A Kolchin V Demidov DESIGN OF AUTOMOTIYE ENGINES A VI K O J ~ ~ H H , B II ~ ~ M W O B PACYET ABTOMOGHnbEZblX M TPAKTOPRbIX P[BI#rATEJIEH AKolchin R Demidw Translated from the Russian by P ZABOLOTNYI[.]
A Kolchin V Demidov DESIGN OF AUTOMOTIYE ENGINES A VI K O J ~ ~ H H , B II ~ ~ M W O B PACYET ABTOMOGHnbEZblX M TPAKTOPRbIX P[BI#rATEJIEH AKolchin R Demidw Translated from the Russian by P ZABOLOTNYI DESIGN OF AUTOMOTIVE ENGINES First published 1984 Revised from the second 1980 Russian edition The Greek Alphabet A a Alpha IL Iota B $ Beta K x Kappa I'y Gamma A h Lambda Mp Mu A Delta E E Epsilon N v Nu 2E Xi Z g Zeta a Omicron H a Eta IIn Pi Theta PP Rho 2a TT ru @ r XX Y9 8w Sigma Tau Upsilon ~ Phi Chi Psi Omega The Russian Alphabet and Transliteration X x kh HK k Aa a B6 b h ts JIn g , ch MM m Bs v n o IIIm sh nfrg shch P '6 n PP Cc r Y s bI b TT YY t 3a e U IQ lo f RR yu ya I'r €! HH An d e e,yo 00 Ee Ee X x zh 3a z kln mii i I ~ 1980 f l a ~ a ~ e a a ct B ~ ~ oc r n amKoJIao, @ English translation, Mir Publishers, 1984 CONTENTS Preface s Part One WORKING PROCESSES AND CHARACTERISTICS 1.1 General 1.2 Chemical ~ e a c t i o n sin &el' ~brnhus'tion 1.3 Heat of Combustion of Fuel and Fuel-Air k i i t u r e 1.4 Heat Capacity of Gases Chapter THEORETICAL CYCLES OF PISTON ENGINES * Chapter FUEL AND CHEMICAL REACTIONS 2.1 General 2.2 Closed heo ore tical CyEles 2.3 Open Theoretical Cycles Chapter ANALYSIS OF ACTUAL CYCLE 3.1 Induction Process 3.2 Compression Process * Combustion Process Expansion Process Exhaust Process and k e t h d d s of ~ o l l i t i o nControl Indicated Parameters of Working Cycle 3.7 Engine Performance Figures 3.8 Indicator Diagram 3.3 3.4 3.5 3.6 Chapter HEAT ANALYSIS AND HEAT BALANCE 4.1 General 4.2 Heat Analysis and Heat 3alaxke'of' a carburettor Eingine 4.3 Heat Analysis and Heat Balance of Diesel Engine Chapter SPEED CHARACTERISTICS 5.1 5.2 5.3 5.4 General Plotting ~ i t e i n a i ~ p e k d'~haracte'ristic Plotting External Speed Characteristic of ~ a r k u i e t t o rEngine Plotting External Speed Characteristic of Diesel Engine Part T ~ v o KINEhfATICS AND DYNAhIICS Chapter KISEhlATICS OF CRANK MECHANISM 6.1 General 6.2 Piston strike 6.3 Piston Speed 6.4 Piston ilcceleration 127 127 130 132 134 137 Chapter DYKAMICS OF CRANK MECHANISM 7.1 General 5.2 Gas Pressure korces 7.3 Referring Masses of crank ~ e c h ' a n i s m parts ' 7.4 lnertial Forces 7.5 Total Forces Acting in 'Crank' hiechan'ism 7.6 Forces Acting on Crankpins " Forces Acting on Main Journals 7.8 Crankshaft Journals and Pins Wear - 8.1 General 8.2 Balancing Engines of biiferint' Types 8.3 Uniformity of Engine Torque and Run 8.4 Design of Flywheel Chapter ANALI-SIS OF EKGISE KINEMATICS AND DYNAMICS Chapter ENGIKE EALA4i\iCING 9.1 Design of a n In-Line Carburettor Engine 9.2 Design of 1:-Type Four-Stroke Diesel Engine Part Three DESIGK O F PRINCIPAL PARTS Chapter 10 PREREQUISITE FOR DESIGN AND DESIGN CONDITIONS 10.1 General 10.2 Design ~ondi'tions 10.3 Dcsign of Parts ~ o r k i n t' "~n i e r s ~ i t e A a i i n gZ'oads Piston Piston Rings Piston Pin Chapter 11 DESIGN OF PISTON ASSEMBLY 11.1 11.2 11.3 Chapter 12 DESIGK OF CONNECTING ROD ASSEMBLY Rod Shank Rod Bolts 12.1 Connecting Rod Small End 12.2 Connecting Rod Big End 12.3 Connecting 12.4 Connecting Chapter 13 DESIGN OF CRANKSHAFT 13.1 13.2 13.3 13.4 13.5 13.6 General Unit Area Design of Design of Design of Design of Pressures on 'crink'pins and Journals Journals and Crankpins Crankwebs In-Line Engine ~ r a ' n k i h a h Type Engine Crankshaft 137 137 139 141 142 147 152 157 158 158 160 167 170 171 171 191 CONTENTS Chapter 14 DESIGN OF ENGINE STRUCTURE 14.1 14.3 14.3 14.4 CyIinder Cylinder Cylinder CyIinder Block and Upper Crankcase Liners Block Head Head Studs Chapter i5 DESIGN OF VALVE GEAR 15.1 General 15.2 Cam profile cdnstruction f 5.3 Shaping Harmonic Cams Time-Section of Valve 15.5 Design of the Valve Gear for a darburkttbr ' ~ n ~ i n e 15.6 Design of Valve Spring 15.7 Design of the Camshaft 296 296 298 302 303 308 308 310 314 320 321 331 339 343 Part Four ENGINE SYSTEMS Chapter 16 SUPERCNARGING 16.1 General 16.2 Supercharging units gnci s'ysiems 16.3 Turbo-Supercharger Design ~ u n d a m e n i a l s 16.6 ;ipgrosimate computation of a Compressor and a Turbine Chapter 17 DESIGN OF FUEL SYSTEM ELEMENTS 372 372 373 380 385 17.1 Genera1 17.2 Carburettor 17.3 Design of carburetto1 1'i.b Design of Diesel Engine Fhei System ~ i e m e n t s Chapter 18 DESIGN OF LUBRICATING SYSTEM ELEMENTS 18.1 18.2 18.3 18.4 Oil Pump Centrifugal oil ' ~ i i t e r Oil Cooler Design of ~ e a r k g s Index 390 390 394 397 400 403 Chapter 19 DESIGN OF COOLING SYSTEM COMPONENTS 19.1 19.2 19.3 19.4 19.5 Appendices References 343 344 348 362 General Water Pump Radiator Cooling Fan Computation of" a i r cooling sur'face 403 404 409 412 415 417 424 426 PREFACE Nowadays the main problems in the field of development and improvement of motor-vehicle and tractor engines are concerned with wider use of diesel engines, reducing fuel consumption and weight per horsepower of the engines and cutting down the costs of their production and service The engine-pollution control, as well as the engine-noise control in service have been raised to a new level Far more emphasis is given to the use of computers in designing and testing engines Ways have been outlined to utilize computers directl y in the construction of engines primarily in the construction of diesel engines The challenge of these problems requires deep knowledge of the theory, construction and design of internal combustion engines on the part of specialists concerned with the production and service of the motor vehicle and tractor engines The book contains the necessary informat ion and systerna tized methods for the design of motor vehicle and tractor engines Assisting the students in assimilating the material and gaining deep knowledge, this work focuses on the practical use of the knowledge in the design and analysis of motor vehicle and tractor engines This educational aid includes many reference data on modern e~iginesand tables covering the ranges in changing the basic mechanical parameters, permissible stresses and strains, etc Part One WORKING PROCESSES AND CHARACTERISTICS Chapter FUEL AND CHEMICAL REACTIONS 1.1 GENERAL The physical and chemical properties of the fuels used in automotive engines m s t meet certain requirements dependent on the type of engine, specific features of it,s design, parameters of working process, and service condit.ions Modern automot,ive carburett,or engines mainly operate on gasolines which are represented by a refined petroleum distillate and cracking process product, or by a mixture of them The minimum requirement,^ to he met by the gasoline grades produced in the USSR are given in Table 1.1 Table 1.1 C h a r a c t ~ r i 7ic t A-66 Antiknock value: octane number, MON* octane number, RON** Content of tetraethyl lead, g per kg of gasoline, mas * ** 66 I Ratings by gasoline grades A-72 72 - 76 Hot rated 0.60 None 0.41 ( dT!-93 ( IU-88 85 89 03 98 0.82 0.82 M o t o r octane number Research octane 1-:umber Except the AH-98 grade, automot,ive gasolines are divided into: (a) Su.mmer grades-intended for use in all areas of t,his country, except for arctic and northeast areas, within the period from April to Oct,ober I n south areas the summer-grade gasolines may be used all over the year