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Technical Paper

CAE Approach to Reduce Engine Mount Rumble Noise

2022-10-05
2022-28-0080
With the increasing competition in the automotive industry, customer experience & satisfaction is at the top of every organization's goals. The customers have evolved & NVH refinement has become the parameter for their decision making in buying a car. The major source of rumble noise in a vehicle is the induced vibrations due to combustion forces in an IC engine. These vibrations are then transferred to the vehicle body through engine mounts. Hence engine mounts play a key role in defining the NVH & the ride performance of any vehicle. However, it is infeasible to validate every mount design through the physical test as it will be both costly & time-consuming. But multiple design iterations can be verified by the CAE approach quite effectively. This paper focuses on the novel CAE approach to evaluate the mount vibrations due to engine dynamics. The process involves preparing a FEA model of the complete Powertrain system.
Technical Paper

In-Cylinder Charge Motion Development for Gasoline Engine

2021-09-22
2021-26-0062
In the recent years world-wide automotive manufacturers are continuously working in the research of the suiTable technical solutions to meet upcoming stringent carbon dioxide (CO2) emission targets, defined by regulatory authorities across the world. Many technologies have been already developed, or are currently under study, to meet the legislated targets. To meet this objective, the generation of tumble at intake stroke and the conservation of turbulence intensity at the end of compression stroke inside the combustion chamber have a significant role in the contribution towards accelerating the burning rate, increasing the thermal efficiency and reducing the cyclic variability [1]. Tumble generation is mainly attained by intake port design, and conservation is achieved during the end of compression stroke 690 ~ 720 crank angles (CA) which is strictly affected by the piston bowl geometry and pentroof combustion chamber shape.
Technical Paper

Intake and Exhaust Ports Design for Tumble and Mass Flow Rate Improvements in Gasoline Engine

2019-04-02
2019-01-0763
In recent years, world-wide automotive manufacturers have been continuously working in the research of suitable technical solutions to meet upcoming stringent carbon dioxide (CO2) emission targets, as defined by international regulatory authorities. Many technologies have been already developed, or are currently under study, to meet legislated targets. In-line with above objective, the enhancement of turbulence intensity inside the combustion chamber has a significant importance which contributes to accelerating the burning rate, to increase the thermal efficiency and to reduce the cyclic variability [9]. Turbulence generation is mainly achieved during the intake stroke which is strictly affected by the intake port geometry, orientation and to certain extends by combustion chamber masking. Conservation of turbulence intensity till 700~720 crank angle (CA) is achieved by optimized shape of combustion chamber geometry and piston bowl shape.
Technical Paper

Integrated Exhaust Manifold Cylinder Head Design Methodology for RDE in Gasoline Engine Application

2020-04-14
2020-01-0169
In recent years, worldwide automotive manufacturers have been continuously working in the research of suitable technical solutions to meet upcoming stringent Real Driving Emission (RDE) and Corporate Average Fuel Economy (CAFÉ) targets, as set by international regulatory authorities. Many technologies have been already developed, or are currently under study by automotive manufacturer for gasoline engines, to meet legislated targets. In-line with the above objective, there are many technologies available in the market to expand lambda 1 (λ=1) region by reducing fuel enrichment at high load-high revolutions per minute (RPM) by reducing exhaust gas temperature (for catalyst protection) for RDE regulation [1]. Integrated Exhaust Manifold (IEM) is the key technology for the Internal Combustion (IC) for the subjected matter as catalyst durability protection is done by reducing exhaust gas temperatures instead of injecting excess fuel for cooling catalyst.
Technical Paper

Noise Problem Resolution and Sound Quality Improvement of Valve Timing Belt in 4 Cylinders PFI Gasoline Engine

2019-04-02
2019-01-0783
IC Engine Timing belt is a major noise prone area and it takes time during development to achieve acceptable NVH characteristics. In an existing engine under series production noise problem observed due to excitation of timing belt span by crank timing sprocket tooth. From vehicle perspective noise was heard in vehicle cabin at around idling RPM and a second peak observed around twice the initial RPM. This paper includes a methodology for use of computer based analytical simulation methods to predict timing belt dynamic behavior and NVH characteristics. Along with development of computer based multi body dynamic model for timing belt, validation of simulation model with actual testing was done and after correlation of testing and simulated results countermeasure were finalized based on iterations in multi body simulation model.
Technical Paper

Valve Opening and Closing Event Finalization for Cost Effective Valve Train of Gasoline Engine

2019-04-02
2019-01-1191
With more stringent emission norm coming in future, add more pressure on IC engine to improve fuel efficiency for survival in next few decades. In gasoline SI (spark ignition) engine, valve events have major influence on fuel economy, performance and exhaust emissions. Optimization of valve event demands for extensive simulation and testing to achieve balance between conflicting requirement of low end torque, maximum power output, part load fuel consumption and emission performance. Balance between these requirements will become more critical when designing low cost valve train without VVT (Variable valve timing) to reduce overall cost of engine. Higher CR (Compression ratio) is an important low cost measure to achieve higher thermal efficiency but creates issue of knocking thereby limiting low speed high load performance. The effective CR reduction by means of late intake valve closing (LIVC) is one way to achieve higher expansion ratio while keeping high geometric CR.
Technical Paper

Valve-Train Dynamics Calculation, Model Simulation and Actual Testing for Friction Reduction to Improve FE

2022-10-05
2022-28-0074
Valve train system is one major contributor to engine overall friction loss and is approximately 30% of total engine friction at lower speed and approximately 20 % at higher engine speed. Valve spring loads (preload and working) are proportional to friction loss of valve train. To optimizing the valve spring design main requirement is valve train perform it function safely at maximum engine cutoff RPM with minimum preload and working load. Robustness and frictional power loss are contradicting requirement, robustness demand high stiffness spring for better valve jump and bounce performance with dynamic safe valve spring design, on the other hand low frictional power loss demand for use of low stiffness spring. To optimize the valve spring stiffness for meeting both the requirement we need accurate prediction of valve spring in design stage and good correlation with testing data to reduce the number of iterations.
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