Design and Assembly of 6-cylinder Engine

Abstract : In this project we will be designing various parts required for a 6-cylinder engine using solidworks. The type of cylinder arrangement we will be designing is a V-motor (Figure 1). There are many parts involved in operations of an engine. Some of the major parts are engine block, cylinder block, piston, crankshaft, camshaft, valves etc. The main outer body of an engine can be divided into 3 parts Cylinder head, Engine Block and Crankshaft case (Figure 2). Cylinder head indeed holds components such as valves, springs etc. Engine block acts as an protection and casing for the pistons. The crankshaft case holds the crankshaft and also collects the oil which is used for the lubricating the engine parts.

The Parts used in this engine assembly and a rough sketch of each part is described below:

• Air Intake Filter: This helps in sucking of fresh cold air into the engine for combustion. It improves engine filtration and gas mileage giving more power usually up to 20% as the cold air pulls more oxygen into the combustion chamber.

Design Methodology :

• Initially we sketch the section of the air fins in the filter and use a circular pattern to create the fins.
• Then we use shell command to remove the solid material from the part.
• We sketch 2 circular base on either end of the part and extrude to desired length and fillet the surfaces respectively to obtain the model of air filter.

• TurboCharger : is a turbine driven forced induction device that increases the efficiency of internal combustion engine and power output by forcing extra compressed air into combustion chamber.

Design Methodology :

• We sketch a circle and use Helix/Spiral command to obtain the circular profile of the turbo charger.
• Then we sketch two rectangular profile and create a loft to obtain the body of the turbocharger.
• Then we sketch a circular profile and use boundary command to produce the outlet section of the turbocharger.
• Then we use shell command and various fillets and use surface Knit command to combine the body and outlet section.

• Engine pulleys: is mounted to the engine of an automobile and drives all belts.

Tools used in Design :

• Revolve.
• Cut extrude.
• Circular pattern.

We design two different pulleys as shown below:

• Camshaft: The camshaft is a mechanical component of an internal combustion engine. It opens and closes the inlet and exhaust valves of the engine at the right time, with the exact stroke and in a precisely defined sequence. The camshaft is driven by the crankshaft by way of gearwheels, a toothed belt or a timing chain.

Design Methodology :

• We sketch the outline of the cam and use extrude command. Then we use Body-Move/copy command to create multiple cams and rotate the cams as per desired angles.
• In the end we use Combine command to merge all the individual cam bodies to create a single solid body.

• Camshaft Bushing: We sketch circular profile and extrude to the part.

• Camshaft Retainer: We sketch the profile and extrude to obtain the part. Then we use Hole Wizard command to obtain the holes in the part.

• Crankshaft : A crankshaft is a rotating shaft which (in conjunction with the connecting rods) converts reciprocating motion of the pistons into rotational motion. Crankshafts are commonly used in internal combustion engines and consist of a series of cranks and crankpins to which the connecting rods are attached.

Tools used to Design :

• Boss Extrude.
• Cut Extrude.
• Mirror and Linear Pattern.
• Combine.

• Crankshaft Bushing: We sketch circular profile and extrude to the part.

• Cylinder Head: In an internal combustion engine, the cylinder head sits above the cylinders on top of the cylinder block. It closes in the top of the cylinder, forming the combustion chamber. This joint is sealed by a head gasket. In most engines, the head also provides space for the passages that feed air and fuel to the cylinder, and that allow the exhaust to escape. The head can also be a place to mount the valves, spark plugs, and fuel injectors.

Tools used to Design :

• Boss Extrude.
• Cut extrude.
• Cut Loft.
• Fileets.
• Hole.
• Linear Pattern.

• Engine Block: We will designing an engine block of V-shaped with an angle 90 degrees. An engine block is the structure which contains the cylinders, and other parts, of an internal combustion engine. In an early automotive engine, the engine block consisted of just the cylinder block, to which a separate crank case was attached. Modern engine blocks typically have the crankcase integrated with the cylinder block as a single component. Engine blocks often also include elements such as coolant passages and oil galleries.

Tools used to Design :

• Boss Extrude.
• Cut Extrude.
• Ribs.
• Mirror.
• Body-Move/Copy.
• Circular Pattern.
• Fillets.

• Engine Valve: Engine valves are located in the cylinder head. The main function of the engine valves is to let air in and out of the cylinders. That air is used to help ignite the fuel which will drive the pistons up and down.

Tools used to Design :

• Revolve.
• Chamfer.

• Exhaust Manifold: Typically made of stainless steel, cast-iron or heavy-gauge steel, the exhaust manifolddirects exhaust gases from multiple cylinders to a single exhaust In so doing, the exhaust manifold also helps to minimize leakage of heat, air and gases.

Tools used to Design :

• Boundary.
• Boss Extrude.
• Shell.
• Combine.
• Fillet.

• Front Cover : It is used as an bracket to hold the engine pulleys and the turbo chargers.

Tools used to Design :

• Boss extrude.
• Cut extrude.
• Shell.
• Fillets.

• Hexagonal Head Screw :

• Intake Manifold: In automotive engineering, an inlet manifold or intake manifold is the part of an engine that supplies the fuel/air mixture to the cylinders.

Tools used to Design :

• Boundary.
• Shell.
• Boss Extrude.
• Fillet.
• Body-Move/Copy.
• Cut Extrude.

• Oil pan /Crankshaft Case: Oil pans are a major engine cooling system parts. They are usually constructed of thin steel and shaped into a deeper section to fully perform its function. It is also where the oil pump is placed. When an engine is not running or at rest, oil pans collects the oil as it flows down from the sides of the crankcase. In other words, oil pans that are mounted at the bottom of the crankcase serves as an oil reservoir. Engine oil is used for the lubrication, cooling, and cleaning of internal combustion engines.

Tools used to Design :

• Boss extrude.
• Cut Extrude.
• Fillet.
• Extrude Thin.
• Mirror.
• Holes.
• Draft.
• Shell.

• Valves Cover : Is used to cover/protect the cam and valves systems of the engine.

Tools used to Design :

• Boss Extrude.
• Hole.
• Cut extrude.
• Draft.
• Fillet.
• Shell.

Piston Parts and Assembly :

• Piston Head : The main purpose is to create a turbulence, for better combustion so that to avoid knocking. Due to the shape of a squish or quench area of piston, Incoming air is set into rotation by the inlet valve being positioned to one side of the cylinder head.

Tools used to Design :

• Cut revolve.
• Linear Pattern.
• Cut extrude
• Fillet
• Boss extrude
• Mirror.

• Piston Pin :

• Connecting Rod: A connecting rod, also called a con rod, is the part of a piston enginewhich connects the piston to the crankshaft. Together with the crank, the connecting rod converts the reciprocating motion of the piston into the rotation of the crankshaft. The connecting rod is required to transmit the compressive and tensile forces from the piston, and rotate at both ends.

Tools used to Design :

• Boss extrude.
• Cut extrude.
• Mirror
• Fillet

• Con-rod cap: A rod capis the removable section of a two-piece connecting rod that provides a bearing surface for the crankpin journal. The rod cap is attached to the connecting rod with two cap screws for installation and removal from the crankshaft.

Tools used to Design :

• Boss extrude.
• Cut extrude.
• Hole
• Mirror
• Fillet.

Piston Assembly: The parts used for this assembly are as below:

• Piston Head.
• Piston Pin.
• Piston Rod/Connecting Rod.
• Piston Rod Cap.

Methodology:

• We use an concentric Mate with piston head and con rod.
• Then we will align the con rod between the grooves in the piston head using the coincident mate.
• Then we will use a coincident mate between the face of the con rod and piston rod cap.
• Then we will use a concentric mate between the holes of the con rod and con rod cap.
• Finally we will insert the piston pin in to the fixed end of the piston rod using concentric and coincident mate.

Rocker Arm Parts and Assembly

• Rocker Arm Pin :

• Rocker Arm Roller:

• Rocker Arm spring : This is used to actuate the valves due to motion of cams.

Tools used to Design :

• Helix/Spiral.
• Sweep.
• 3D sketch.
• Boss Extrude.
• Surface Cut.

• Rocker Arm: A rocker arm(in the context of an internal combustion engine of automotive, marine, motorcycle and reciprocating aviation types) is an oscillating lever that conveys radial movement from the cam lobe into linear movement at the poppet valve to open it.

Tools used to Design :

• Boss extrude.
• Chamfer.
• Cut Extrude.

Rocker Arm Assembly: The parts used for this assembly are as below:

• Rocker Arm.
• Rocker Arm pins.
• Rocker Arm Rolls.
• Hexagonal Head Screw.

Methodology:

• Initially we use a concentric mate between the rocker arm pin and the center groove of the rocker arm.
• Next we will be using an advanced mate – Width mate between pin and rocker arm on both the sides. Hence the results would be an exact fit in the groove.
• Then we use a concentric mate to the hole between the rocker rollers and the ends of rocker arm.
• Then we use the width mate between the rollers face and the rocker arm end faces to align themselves between the prescribed area.
• Finally we use a concentric mate with the roller hole and the roller pin and use a width mate to fix them in their position.
• Finally we insert a hexagonal head screw in the center of rocker arm using a concentric and distance mate.

Main Engine Assembly : We will be using all the parts and the above two assemblies in the main engine assembly.

Mates : The mates used in the assembly are as follows.

Standard Mates:

• Coincident Mates
• Concentric Mates
• Parallel Mates
• Tangent Mates
• Distance Mates.

Advanced Mates:

• Width Mates.

Mechanical Mates:

• Cam Mates
• Gear Mates.

Above is the exploded view of the whole engine assembly.

Once the assembly is completed we subject our engine for the motion study. Below is the link for the simulation of the above engine assembly.

In the link below is the part and assembly files of the engine assembly.

https://drive.google.com/open?id=16qholCYfZ_Gr_BQi-GmVmpe1QVYUZZeg