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MECHANICAL DESIGN OF INTERNAL COMBUSTION ENGINE

Article · October 2015

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 MECHANICAL DESIGN OF INTERNAL COMBUSTION ENGINE
F.Y.Wong

ABSTRACT

Internal combustion engine plays an important role in most of the field from energy production to generate
electricity in night market until the production of power for moving a vehicle. Designing an internal combustion
engine requires a number of consideration. In this study, the considerations stated are the connecting rod, fluid
motion in the engine, air fuel ratio of the engine, engine speed, multiaxial loading effect, cooling system, gas
mixer, heat treatment on the cylinder block, heat conduction between engine body and other components and
crankshaft. A number of softwares been used to assist the performance simulation and durability prediction. The
engine speed of 2500 rpm produced the highest torque while the engine speed of 3000 rpm produced the highest
in-cylinder temperature and pressure. All these parameters are need to design the internal combustion engine.
Keywords: GT-SUITE, engine speed, internal combustion engine

INTRODUCTION
For high energy production, the energy is produced by combustion process such as the Moderate and Intense
Low oxygen Dilution (MILD) combustion [1]. However, in small scale energy production such as night market of
moving a vehicle only need moderate energy production. Thus, here only discuss on normal internal combustion
engine. There is a lot of consideration need to make when design an internal combustion engine. First of all,
connecting rods is one of the important parts to be considered. Connecting rods are highly dynamically loaded
components used for power transmission in combustion engines where it is subjected to many millions of repetitive
cyclic loadings [2]. Shaari [2] has developed a simple piston rod by using SolidWorks software while Muhamad [3]
developed a piston in Catia and performed finite element analysis. Besides, internal combustion engine design also
need a clear understanding of the fluid motion and dynamics processes of the fluid in engine [4] .To obtain a good
performance engine, the air fuel ratio also very important. The effect of air-fuel ratio on the performance of four
cylinder hydrogen fueled direct injection internal combustion engine was researched [5]. The engine speed also
need to be considered during the design of the internal combustion engine [6-11]. On top of that, when designing an
internal combustion engine, it must be noted that the fatigue failure under multiaxial loading condition is very
common [12]. Besides, when design a real system subjected to the environment loadings, both the fatigue strength
and dynamic properties of the external loads are important [13]. The internal combustion engine also need to
consider the cooling system. For example, the cooling system that uses nanofluids has higher thermal conductivity
about 10 to 15% compared to using base fluid [14]. Thus, the cooling system should be designed to be able to
function with nanofluid if the internal combustion engine to be run at a long period of time. Gas mixer is a device
used to determine the amount of natural gas and air before entering the engine where the size of intake air passage,
the number and size of the radial holes and tubes for every type of engines is different [15]. On top of that, the
roughness of a surface plays an important role in determining how a real object will interact with its environment
[16, 17]
. This is significant in setting the roughness of the cylinder wall and the internal parts surfaces. The type of
heat treatment to be used for the cylinder block also important in determining the service life [18]. The thermal
effect also affect the vehicle engine. The behaviors of heat conduction between the engine body and other
components can be determined by using Finite Element Method (FEM) [19]. The material used for the engine
connecting part such as the air duct, the hosing and the fluid hose also very important. Ruzaimi [20] stated that
composites have excellent corrosion resistance and good resistance to temperature extremes and wear. Crankshaft
is a very crucial part in internal combustion engine especially in term of the natural frequencies and mode shape
[21]
.

DISCUSSION
The element size of 1.25mm and pressure of 7.0 MPa was applied to the cylinder head surface while 0.3Mpa
of pressure is applied to the bolt-hole surface to analyses the cylinder head with material AA6061-T91 as the
highest life compared to other material [22]. The engine speed from 2000-5000 rpm is used to in GT-SUITE
simulation and the heat transfer rate increases when the engine speed increases [6, 7, 10]. Muhamad [8] stated that the
maximum in-cylinder temperature and pressure is at the engine speed of 3000 rpm with the value of 650 K and
5.8 MPa. For hydrogen fueled engine, the maximum torque occur at the engine speed of 2500 rpm [9]. On the other
hand, the BMEP decreases when the AFR and engine speed increases [5]. Internal combustion engine components
like the cylinder block can be analyses for its durability by using finite element method to estimate the fatigue life
[3]
.
 CONCLUSION
Internal combustion engine design requires a lots of consideration. However, with the help from FE simulation
software such as Algor, Ansys Fluent and GT-SUITE, the designing process of internal combustion engine has
been much simpler. The performance parameter can be simulated before the engine been fabricated thus saving
both cost and time. In conclusion, the design of internal combustion engine has been simplify with the help of
various engineering simulation tools.

REFERENCES

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