See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/311613953

Design selection of eco-material inlet adapter for hybrid six-stroke engine

Conference Paper · August 2014

CITATIONS READS

0 443

4 authors, including:

Zarina Amat Jafar Faizil Wasbari

4 PUBLICATIONS   1 CITATION   
Technical University of Malaysia Malacca
20 PUBLICATIONS   61 CITATIONS   
SEE PROFILE
SEE PROFILE

Rosli Abu Bakar

Universiti Malaysia Pahang
163 PUBLICATIONS   877 CITATIONS   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

new energy for vehicle View project

Compressed View project

All content following this page was uploaded by Faizil Wasbari on 14 December 2016.

The user has requested enhancement of the downloaded file.

DESIGN SELECTION OF ECO-MATERIAL INLET ADAPTER FOR HYBRID
SIX-STROKE ENGINE

Z. A. Jafar1*, F. Wasbari1, 2, R. A. Bakar1 and L. M. Gan1

1
Faculty of Mechanical Engineering, Universiti Malaysia Pahang,
26600 Pekan, Pahang, Malaysia
*
Email: zarinajafar@gmail.com
Phone: +60142815937; Fax: +609424622
2
Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah
Jaya, 76100 Durian Tunggal, Melaka, Malaysia

ABSTRACT

Materials play a crucial role during the design stage. Improper selection will lead to the
increasing of cost, wastage and the worst are product failure. This paper attempts to find
suitable eco-material to fabricate an inlet adapter for the hybrid six-stroke engine. The
hybrid six-stroke engine is used to optimize the efficiency of the engine and minimize
the fuel consumption to reduce the impact of the environment. The approach of 39
engineering parameters and TRIZ contraction method is used to define the problem and
to select the critical criteria. Cambridge Engineering Selector (CES) software and
material indices are used as tools in the selection of a suitable material. The Eco Audit
simulation is used as a tool to find a comparison value of energy and carbon footprint
for selected materials. Based on CES result, there are four (4) group of materials passed
the measures. One from each ferrous group and three polymer composite materials were
selected and simulated in the Eco Audit. Finally, Epoxy SMC found to be the best
material to be used in this environmental project because it saved 97% energy and
produced 97% less carbon footprint compared to reference material, cast iron. In
conclusion, CES and Eco Audit method are one of the most practical ways of selecting
environmental material of inlet adapter for hybrid six-stroke engine. It also can be
adapted for most of the automotive components for lightweight material towards fuel
consumption reduction and environmental purpose.

Keywords: Eco-material; green design; green material; eco-design

INTRODUCTION

Nowadays, every automotive manufacturer contends each other towards producing a

better technology of the engine, better and design. They put their efforts towards the
improvement of efficiency and saving on fuel consumption. The latest commercialize
technology in the automotive industry is hybrid electric which combining electric
propulsion with internal combustion engine (ICE) (Fuhs, 2009). The technology is
sufficient enough to increase the vehicle efficiency, however; it still suffers un-solving
issues such as low capacity of battery power and battery charging time is too long. One
of the reliable solutions to improve the efficiency of the vehicle is by introducing
pneumatic hybrid engine which combine compressed air and internal combustion
engine (Huang, Hu, Yu, & Sung, 2013). Others suggested introducing the energy
recovering concept (Huang, Tzeng, Ma, & Chang, 2005). In order to apply these
alternatives author decided to modify the current internal combustion engine to become
six-stroke hybrid engines. The engine that needs to modify is oppose-type engine. The
engine chose because of the orientation of the cylinders and the advantages of the boxer
engine compare to the vertical type. Camshaft and intake adapter need to modify due to
the differences in operational and functional. The type of material should be ascertained
first before committing to fabrication. CES and Eco Audit will be used to determine the
type of suitable material based on the impact to the environment.

MATERIALS AND DESIGN

The inlet adapter works to ensure the filling of engine cylinder with a suitable mass of
fresh air. The closest component that has similar functions with an inlet adapter is the
intake manifold. Since both of these components have similar functions, then the
material selection shall refer to the manifold. Cast iron, stainless steel and carbon steel
are the common materials for the intake manifold. However, lately, many companies
put their efforts on lightweight material. Based on intake manifold manufacturer,
Dorman Products Incorporation, focus is given to the lightweight material such as
aluminum, plastic, composites and alloy in manifold production. These are due to the
weight reduction target for the engine itself. The company added that the under hood
temperature varied from 99C to 119C, material with lower temperature resistance
would fail (Dorman Products Inc., 2014). Magneti Marelli company claimed that their
product was used thermoplastic material with high thermal and mechanical resistance
(Magneti Marelli S.p.A., 2014).
The oppose-type engine originally 4-stroke type with 4 cylinders. After
modification, it will operate at 4-stroke with two cylinders (cylinder 1 and 2) which in
internal combustion engine (ICE) mode and the other two cylinders (cylinder 3 and 4)
will be modified to be 2-stroke. Cylinder number 3 runs as energy recovery and number
4 as a compressor. Once energy saving required, the ICE will stop running, and the air
compressed tank is in full storage condition will be supplied in both 2-stroke cylinders
which acted as a piston propulsion unit as illustrated in Figure 1.

Figure 1. Configuration for each cylinder

2
 The current intake manifold needs to modify. The modifications include closing
the current intake port, creating the new intake port for each cylinder, design new inlet
adapter, align with the new port and assemble the connector from the intake port to the
adapter. The old air intake inlet no longer used and has sealed. The air will enter the
manifold and then go to the new intake adapter for cylinder number 1 and 2 only. Then
through the connector, the air will be directed to the cylinder's intake for the combustion
process. Figure 2 illustrated the position of the intake adapter in engine assembly and
detail of inlet adapter components. The same design applies to modification of cylinder
3, but the hose fitting is coming from the exhaust of cylinder 1 and 2.

Figure 2. (a) Inlet adapter is placed between the manifold and the engine block (b) Air
enter from A to the B
CES is material database software that provides a comprehensive database of
materials and process information (Findik & Turan, 2012). Lately, most of the products
consider environmental as one of selection criteria in the design stage due to the
environmental become worldwide issue (Knight & Jenkins, 2009; Yun, Filip, & Lu,
2010). The environment elements are including carbon footprint of the product,
suggestion to reduce its energy usage, cut wastes, specify the manner of its disposal and
emissions (Zhao, Neighbour, Deutz, & McGuire, 2012). With a response towards the
environmental impact, CES has added a new tool called Eco Audit. The Eco Audit is an
add-on tool to CES that help to address the suitable environmental material in design.
The tool aims to enable product designers quickly to evaluate the impact of their
product to the environment and guide them on how to reduce the impact. In Granta's
environment, there are three parameters that have to be determined first before it can
simulate. There are material, transport and use of the product. All these parameters will
contribute to the carbon footprint and energy. Lower carbon footprint means the
environment is green. Save in energy means saving in materials and less impact to the
environment. The tool consists of 6 phases named material, manufacture, transport, use,
disposal and end of life (EoL) potential. Each stage used particular equation or referred
table to determine the total energy and carbon footprint, which is the impact indicator of
the environment.

3
 METHODOLOGY

Several methods implemented to find a suitable eco-material for the intake adapter. It
started with the definition; which is to define the project intention. The purpose is
clearly to identify the design intention and any subsequent adverse effect that maybe or
not to compromised. The 39 engineering parameters regularly applied to enable the
inventive problem solving (Gadd & Goddard, 2011; Triz, 2011).
Table 1 Contraction matrix for the inlet adapter material selection
Improving features Worsening features TRIZ solution principle

39 engineering parameters 39 engineering parameters 40 inventive parameters

# Use of energy by a moving object # Weight of moving object # Composites materials

- Impact on the environment
# Cheap short-living object

# Temperature # Thermal expansion /performance

# Parameter changes

Figure 3. The outcome of 39 engineering parameter and TRIZ method

In several cases, the 39 engineering parameters also embedded in various other
methods such as TRIZ and Morphological chart-analytic method (Mansor, Sapuan,
Zainudin, Nuraini, & Hambali, 2014; Mansor, Sapuan, Zainudin, Nuraini, & Hambali,
2013). The 39 engineering parameters used to find improving and worsening features.
Meanwhile, TRIZ method is used to find the solution principle. The result is shown in
Table 1 and Figure 3. Besides the above mentioned parameters, there are a few more
parameters that defined as a design specification of the material. Operating temperature
is one of it. The adapter operates efficiently within the specified temperature range due
to the thermal effect. In addition, it is essential for the adapter to have adequate
corrosion and wear resistance properties as this feature will decrease the safety

4
coefficient of the camshaft through time. In the traditional method, cost frequently set as
“order winner” in selecting materials. In environmental impact material, the cost is still
significant but not always, be the primary factors in the selection (Findik & Turan,
2012). Figure 4 shows the methodology of the project. Through Eco Audit, material,
manufacture and end of life setting, the material sets as virgin, mass is according to the
average density, it has gone through primary, secondary and finishing process.
Percentage of volume removal sets based on dedicated process. For ferrous materials,
100% are recyclable and recoverable meanwhile polymer based set as landfill.
Appropriate transport distance fixed for all materials based on source of raw material,
primary extraction, secondary process, distribution to dealer and end user. The life cycle
of this product assumed to be the same age with average car age, 9 years. Based on
Ashby handbook, the equation of material indices are as following (Ashby, 2004).
Performance for Thermal Shock Resistance;

y
M  (1)
E
Where 𝑀 is performance indices, 𝜎𝑦 is failure strength, 𝐸 is modulus young and 𝛼 is
thermal expansion coefficient. In order to find the minimum slope, the equation derived
as logarithm function, simplified and rearranged to be

log E  log  y  (log M  log  ) (2)

y
Slope of minimum 1
E

Figure 4. Flowchart of project

5
 RESULTS AND DISCUSSION

Cambridge Engineering Selector

Figure 5. CES result with performance indices presented in Ashby chart

Based on the CES simulation result, 1213 materials passed the first stage where Young
Modulus versus Yield strength and performance index has taken place. In the second
stage, 1447 materials were met the constraint and lastly, 3791 materials passed stage 3
for process universe. When combine all the stage, the configuration had finally returned
222 results out of 3905 materials by using CES software. The results came from 3
groups of ferrous material and one (1) group of polymer as shown in Figure 5. Based on
the similarity of composition and properties, only one (1) material from each group of
ferrous material was selected. Cast iron, aluminum and stainless steel are the materials
of ferrous group. Meanwhile, the three polymer composite materials are DAP (mineral
filled), epoxy SMC (carbon fiber) and polyester (glass fiber) as illustrated in Table 2.
Table 2. Selected materials to be simulated in Eco Audit tool

No. Material
1 Cast iron EN GJSA XNiCr 20 2
2 Aluminum 356.0
3 Stainless steel AISI 321
4 DAP (mineral filled)
5 Epoxy SMC
6 Polyester (glass fiber)

Eco Audit

The current engine intake manifold is using cast iron. Therefore, cast iron is set as a
reference point for this project. Figure 6 shown energy used for each Eco Audit phases.

6
The result presented in percentage of change compared to the reference point; which is
cast iron as a reference point.

Figure 6. Fraction energy based on Eco Audit phases

In overall, the highest required energy material is aluminum, 356.0 which is
extra 94% compared to energy required by cast iron. These are due to the aluminum
production takes much energy. It is about 11.35 - 17.4 MJ of electrical energy to
produce one metric ton of 100% recycled aluminum and 227 - 342 MJ energy required
to process from bauxite to aluminum (Oleg, 2010). It is about 75% of the energy spent
in aluminum smelting process (Gutowski et al., 2012). This figure is three times more
energy than is needed to make a metric ton of standard steel, and it is almost double
compared to stainless steel 356.0. However, aluminum waste can be recycled. The
lowest energy required is epoxy SMC material which is less 97% than the energy
required by cast iron. Most of the reasons that contributed to the lower energy are
because of the embodied epoxy energy is low and to manufacture the epoxy resin only
required 1.74 MJ of energy (De Vegt & Haije, 1997). Stainless steel requires additional
88% energy, DAP and polyester material requires less 57% of energy comparable to
cast iron power. In terms of the End of Life potential, ferrous material shows better
performance since all the ferrous material can be 100% recycled. Meanwhile, most of
polymer-thermoset and composite material can only be downgraded or landfill.

7
 Figure 7. Fraction carbon footprint based on Eco Audit phases
Figure 7 shown carbon footprint released for each phase of Eco Audit phases.
The highest material that released carbon footprint is stainless steel AISI 321 which
additional 83% compared to the reference; cast iron. These are due to high carbon yield
in material, manufacturing process and use of the product. Stainless steel is heavier than
the other materials, it requires more fuel and produce more emissions, so, it produces
more carbon footprint. Epoxy SMC produced 97% less carbon footprint compared to
cast iron. These are due to low energy produced in making the material, manufacture
and use of material.
Based on the result, the best eco-material for the inlet adapter is epoxy SMC
since it requires less energy, produce less carbon footprint to the environment and suit
the application in a research environment. Second is polyester; next is DAP, cast iron,
stainless steel and the last is aluminum. The study focused on energy and carbon
footprint instead of the overall cost of the project. If cost needs to consider as one of the
major factors in selecting the material which regards to environmental, further research
and analysis needs to conduct.

CONCLUSION

In this project, the use of Eco Audit as a tool to select eco-material is the best option.
The matrix of weighting method uses weight factor, and it is decided by the designer’s
experience. Different designers will come with different weight factor. So, the result
will be different from one engineer to another. The Eco Audit tool, not only show the
impact to the environment, but also provide guidance to reduce the impact. The best

8
eco-material for hybrid six-stroke inlet adapter is epoxy SMC because it saves more
energy at 97% and release 97% less carbon footprint compared to cast iron. Epoxy SMC
is considered as lightweight material with a density of 1.5 × 103 Kg/m3. The density is
much lighter compared to the reference material, cast iron, which will reflect energy
saving. The service temperature of Epoxy SMC is 175˚C, and it is higher than typical
under hood temperature (Dorman Products Inc., 2014). Average young’s modulus for
Epoxy SMC is 110 GPa, which is equivalent to fractional metal and not easy to deform.
That is made it very suitable material for the inlet manifold application. Effects of cost
regards to the environment still need to be further research since the current research
only focused on energy and carbon footprint. New approach needs to justify in order
considering the cost as part of eco-tools. In conclusion, it is found that epoxy SMC is
the greener material to use in a research environment where cost is less crucial. It is
suitable for low production and reasonable price. However, polymer material has
limitation since plastic material needs high setup cost since mold fabrication required. If
polymer based and cast iron invalid because of the high setup cost, then stainless steel
AISI 321 will be the best material for this project.

ACKNOWLEDGEMENTS

The authors would like to be thankful to Faculty of Mechanical Engineering, Universiti

Teknikal Malaysia Melaka (UTeM) for sharing the latest software of Cambridge
Engineering Selector in order to conduct the design selection for inlet adapter material.

REFERENCES

Ashby, M. F. (2004). Materials Selection in Mechanical Design. Elsevier Science.

Barry, K., Domb, E. and Michael, S. S. (2014). Integration of TRIZ and roadmapping
for innovation , strategy , and problem solving. The TRIZ journal webpage.
Retrieved from http://www.triz-journal.com/archives/what_is_triz/. (Accessed on
June 01, 2014).

De Vegt, O. M., & Haije, W. G. (1997). Comparative environmental life cycle

assessment of composite materials (pp. 1–37). Retrieved from
http://www.ecn.nl/docs/library/report/1997/i97050.pdf. (Accessed on June 01,
2014).

Dorman Products Inc. (2014). Retrieved from

http://www.dormanproducts.com/documents4rb/Intake TechSpeak.pdf. (Accessed
on June 01, 2014).

Findik, F., & Turan, K. (2012). Materials selection for lighter wagon design with a
weighted property index method. Materials & Design, 37, 470–477.
doi:10.1016/j.matdes.2012.01.016

9
 Fuhs, A. E. (2009). Hybrid vehicles and the future of personal transportation. Boca
Raton: CRC Press.

Gadd, K., & Goddard, C. (2011). TRIZ for Engineers: Enabling Inventive Problem
Solving. Wiley.

Gutowski, T. G., Sahni, S., Allwood, J. M., Ashby, M. F., Allwood, M., & Worrell, E.
(2012). The energy required to produce materials: Constraints on energy-intensity
improvements, parameters of demand. The Royal Society, Published online.
doi:http://dx.doi.org/10.1098/rsta.2012.0003

Huang, C. Y., Hu, C. K., Yu, C. J., & Sung, C. K. (2013). Experimental Investigation
on the Performance of a Compressed-Air Driven Piston Engine. Energies, 6(3),
1731–1745. doi:10.3390/en6031731

Huang, K. D., Tzeng, S. C., Ma, W. P., & Chang, W. C. (2005). Hybrid pneumatic-
power system which recycles exhaust gas of an internal-combustion engine.
Applied Energy, 82(2), 117–132. doi:10.1016/j.apenergy.2004.10.006

Knight, P., & Jenkins, J. O. (2009). Adopting and applying eco-design techniques: a
practitioners perspective. Journal of Cleaner Production, 17(5), 549–558.
doi:10.1016/j.jclepro.2008.10.002

Magneti Marelli S.p.A. (2014). Retrieved from

http://www.magnetimarelli.com/business_areas/powertrain/gasoline-system-
pfi/air-intake-manifold. (Accessed on June 01, 2014)

Mansor, M. R., Sapuan, S. M., Zainudin, E. S., Nuraini, A. A., & Hambali, A. (2013).
Hybrid natural and glass fibers reinforced polymer composites material selection
using Analytical Hierarchy Process for automotive brake lever design. Materials &
Design, 51, 484–492. doi:10.1016/j.matdes.2013.04.072

Mansor, M. R., Sapuan, S. M., Zainudin, E. S., Nuraini, A. A., & Hambali, A. (2014).
Conceptual design of kenaf fiber polymer composite automotive parking brake
lever using integrated TRIZ–Morphological Chart–Analytic Hierarchy Process
method. Materials & Design, 54, 473–482. doi:10.1016/j.matdes.2013.08.064

Oleg, D. (2010). China’s Aluminum Foil: Foreigners can find comparative advantages
even in heavy industries. The Wall Stret Journal: Business Asia,
http://online.wsj.com/news/articles/SB100014240527.

Yun, R., Filip, P., & Lu, Y. (2010). Performance and evaluation of eco-friendly brake
friction materials. Tribology International, 43(11), 2010–2019.
doi:10.1016/j.triboint.2010.05.001

Zhao, R., Neighbour, G., Deutz, P., & McGuire, M. (2012). Materials selection for
cleaner production: An environmental evaluation approach. Materials & Design,
37, 429–434. doi:10.1016/j.matdes.2012.01.014

10

View publication stats