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3. Design Analysis and Development of Aluminium Cylinder Block with Slip-Fit Cylinder Liners for High Performance New Generation Passenger Car Diesel Engine

Author

AMIT G. KAWATKAR, Vikraman Vellandi, Bharani Dharan R, and S Loganathan

Abstract

The global automotive industry is growing rapidly in recent years and the market competition has increased drastically. There is a high demand for passenger car segment vehicles with high torque delivery and fuel economy for a pleasant drivability experience. Also, to meet the more stringent emission requirements, automakers are trying very hard to reduce the overall vehicle gross weight. In lowering both fuel consumption and CO2 generation, serious efforts have been made to reduce the overall engine weight. An engine cylinder block is generally considered to be the heaviest part within a complete engine and block alone accounts for 3-4% of the total weight of the average vehicle, thus playing a key role in weight reduction consideration. Aluminum casting alloys as a substitute for the traditional cast iron can mean a reduction in engine block weight between 40 and 55% [9], even if the lower strength of aluminum compared to grey cast iron is considered. Thus, designers of aluminum engine blocks are constantly striving to design better and lighter blocks in order to improve and enhance the efficiency of automobile engines.This work is a part of design and development of 2.2 L, 4-cylinder turbocharged intercooler (TCIC) diesel engine for a complete new monocoque vehicle platform, focused on automotive passenger car application with high operating in cylinder combustion pressures around 190 bar. The paper portrays the effective system approach essential for selecting aluminum as the choice of material, selection of alloy composition, casting process, heat treatment and key design criteria. The ongoing substitution of cast iron in engine blocks by aluminum casting alloys also requires the design and development of a new “tribological” system. Selection of cost-effective cylinder liner system and the drawbacks of this heterogeneous concept such as the lack of metallic bonding with the surrounding cast aluminum alloy and higher bore distortion are addressed during design and development. Statistical database, quality tools like design failure mode and effect analysis (DFMEA), design for manufacture and assembly (DFMA) etc., classical design methods, finite element analysis (FEA), advanced computer-aided engineering (CAE) and computational fluid dynamics (CFD) simulation tools have helped in materializing this concept into production. Experimental validation of the design is carried out as a part of design verification and validation. And results are elaborated to show the effectiveness of integrated approach used for the development program.

Published
2023
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10. Development and Influence of Setting Process Variables in Single Point Incremental Sheet Metal Forming of AA 8011 Using Complex Proportional Assessment and ANOVA

Author

K. Saravanan, Durai Kumaran, Ganesh Babu Loganathan, Sundar Singh Sivam Sundarlingam Paramasivam, R. Rajendran, and Harish Sriram

Subjects
business.industry, visual_art, Process (computing), visual_art.visual_art_medium, Development (differential geometry), Structural engineering, Single point, business, Sheet metal, Mathematics
Published
2019
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16. A Study on Mechanical Properties and Multi Response Optimization of Process Parameters for Showing Signs of Improvement Product Quality in Drilling AlSi7Cu4 Utilizing GRA in Taguchi Method

Author

R. Rajendran, K. Saravanan, Durai Kumaran, Ganesh Babu Loganathan, and Sundar Singh Sivam Sundarlingam Paramasivam

Subjects
Taguchi methods, Multi response, business.industry, Computer science, Product (mathematics), media_common.quotation_subject, Process (computing), Drilling, Quality (business), Process engineering, business, media_common
Published
2019
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18. Function of Taguchi Grey Relation Analysis for Influencing the Process Parameter for Getting Better Product Quality and Minimize the Industrial Pollution by Coolants in Turning of Ti-6Al-4V Alloy

Author

K. Saravanan, Durai Kumaran, Ganesh Babu Loganathan, R. Rajendran, Harish Sriram, and Sundar Singh Sivam Sundarlingam Paramasivam

Subjects
Relation (database), business.industry, media_common.quotation_subject, Process variable, Function (mathematics), Industrial pollution, Coolant, Taguchi methods, Environmental science, Quality (business), Product (category theory), Process engineering, business, media_common
Published
2019
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19. Investigation of Setting Input Process Parameters for Getting Better Product Quality in Machining of AM60 Magnesium Alloy - TOPSIS and ANOVA Approach

Author

R. Rajendran, K. Saravanan, Ganesh Babu Loganathan, Harish Sriram, Durai Kumaran, and Sundar Singh Sivam Sundarlingam Paramasivam

Subjects
Machining, business.industry, Product (mathematics), media_common.quotation_subject, Process (computing), Quality (business), TOPSIS, Magnesium alloy, Process engineering, business, media_common, Mathematics
Published
2019
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21. Modal Model Correlation of Commercial Vehicle Frame

Author

Karalmarx Rajamohan, Aditya Palsule, Ekambaram Loganathan, Saisankaranarayana Kuppili, and Sivasankaran Sadasivam

Subjects
Correlation, Modal, Computer science, business.industry, Commercial vehicle, Frame (networking), Structural engineering, business
Published
2019
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