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This work is a part of program on “Development of High Power Density DI, Diesel Engine to Meet US EPA - Tier III Emission norms for off highway and Genset application purpose. This is a 4 Cylinder, TCIC engine delivering 165 Hp @ 2500 rpm. BMEP at max torque comes to be 18 bar giving max cylinder firing pressure of 160 bar. Engine block is a most vital component which has to serve various functions all together. Also design of block for such a high BMEP levels, demands to give a different design strategy required for development of High Performance Engines. In order to reduce overall production cost, several constraints are imposed on design of new block. Design of block is carried out within several design, assembly and manufacturing constraints such as maintain a specific cylinder centre distance, integral oil cooler in the engine block, re-location of camshaft and FIE positions, incorporation of various accessories viz. steering pump, Air Compressor etc.

Engine Block, being the most vital component requires serving various functions all together. Design of block for higher power densities and BMEP levels, needs a complete change in the design strategy compared to the existing design approach. Also, balancing other factors like engine cooling efficiency, blow by targets, weight, and manufacturing cost becomes a huge challenge upfront in designing an engine block. Design of block is carried out within several design, assembly and manufacturing constraints such as to maintain a specific cylinder centre distance, Block NVH, Better cooling jacket, controlled bore deformation and incorporation of various accessories viz. CRDI System, Fuel Filter, Oil Filters, Fuel Injection System, steering pump, Air Compressor etc. This paper portrays the complete perspective and design methodology used during design process. Integration of classical methods, and FE analysis is presented.

The increasing demand for higher specific power and the need for weight reduction and decrease of emissions have become the driving factors of product development in the automotive market today. 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. One of the approaches to optimize the design is through the process of integration which involves integrating the functional elements of two or more components into one and achieving a reduction in weight and cost without impacting required performance. This paper explains a similar approach followed as a part of the Design and Development of 1.5 L, 3 Cylinder CRDI Diesel Engine for a new vehicle platform, developed for automotive passenger car application.

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.

Closed crankcase ventilation prevent harmful gases from entering atmosphere thereby reducing hydrocarbon emissions. Ventilation system usually carries blowby gases along with oil mist generated from Engine to Air intake system. Major sources of blowby occurs from leak in combustion chamber through piston rings, leakage from turbocharger shafts & leakage from valve guides. Oil mist carried by these blowby gases gets separated using separation media before passing to Air Intake. Fleece separation media has high separation efficiency with lower pressure loss for oil aerosol particles having size above 10 microns. However, efficiency of fleece media drops drastically if size of aerosol particles are below 10 microns. Aerosol mist of lower particle size (>10 microns) generally forms due to flash boiling on piston under crown area and from shafts of turbo charger due to high speeds combined with elevated temperatures. High power density diesel engine is taken for our study.