25% of the total oil flow requirement of the engine. In a conventional oil supply concept, the big-end bearing of each connecting rod is connected to the adjacent main bearing through an internal oil hole.

Flow variations from one cycle to the next significantly influence the mixture formation and combustion processes in engines. Therefore, it is important to understand the fluid motion and its cycle-to-cycle variations (CCVs) inside the engine cylinder. Researchers have generally investigated the cycle-to-cycle flow variations in moderate- to large-sized engines. In the present work, we have performed the flow measurement and analysis in a small spark-ignition engine. Experiments are conducted in an optically accessible, single-cylinder, port-fuel-injection engine with displacement volume of 110 cm3 at different throttle openings (i.e. 50% and WOT) using particle image velocimetry. Images are captured at different crank angle positions during both intake and compression strokes over a tumble measurement plane, bisecting the intake and exhaust valves and passing through the cylinder axis.

The ever-increasing customer expectations put a lot of pressure on car manufacturers to constantly reduce the noise, vibration, and harshness (NVH) levels. This paper presents the holistic approach used to achieve best-in-class NVH levels in a modern high-power density 1.5 lit 4-cylinder diesel engine. In order to define the NVH targets for the engine, global benchmark engines were analysed with similar cubic capacity, power density, number of cylinders and charging system. Moreover, a benchmark diesel engine (considered as best-in-class in NVH) was measured in a semi-anechoic chamber to define the engine-level NVH targets of the new engine. The architecture selection and design of all the critical components were done giving due consideration to NVH behaviour while keeping a check on the weight and cost.

Stringent emission regulations on one hand and increasing demand for better fuel economy along with lower noise levels on the other hand require adoption of advanced common-rail direct-injection technologies in diesel engines. In the present work, a small 0.9-l, naturally aspirated, two-cylinder, common-rail direct-injection diesel engine is used for the analysis of combustion noise at different engine operating conditions. Experiments are conducted at different loads and engine speeds, incorporating both single and multiple (i.e. pilot and main) injections along with different injection timings. In the case of multiple injections, the influence of pilot injection quantity is also evaluated on the combustion noise while maintaining the same load. In-cylinder pressure was recorded with the resolution of 0.1 crank angle degree, and it was used for the quantitative analysis of noise assessed from the resulting cylinder pressure spectra, and sound pressure level.

In a direct-injection (DI) engine, charge motion and mixture preparation are among the most important factors deciding the performance and emissions. This work was focused on studying the effect of injector positioning on fuel-air mixture preparation and fuel impingement on in-cylinder surfaces during the homogeneous mode of operation in a naturally aspirated, small bore, 0.2 l, light-duty, air-cooled, four-stroke, spark-ignition engine modified to operate under the DI mode. A commercially available, six-hole, solenoid-operated injector was used. Two injector locations were identified based on the availability of the space on the cylinder head. One location yielded the spray-guided (SG) configuration, with one of the spray plumes targeted towards the spark plug. In the second location, the spray plumes were targeted towards the piston top in a wall-guided (WG) configuration so as to minimize the impingement of fuel on the liner.

In this work methanol was port injected while diesel was injected using a common rail system in a single cylinder non-road CI engine. Experiments were conducted with single (SPI) and double (DPI - pilot and main) injection of the directly injected diesel at 75% load and at a constant speed of 1500 rpm. The effects of methanol to diesel energy share (MDES) and injection scheduling on combustion stability, efficiency and emissions were evaluated. Initially, in the SPI mode, the methanol to diesel Energy Share (MDES) was varied, while the injection timing of diesel was always fixed for best brake thermal efficiency (BTE). Increase in the MDES resulted in a reduction in NOx and smoke emissions because of the high latent heat of vaporization of methanol and the oxygen available. Enhanced premixed combustion led to a raise in brake thermal efficiency (BTE). Coefficient of variation of IMEP, peak pressure and BTE were deteriorated which limited the usable MDES to 43%.

In automotive door engineering, fitting the side door glass surface from styling into the cylinder or torus is the basic requirement. Optimization is required to do this, which requires a solver which could be efficacious for best surface fitting. This paper propounds a methodology which could be used for fitting a side door glass surface from styling into the cylinder or torus. The method will significantly help in developing the required surface and can successfully eliminate the cumbersome manual calibrations. The mathematical model mentioned is a novel approach based on “Particle Swarm Optimization” (“PSO” will be used to represent in the paper) towards surface optimization technique. VB script is used to make it applicable in CATIA but could be easily applied in any other programming language like python, java etc. Usually the surface fitting problems deals with the initial guess of the required surface and then its further optimization.

Predicting the brake performance and characteristics is a crucial task in the vehicle development activity. Performance prediction is a challenge because of the involvement of various parts in the brake assembly like booster, master cylinder, calipers, disc and drum brakes. Determination of these characteristics through vehicle level tests requires a lot of time and money. This performance prediction is achieved by theoretical calculations involving vehicle dynamics. The final output must satisfy the regulations. This project involves the creation of a standalone application using MATLAB to predict the various brake performances such as: booster characteristics, adhesion curves, deceleration and pedal effort curves, behavior of brakes during brake and booster failed conditions and braking force diagrams based on the given user inputs. Previously, MS Excel and an application developed in the TK Solver environment was used to predict the brake performance curves.

In the present work, a tuned gas dynamics based blow by model was used for prediction of thermodynamic state variables till start of combustion in a high speed diesel engine. The burn rate fraction was determined from experimental pressure trace using Rassweiller-Withrow method. Furthermore, suitable single and double Wiebe parameters, consistent with the experimental combustion behavior were determined statistically. The comparison with experimental heat release and burn rate fraction confirmed the unsuitability of single Wiebe function for diesel combustion. A stochastic zero-dimensional thermodynamic model was used to predict pressure traces for various load/fueling conditions. The results exhibited a sub-15% error margin between predicted and experimental pressure traces across all crank angles and fuelling rates. Finally, the model constants are proposed as a function of non-dimensional fuelling rate.

Effective control of exhaust emissions from modern diesel engines requires the use of aftertreatment systems. Elevated aftertreatment component temperatures are required for engine-out emissions reductions to acceptable tailpipe limits. Maintaining elevated aftertreatment components temperatures is particularly problematic during prolonged low speed, low load operation of the engine (i.e. idle, creep, stop and go traffic), on account of low engine-outlet temperatures during these operating conditions. Conventional techniques to achieve elevated aftertreatment component temperatures include delayed fuel injections and over-squeezing the turbocharger, both of which result in a significant fuel consumption penalty. Cylinder deactivation (CDA) has been studied as a candidate strategy to maintain favorable aftertreatment temperatures, in a fuel efficient manner, via reduced airflow through the engine.

Today, homogenous charge compression ignition (HCCI) engines are becoming very popular because of their potential to reduce soot and nitric oxides (NOx) emissions simultaneously. But, their performance and emission characteristics are very much dependent upon fuel injection strategy and parameters. However, they also have many challenges viz., improper combustion phasing, high rate of pressure rise and narrow operating range. Therefore, addressing them is very essential before making them a commercial success. This study focuses on evaluating the effect of fuel injection strategy and parameters on the performance and emission characteristics of a HCCI engine by computational fluid dynamics (CFD) analysis. In this study, a four-stroke engine operating in the HCCI mode is considered and the CFD analysis is carried out by using the CONVERGE.

NVH is becoming one of the major factor for customer selection of vehicle along with parameters like fuel economy and drivability. One of the major NVH challenges is to have a vehicle with aggressive drivability and at the same time with acceptable noise and vibration levels. This paper focuses on the compact utility vehicle where the howling noise is occurring at higher rpm of the engine. The vehicle is powered by three cylinder turbocharged diesel engine. The noise levels were higher above 2500 rpm due to the presence of structural resonance. Operational deflection shapes (ODS) and Transfer path analysis (TPA) analysis was done on entire vehicle and powertrain to find out the major reason for howling noise at higher engine rpm. It is observed that the major contribution for noise at higher rpm is due to modal coupling between powertrain, half shaft and vehicle sub frame.

Serious efforts have been put in space to focus on lowering the fuel consumption and CO2 discharge to the environment from Automotive Diesel Engines. Though more focus is put on material up gradation approach on weight perspective, it is accompanied by undesirable cost increase and manufacturing complexity. As a part of development of a single cylinder engine for a light commercial vehicle application, a unique approach of integrated split type crankcase design is designed and developed. This design have addressed all the key factors on Weight, Cost and Manufacturing perspectives. The split type crankcase configuration, particularly middle-split configuration, integrates the oil sump, front cover and flywheel housing in a single unit beneficial from the point of view of reducing engine weight and thus reducing the manufacturing costs. This crankcase is also excellent from the serviceability point of view.

In this study, 3D air-flow-field evolution in a single cylinder optical research engine was determined using tomographic particle imaging velocimetry (TPIV) at different engine speeds. Two directional projections of captured flow-field were pre-processed to reconstruct the 3D flow-field by using the MART (multiplicative algebraic reconstruction technique) algorithm. Ensemble average flow pattern was used to investigate the air-flow behavior inside the combustion chamber during the intake and compression strokes of an engine cycle. In-cylinder air-flow characteristics were significantly affected by the engine speed. Experimental results showed that high velocities generated during the first half of the intake stroke dissipated in later stages of the intake stroke. In-cylinder flow visualization indicated that large part of flow energy dissipated during the intake stroke and energy dissipation was the maximum near the end of the intake stroke.

Diesel particulates are mainly composed of elemental carbon (EC) and organic carbon (OC) with traces of metals, sulfates and ash content. Organic fraction of the particulate are considered responsible for its carcinogenic effects. Diesel oxidation catalyst (DOC) is an important after-treatment device for reduction of organic fraction of particulates. In this study, two non-noble metal based DOCs (with different configurations) were prepared and evaluated for their performance. Lanthanum based perovskite (LaMnO3) catalyst was used for the preparation of DOCs. One of the DOC was coated with support material ceria (5%, w/w), while the other was coated without any support material. Prepared DOCs were retrofitted in a four cylinder water cooled diesel engine. Various emission parameters such as particulate mass, particle number-size distribution, regulated and unregulated emissions, EC/OC etc., were measured and compared with the raw exhaust gas emissions from the prepared DOCs.

The present work is concerned with the computation of in-cylinder flow field of a naturally aspirated single cylinder diesel engine using 3D CFD methods. Flow in the intake port and across the valve and subsequent in-cylinder flow is simulated for different valve lift conditions. The in-cylinder flow field is thoroughly analyzed for the flow asymmetry, number of vortices and swirling motion. Predicted velocity field at 20 mm and 92 mm sections from the cylinder head is compared with those obtained from the experiments. Doppler global velocimetry has been used to measure the velocity vectors at the two earlier identified sections for vale lifts of 2, 4, 6, 8 and 9 mm. The development of flow in the longitudinal and transverse directions is studied from the measured velocity vectors. The evolution of the global in-cylinder flow structure with respect to the lift is presented.

Fuel-air mixing is the main parameter, which affects formation of NOx and PM during CI combustion. Hence better understanding of air-flow characteristics inside the combustion chamber of a diesel engine became very important. In this study, in-cylinder air-flow characteristics of four-valve diesel engine were investigated using time-resolved high-speed tomographic Particle Imaging Velocimetry (PIV). For visualization of air-flow pattern, fine graphite particles were used for flow seeding. To investigate the effect of different operating parameters, experiments were performed at different engine speeds (1200 rpm and 1500 rpm), intake air temperatures (room temperature and 50°C) and intake port configurations (swirl port, tangential port and combined port). Intake air temperature was controlled by a closed loop temperature controller and intake ports were deactivated by using a customized aluminum gasket.