O objetivo deste trabalho é avaliar a influência sobre o número de swirl e desempenho do motor diesel a partir de cabeçotes fabricados com variação no posicionamento relativo dos dutos de admissão em duas direções perpendiculares. Inicialmente definiu-se que o valor a ser deslocado seria de 1 milímetro, e então para cada combinação entre os dutos de admissão curto e longo deveria ser fabricado um número mínimo de seis cabeçotes para posteriores ensaios em bancada com dinamômetro. Após a fundição fabricar as nove combinações definidas, sendo uma delas com os eixos em suas condições nominais, isto é, sem o deslocamento de um milímetro, obtiveram-se um total de 60 cabeçotes. Os cabeçotes foram então controlados em máquina tridimensional, usinados e montados todos os seus componentes e enviados para a medição do número de swirl em máquina desenvolvida especialmente para este teste. Para cada cabeçote mediu-se o número de swirl duas vezes, e em seguida cada uma das nove combinações foram ensaiadas no mesmo dinamômetro e avaliados os respectivos parâmetros: consumo específico de combustível, curva de torque e emissão de poluentes. Para cada combinação mediu-se a curva de torque duas vezes e mediu-se três vezes o ciclo de emissões com treze pontos (ESC). Nos resultados de swirl, três combinações apresentaram-se fora dos limites da tolerância, uma abaixo do mínimo da tolerância em 22,7% e as outras duas além do máximo da tolerância em respectivamente 18,2% e 17,8%. Nos resultados de dinamômetro, nenhuma combinação se apresentou fora dos limites estabelecidos para o modelo de motor ensaiado nos seguintes parâmetros: consumo específico de combustível, torque e emissões de CO, HC, MP e NOx. / The main purpose of this work is to evaluate the influence on the swirl number and the engine diesel performance based on cylinder heads produced with variation on relative positioning of inlet ports in two perpendicular directions. Firstly, it was defined that the value to be displaced would be 1 millimeter, and then for each combination between the short and the long inlet ports should be produced a minimum of six cylinder heads for further testing on the dynamometer. After the foundry production of the defined nine combinations, one of them having the axis in their nominal positions, i.e. without the displacement of 1 millimeter, a total of 60 cylinder heads were obtained. These cylinder heads were measured in a tridimensional machine, machined and all of their components were assembled and their swirl number were measured in the machine developed specially for this method. For each cylinder head the swirl number was measured twice and after that all nine combinations were performed at the same dynamometer and the following parameters were evaluated: fuel consumption, torque curve and pollutants emission. For each combination the torque curve was measured twice and the thirteen point\'s emissions cycle (ESC) was measured three times. Concerning the swirl results, three combinations ended up out of the tolerance limits, one of them as 22,7% below the minimum tolerance and the other two as 18,2% and 17,8% respectively over the maximum tolerance. Regarding the dynamometer results, no combination ended up out of defined tolerances for the kind of engine tested in the following parameters: fuel consumption specific, torque and emissions of CO, HC, PM and NOx.

O objetivo deste trabalho é avaliar a influência sobre o número de swirl e desempenho do motor diesel a partir de cabeçotes fabricados com variação no posicionamento relativo dos dutos de admissão em duas direções perpendiculares. Inicialmente definiu-se que o valor a ser deslocado seria de 1 milímetro, e então para cada combinação entre os dutos de admissão curto e longo deveria ser fabricado um número mínimo de seis cabeçotes para posteriores ensaios em bancada com dinamômetro. Após a fundição fabricar as nove combinações definidas, sendo uma delas com os eixos em suas condições nominais, isto é, sem o deslocamento de um milímetro, obtiveram-se um total de 60 cabeçotes. Os cabeçotes foram então controlados em máquina tridimensional, usinados e montados todos os seus componentes e enviados para a medição do número de swirl em máquina desenvolvida especialmente para este teste. Para cada cabeçote mediu-se o número de swirl duas vezes, e em seguida cada uma das nove combinações foram ensaiadas no mesmo dinamômetro e avaliados os respectivos parâmetros: consumo específico de combustível, curva de torque e emissão de poluentes. Para cada combinação mediu-se a curva de torque duas vezes e mediu-se três vezes o ciclo de emissões com treze pontos (ESC). Nos resultados de swirl, três combinações apresentaram-se fora dos limites da tolerância, uma abaixo do mínimo da tolerância em 22,7% e as outras duas além do máximo da tolerância em respectivamente 18,2% e 17,8%. Nos resultados de dinamômetro, nenhuma combinação se apresentou fora dos limites estabelecidos para o modelo de motor ensaiado nos seguintes parâmetros: consumo específico de combustível, torque e emissões de CO, HC, MP e NOx. / The main purpose of this work is to evaluate the influence on the swirl number and the engine diesel performance based on cylinder heads produced with variation on relative positioning of inlet ports in two perpendicular directions. Firstly, it was defined that the value to be displaced would be 1 millimeter, and then for each combination between the short and the long inlet ports should be produced a minimum of six cylinder heads for further testing on the dynamometer. After the foundry production of the defined nine combinations, one of them having the axis in their nominal positions, i.e. without the displacement of 1 millimeter, a total of 60 cylinder heads were obtained. These cylinder heads were measured in a tridimensional machine, machined and all of their components were assembled and their swirl number were measured in the machine developed specially for this method. For each cylinder head the swirl number was measured twice and after that all nine combinations were performed at the same dynamometer and the following parameters were evaluated: fuel consumption, torque curve and pollutants emission. For each combination the torque curve was measured twice and the thirteen point\'s emissions cycle (ESC) was measured three times. Concerning the swirl results, three combinations ended up out of the tolerance limits, one of them as 22,7% below the minimum tolerance and the other two as 18,2% and 17,8% respectively over the maximum tolerance. Regarding the dynamometer results, no combination ended up out of defined tolerances for the kind of engine tested in the following parameters: fuel consumption specific, torque and emissions of CO, HC, PM and NOx.

Orientador: Amilcar Porto Pimenta / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-16T14:56:57Z (GMT). No. of bitstreams: 1 Soares_SergioLeal_M.pdf: 10822438 bytes, checksum: bf38004d90969d8ce0aa87842d2431f9 (MD5) Previous issue date: 2010 / Resumo: Da constante necessidade de aperfeiçoar a fabricação de produtos, as indústrias têm introduzido em suas linhas de fabricação diversos conceitos já consagrados para estabelecer a qualidade otal nas suas concepções, garantindo que seus produtos estejam dentro das especificações e que todos enham o mesmo resultado funcional. Na fabricação de motores ocorre a mesma tendência. Eles necessitam de processos confiáveis na concepção, buscando repetibilidade dos resultados, onde o motor tem grande influencia nos veículos que os equipa, sendo esses grandes fontes de emissões de poluentes. Dessa forma, é muito importante aperfeiçoar o funcionamento dos motores, para que haja redução nas emissões. Além disso, é necessário efetuar melhorias funcionais, atendendo as exigências feitas pelo mercado, reduzindo as perdas de potência e o consumo de combustível. Uma das formas para aumentar o rendimento funcional do motor é aperfeiçoar a passagem do ar de admissão dentro do motor. Isto pode trazer como resultado redução do consumo de combustível, aumento de potência, redução de temperaturas e pressões internas no motor, redução de desgaste dos componentes, aumento de vida útil, redução dos níveis de emissões e melhorias na condução do veículo, principalmente na partida do veículo. Porém, mesmo tendo um bom projeto, é necessário conhecer as conseqüências quando ocorrem dispersões no processo de fabricação, sabendo também o quanto o produto é susceptível a possíveis falhas de fabricação. Na produção dos cabeçotes existem diversos pontos críticos que podem gerar falhas de posicionamento da peça durante o processo de usinagem. Para reduzir essas falhas foi construído um dispositivo de fixação da peça na operação de usinagem dos primeiros furos. Mesmo com esse dispositivo, algumas peças ainda ficam fora da especificação dimensional. O grande interesse desse trabalho é conhecer, através de avaliações dimensionais, testes funcionais em bancada de fluxo e em dinamômetro (ensaio de desempenho a plena carga e emissões), se existe alguma influência gerada pela dispersão da usinagem dos furos das guias no cabeçote de um certo motor e quantificar essa diferença. Para isso, foram confeccionados três grupos de quatro cabeçotes cada onde o primeiro grupo tem suas dimensões dentro da especificação, escolhido como padrão, o segundo grupo tem a cota de posicionamento do furo da válvula de admissão 1,5 mm fora do especificado a esquerda e o terceiro grupo tem esta mesma cota 1,5 mm fora do especificado a direita. Todos os cabeçotes foram testados no mesmo conjunto motor-dinamômetro e com mesma instrumentação, para aumentar a confiabilidade dos resultados. Constatou-se uma variação de 4% em média no número de swirl nos cabeçotes alterados em relação ao grupo padrão. Foi mostrado ainda que a influência provocada pelas dispersões dimensionais não afetaram significantemente o desempenho do motor / Abstract: The constant need to improve the manufacturing of products, industries have introduced into their production lines several existing concepts to estabilish total quality in their designs, ensuring that their products are within specifications and that they all have the same functional outcome. In the engines manufacturing, the same trend can be seen. They need reliable processes in the design, seeking repeatability of results, since they have great influence in vehicles (large sources of emissions). Thus, it is very important to improve the engine's functioning, in order to reduce emissions. Furthermore, it is necessary to make functional improvements, meeting the requirements made by the market, reducing power losses and fuel consumption. One way to increase the engine functional efficiency is to improve the airflow intake inside the engine. This could bring as a result a reduction in fuel consumption, increased power, lower temperatures and pressures inside the engine, reduced wear of components, increased life cycle, reduced emission levels and improved vehicle drivability, especially at the vehicle startup. However, even with a good design, it is necessary to know the consequences when dispersions occur in the manufacturing process, also knowing how the product is susceptible to possible manufacturing faults. In the cylinder-heads production, there are several critical points that can generate position failure of the working piece during the machining process. To reduce these failures, a fixing device was built in the operation of machining the first holes. Even with this device, some parts are still out of dimensional specification. The great interest of this work is to know, through dimensional assessments, functional testing flow and dynamometer in lab scale (performance at full load and emissions tests), if there is any influence caused by the dispersion of an engine cylinder-head guide holes machining and quantify this difference. For so, three groups of four cylinder-heads each were created, where the first group has its dimensions within the specification, chosen as standard; the second group has a quota of positioning hole inlet valve of 1.5 mm out of specification at left; and the third group has the same dimension of 1.5 mm out of specification at right. All cylinder-heads were tested in the same engine-dynamometer set and with the same instrumentation, in order to increase the reliability of results. There was an average variation of 4% in the number of swirl in the cylinder-heads changed regarding the standard group. It was also shown that the influence caused by the dimensional dispersions did not significantly affect the engine performance and emission level / Mestrado / Motores / Mestre em Engenharia Mecânica

Dans une optique d'allègement, les alliages d'aluminium de fonderie représentent une excellente solution technique. Ainsi, pour les culasses automobiles, les alliages d'aluminium Al-Si-Cu (Aluminium-Silicium-Cuivre) sont souvent choisis pour leurs performances mécaniques ainsi que leur bonne coulabilité. L'objectif de cette étude est d'améliorer la compréhension des mécanismes en fatigue oligocyclique pour définir un critère de fatigue adapté. Cet objectif est réalisé en combinant des essais (en fatigue oligocyclique à température ambiante et élevée), de nombreuses observations (microscopie à balayage électronique, microtomographie 3D rayons-X de laboratoire, suivi de fissure) et des simulations (génération de population de défauts et calculs éléments finis). À l'aide d'outils spécialement développés, la population de défauts (défauts de fonderie) est analysée en détails : la taille de défaut est modélisée par une distribution de Pareto généralisée et leurs positions par un processus ponctuel de type agrégé (démontrant que les défauts ne sont pas spatialement distribués de manière totalement aléatoire). Les processus ponctuels marqués permettent de montrer que tailles et positions de défauts ne sont pas corrélées. En utilisant ces informations statistiques, il est démontré que seuls les défauts proches de la surface sont critiques pour la fatigue oligocyclique. Un critère de fatigue basé sur l'énergie de déformation est utilisé pour prévoir la durée de vie en fatigue. Par la suite, un modèle de propagation de fissure permet de prendre en compte la taille de défaut dans la prévision de la durée de vie. Combiné à la statistique des défauts, ce modèle permet d'estimer la dispersion des essais. En dernier lieu, des essais et des simulations sur éprouvettes entaillées montrent que l'étude de la population de défauts est d'autant plus critique que le volume fortement sollicité mécaniquement devient plus faible. / In a search for lightweight materials, cast aluminium alloys have become an efficient solution for the automotive industry. For cylinder heads, cast aluminium alloys (Aluminium-Silicon-Copper based) are often chosen for their mechanical performances combined with their good casting abilities. This study aims at better understanding the damage mechanisms of Low-Cycle Fatigue (LCF) to help define a suitable design criterion. This is achieved by combining experiments (LCF tests at ambient and high temperature), various observations (Scanning electron microscopy, laboratory 3D X-ray microtomography, crack propagation monitoring) and numerical techniques (Finite element method simulations and defect population generation). Specifically designed statistical tools allow clearly identifying the defect (casting defects) population: the defect size can be modelled by a generalized Pareto distribution and their positions by a clustered point process (thus showing the defect locations are not completely random). Using marked point processes, it is also shown that defect size and defect position are uncorrelated. Using this statistical information and by systematic observations, it is proven that only defects close to the surface are critical for the fatigue life. The different interactions between cracks and defects are also studied, especially with respect to temperature. A strain energy based fatigue criterion is introduced and allows estimating the fatigue life. Then, a crack propagation model provides a mean of taking the defect size into account, which combined with the statistics of defects, gives an estimate of the fatigue life dispersion. Finally, notched specimens tests and simulations show the study of the defect population is even more critical as the highly loaded volume becomes smaller.

The constants modernization in the fuels used request improvements in the combustioneffectiveness, as a consequence the material for components as the cylinder heads mustenhance their properties. Seven different compositions of compacted graphite iron (CGI)are analysed with the aim of characterized and select the most suitable material for thecylinder head service condition. The present master thesis report focuses on the impactof the matrix- either pearlitic or ferritic- and alloying elements such as molybdenum andnickel in the fatigue crack propagation ratedadNand fracture toughness (kIc).Tests to determined the fatigue crack growth rate, according to the ASTM standardE647 and fracture toughness (ASTM E399) were conducted. The equipment utilized was aservo hydraulic machine, for the fatigue crack propagation rate test and a electromechanicalmachine for the fracture toughness. Moreover, for measure the crack length a portablemicroscope camera and a camera connected to a DIC(digital image correlation) softwarewas used. The interpretation of the data obtained from the tests were done by TEMA- aDIC software- and MATLAB.The test results are analysed describing the influence of the composition and the microstructurehave over the mechanical properties achieved. Furthermore, an analyse forrelating the graphite average length and the hardness with the fatigue crack growth rateand the fracture toughness of the materials is performed.

This thesis deals with analysis of mechanical and thermal load of a diesel engine cylinder head with fatigue life prediction. In the first part common solution options are described. The second part contains stress, deformation and fatigue life prediction computation of the given diesel engine cylinder head.

There is a continuous need within most manufacturing environments for more flexible production equipment, particularly where customer satisfaction and responsiveness promote quality improvement. In this paper, an automated agile manufacturing system that uses high-speed computer numerically controlled (CNC) machines to make automotive cylinder heads is proposed and evaluated by means of discrete event simulation using the ARENA simulator. Two alternative agile system configurations are constructed and simulated to achieve the production target. The simulation shows some significant benefits in using the agile system and demonstrates that high-speed CNC equipment is a viable option for cylinder head manufacture at a production volume of 550 000 units per annum. It is shown that the agile system can provide more flexibility and half the throughput time of the transfer line.

Size and distribution of mount deformation are the main topics discussed in this thesis, using different static loading. The thesis’ primary focus is to show how deformation and stress of the engine block with cylinder liner are affected in the assembly order of the cylinder head. The calculation and evaluation of the solution are calculated by using method finite element, software Ansys. In addition other methods are discussed which can also measure the deformation of the engine block.

Ett behov av att förbättra och utveckla dagens kvalitetzon för cylinderhuvud har framkommit för att kunna hänga med i det ökande kravet på kvalitetsutveckling. Dagens zon är både fysiskt krävande för operatörerna samt att den saknar rätt förutsättningar för ett effektivt arbete. Följderna blir utslitna arbetare samt onödigt höga avsyningsmissar som i slutändan skapar kostnader för Scania. Huvudmålet för arbetet har därför varit att lämna ett lösningsförslag på en optimerad layout samt vad för utrustning denna zon ska innehålla. För att skapa en grundförståelse över problemet utfördes en nulägesanalys och stationen observerades för att se hur personalen arbetade. Intervjuer med operatörer hölls då projektprojektgruppen vill höra deras tankar om vad de ansåg om problemet och vad de hade för behov. En benchmarking samt litteraturstudie utfördes vilket gav en bild av hur projektprojektgruppen skulle gå tillväga samt vilka metoder projektgruppen skulle använda sig av. Med hjälp av diverse kvalitetsverktyg kunde olika brister, behov och rotorsaker lokaliseras. En fokusgrupp samordnades mellan relevanta parter för att kunna få feedback på de layout-förslag som presenterades och på så sätt iterera fram den optimala lösningen. Samtidigt pågick ett konstant sökande efter leverantörer som kunde uppfylla det krav som ställdes på den nya utrustningen som behövdes införskaffas. Ett slutgiltigt lösningsförslag med tillhörande implementeringsplan kunde till sist presenteras där bansystemet hade omarbetats samt att hela avsyningen nu skulle ske i en process istället för två med hjälp av de nya rolloverna. Två stationer skulle arbeta rygg mot rygg avgränsade av bullerdämpande väger med utökade belysning och tillhörande endoskop för samtliga stationer. / A need to improve and develop today's cylinder head quality zone has been identified in order to be able to keep up with the ever-increasing demands for quality. Today's zone is both physically demanding for the operators and that it lacks the right conditions for efficient work. The consequences are worn out workers and unnecessarily high utilities who ultimately create costs for Scania. The main objective of the work has therefore been to provide a solution on an optimized layout and what this zone should contain. To provide a basic understanding of the problem, a zero-state analysis was performed and the station was observed to see how the staff worked. Interviews with operators were held when the project team wanted to hear their thoughts about what they considered the problem to be and what they needed. A benchmarking and literature study were also conducted, which gave a better picture of how the project group would go along and what methods would be used. Different deficiencies, needs and rotors could be found using various quality tools. A focus group was coordinated between relevant parties in order to get feedback on the layout proposals presented and thus iterate the optimal solution. At the same time there was a constant search for suppliers who could meet the demands placed on the new equipment that was required to be acquired. Finally, a final solution with its associated implementation plan proposal was presented where the conveyor system had been reworked and that the entire inspection would now take place in one process instead of two thanks to using the new rollover. Two stations would work back to back bounded by noise-damping walls with extended lighting and associated endoscopes for all stations

Controlling the temperature of the exhaust valves is paramount for proper functioning of engines and for the long lifespan of valve train components. The majority of the heat outflow from the valve takes place along the valve-seat-cylinder head-coolant thermal path which is significantly influenced by the thermal contact resistance (TCR) present at the valve/seat and seat/head interfaces. A test rig facility and experimental procedure were successfully developed to assess the effect of the valve/seat and seat/head interfaces on heat outflow from the valve, in particular the effects of the valve/seat interface geometry, seat insert assembly method, i.e. press or shrink fit, and seat insert metallic coating on the operating temperature of the valve. The results of tests have shown that the degree of the valve-seat geometric conformity is more significant than the thermal conductivity of the insert: for low conforming assemblies, the mean valve head temperature recorded during tests on copper-infiltrated insert seats was higher than that recorded during tests on noninfiltrated seats of higher conformance. The effect of the insert-cylinder head assembly method, i.e. shrink-fitted versus press-fitted inserts, has proved negligible: results have shown insignificant valve head temperature variations, for both tin-coated and uncoated inserts. On the other hand, coating the seat inserts with a layer of tin (20-22μm) reduced the mean valve head temperature by approximately 15°C as measured during tests on uncoated seats. The analysis of the valve/seat and seat/head interfaces has indicated that the surface asperities of the softer metal in contact would undergo plastic deformation. Suitable thermal contact conductance (TCC) models, available in the public domain, were used to evaluate the conductance for the valve/seat and seat/cylinder head interfaces. Finally, a FE thermal model of the test rig has been developed with a view to assess the quality of the calculated TCC values for the valve/seat and seat/head interfaces. The results of the thermal analysis have shown that predicted temperatures at chosen control points agree with those measured during tests on thermometric seats with an acceptable level of accuracy, proving the effectiveness of the used TCC models.