Internal Combustion Engine Handbook Basics, Components, Systems, and Perspectives Edited by Richard van Basshuysen and Fred Schafer Sr1E lnternationaf SIEMENSVCO A u t o m o t l v • www.TechnicalBooksPDF.com Internal Combustion Engine Handbook Basics, Components, Systems, and Perspectives www.TechnicalBooksPDF.com Other SAE titles of interest: Direct Injection Systems: T he Next Decade in Engine Technology By Cornel Stan (Order No R-347) Engine Combustion Instrumentation and Diagnostics By Hua Zhao and Nicos Ladommatos (Order No R-264) Introduction to Internal Combustion Engines By Richard Stone (Order No R-278) The Romance of Engines By Takashi Suzuki (Order No R-188) For more information or to order a book, contact SAE at 400 Commonwealth Drive, Warrendale, PA 15096-0001; phone 724-776-4970; fax 724-776-0790; e-mail CustomerService@sae.org; website http://store.sae.org www.TechnicalBooksPDF.com Internal Combustion Engine Handbook Basics, Components, Systems, and Perspectives Edited by Richard van Basshuysen and Fred Schafer s,ã.,E lnternationar Warrendale, Pa Copyright â 2004 SAE International www.TechnicalBooksPDF.com eISBN: 978-0-7680-7196-2 All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmit ted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE For permission and licensing requests, contact: SAE Permissions 400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: permissions@sae.org Tel: 724-772-4028 Fax: 724-772-4891 Library of Congress Cataloging-in-Publication Data Handbuch Verbrennungsmotor English Internal combustion engine handbook: basics, components, systems, and perspectives I edited by Richard van Basshuysen and Fred Schiifer p cm Includes bibliographical references and index ISBN 0-7680-1139-6 Internal combustion engines 11 Schiifer, Fred, 1948- I van Basshuysen, Richard, 1932- Ill Title TJ755.H2513 2004 621.43-dc22 2004048172 Translated from the German language edition: Handbuch Verbrennungsmotor by Richard van Basshuysen and Fred Schiifer Copyright ® Vieweg Verlag, Wiesbaden, Germany, 2002 SAE 400 Commonwealth Drive Warrendale, PA 15096-0001 USA E-mail: CustomerService@sae.org Tel: 877-606-7323 (inside USA and Canada) 724-776-4970 (outside USA) Fax: 724-776-1615 Copyright © 2004 SAE International ISBN 0-7680-1139-6 SAE Order No R-345 Printed in the United States of America www.TechnicalBooksPDF.com V Foreword The complexity of a modem internal combustion engine is certainly one of the reasons why one person is no longer able to comprehensively present all the important interplays in their full depth Perhaps it is also one of the reasons why there has been no complete work on this subject to date Although a large number of technical books deal with certain aspects of the internal combustion engine, there has been no publication until now that covers all of the major aspects of the topic The more than lOO-year development of the internal combustion engine has resulted in an enormous amount of important information and detailed knowledge on the different demands, the large number of components, and their interaction With a volume of almost 950 pages, more than 1250 illustrations, and nearly 700 bibliographical references, we believe that with this book we have now succeeded in covering all the main technical aspects of the internal combustion engine It was, therefore, a particular endeavor of the publishers to place emphasis in all the right places and thus to present a work that closes a significant gap in the technical literature Of particular note is the fact that this book was produced in just eighteen months and, therefore, effectively reflects the current high status of the present-day technical development Apart from illustrating the latest level of knowledge in engine development, the editors were extremely keen to present theory and practice in a balanced ratio This was achieved, in particular, by winning the coop eration of more than 90 authors from science and industry With their help, a publication has been created that is a valuable source of information and advice in the day-to-day work of education, research, and practice It is aimed, in particular, at specialists involved in science and practice in the automotive, engine, min eral oil, and accessories industry and at students for whom it is designed to provide valuable help through out their studies Furthermore, it is intended to be a useful advisor for patent lawyers, the motor vehicle trade, government offices, journalists, and interested members of the general public The question of the future of the internal combustion engine is reflected in many new approaches to the solution of the problems concerning fuel consumption and environmental compatibility Particularly under these aspects, by comparison with the alternatives, it is not difficult to predict that the reciprocating piston engine as the driving power for cars will probably remain with us in its fundamental elements for many years to come New drive systems always have the problem of having to compete with more than 100 years of development with enormous development capacities worldwide Starting from the present-day status of motor development, it is important to answer the questions: In what direction is the internal combustion engine developing? What is its potential after more than 100 years of development? How is the fuel situation of the future to be assessed? Are there competing systems that could replace it in the coming years and decades? This book tries to give conclusive answers to these questions Even though the main focus of the book is on the car engine, certain basic aspects also relate to the com mercial vehicle engine It is also new that the different aspects of the gasoline engine as compared with the diesel engine in many areas are illustrated in this book Will there be any fundamental difference between the gasoline and the diesel engines in a few years? We have only to look at the growing approximation between gasoline and diesel engines: Gasoline engines with direct injection-in the future perhaps diesel engines with homogeneous combustion Our special thanks go to all the authors for their collaboration and for their appreciation of this difficult task With their discipline they made it easy for us to coordinate more than 90 authors Of particular note is the punctuality of the authors that enabled the book to appear six months ahead of schedule-an almost unique occurrence The editors know that the work on this book has often been at the expense of partners and families, and so we express our thanks to them, too, for their understanding A few improvements have been made to the second edition: Numerous illustrations have been enlarged, and the formulas improved Thanks also to the Society of Automotive Engineers for its constructive and understanding cooperation Last but not least we thank Siemens V DO Automotive for the technical and material support in the crea tion of this work, without whose cooperation this book could never have been published Richard van Basshuysen Fred Schiifer Bad Wimpfen/Hamm, June 2002 www.TechnicalBooksPDF.com www.TechnicalBooksPDF.com VII Chapters, Articles and Authors Prof Dr.-lng Stefan Zima Historical Review Definition and Classification of 2.1 Definitions Dr.-lng Hanns-Erhard Heinzel 2.2 Potentials for Classification Prof Dr.-lng Helmut T schoke Characteristics Prof Dr.-lng Ulrich Spicher 3.1 Piston Displacement Reciprocating Piston Engines and Bore-to-Stroke Ratio 3.2 Compression Ratio 3.3 Rotational Speed and Piston Speed 3.4 Torque and Power Fuel Consumption 3.6 Gas Work and Mean Pressure Efficiency 3.8 Air T hroughput and Cylinder Charge 3.9 Air-Fuel Ratio Maps 4.1 Consumption Maps Dr.-lng Peter Woltersl 4.2 Emission Maps Dipl.-lng Bernd Haake 4.3 Ignition and Injection Maps 4.4 Exhaust Gas Temperature Maps Thermodynamic Fundamentals 5.1 Cyclical Processes Comparative Processes 5.3 Open Comparative Processes 5.4 Efficiency 5.5 Energy Balance in the Engine Crank Gears 6.1 Crankshaft Drive 6.2 Rotational Oscillations Engine Components 7.1 Prof Dr.-lng Fred Schafer Prof Dr.-lng Stefan Zima Dr.-lng Uwe Mohr Pistons I Wristpins I Wristpin Circlips Connecting Rod Philippe Damour Piston Rings Dr.-lng Rolf Jakobs 7.4 Engine Block Dipl.-lng GOnter Helsper 7.5 Cylinders Dipl.-lng Frank Zwein 7.6 Oil Pan Dipl.-lng Markus Muller Dipl.-lng GOnter Helsper Dipl.-lng Karl B Langlois 7.7 Crankcase Venting 7.8 Cylinder Head Dipl.-lng Karl B Langlois Prof Dr.-lng Wilhelm Hannibal 7.9 Crankshafts Dr.-lng Leopold Kniewallner 7.10 Valve Train Components Dipl.-lng Michael Haas 7.11 Valves Dr.-lng Klaus Gebauer www.TechnicalBooksPDF.com Vlll 7.12 Valve Springs Dr.-lng Rudolf Bonse 7.13 Valve Seat Inserts Dr.-lng Gerd KrOger 7.14 Valve Guides 7.15 Oil Pump Dr.-lng Christof Lamparski Christof Harle Bernd Schreiber 7.16 Camshaft Dr.-lng Martin Lechner 7.17 Chain Drive Dr.-lng Peter Bauer 7.18 Belt Drives Dr.-lng Manfred Arnold 7.19 Bearings in Internal Combustion Engines Dipl.-lng Ulf G Ederer 7.20 Intake Systems Dr.-lng Olaf Weber Dipl.-lng Rolf Kirschner Dipl.-lng Matthias Farrenkopf 7.21 Sealing Systems 7.21.1 Cylinder Head Sealing Systems 7.21.2 Special Seals Dipl.-lng Armin Diez Dipl.-lng T homas Breier Dipl.-lng Wilhelm Kullen 7.21.3 Elastomer Sealing Systems 7.21.4 Development Methods Dipl.-lng Eberhard Griesinger Dipl.-lng Uwe Georg Klump Dr rer nat Hans-Peter Werner 7.22 T hreaded Connectors at the Engine Dipl.-lng Siegfried Jende 7.23 Exhaust Manifold Dipl.-lng Hubert Neumaier 7.24 Control Mechanisms for Two-Stroke Dipl.-lng Uwe Meinig Cycle Engines Lubrication 8.1 Tribological Principles 8.2 Lubrication System Friction 9.1 Parameters Prof Dr.-lng Stefan Zima Dr.-lng Franz Koch 9.2 Friction States 9.3 Methods of Measuring Friction 9.4 Influence of the Operating State and the Boundary Conditions 9.5 Influence of Friction on the Fuel Consumption 9.6 Friction Behavior of Internal Combustion Engines Already Built 10 Charge Cycle 10.1 Gas Exchange Devices in Prof Dr.-lng Ulrich Spicher Four-Stroke Engines 10.2 Calculating Charge Cycles 10.3 T he Charge Cycle in Two-Stroke Engines Dr.-lng Uwe Meinig 10.4 Variable Valve Actuation Dipl.-lng Andreas Knecht Dipl.-lng Wolfgang Stephan Prof Dr.-lng Wilhelm Hannibal 10.5 Pulse Charges and Load Control of Dr.-lng Alfred ElsaBer Reciprocating Piston Engines Using Dipl.-lng Wolfgang Schilling an Air Stroke Valve Dipl.-lng Jan Schmidt Dipl.-lng Kay Brodesser Dr.-lng Oskar Schatz www.TechnicalBooksPDF.com Camshaft shift schematic Camshaft position sensor Trigger wheel Chamber comected to pressurized oil Pressure-free chamber I oil retum Fig 7-224 Continuous camshaft shifting (See page 211.) Camshaft attitude in regulated pos�ion Home pos�ion Chamber connected to pressurized oil Pressure-tree chamber I oil retum Fig 7-225 Stewing motor or vane shifter (See page 212.) Camshaft attitude in regulated position Chamber connected fD pressurized oil Pressure-free chamber I oil return Fig 7-226 Camshaft shifter with helical toothing (See page 213.) Fig 11-28 Waste gate.9 (See page 364.) Fig 11-31 Variable slide valve turbine.9 (See page 365.) Fig 15-48 Section of the Iiter three-cylinder two-stroke engine by Orbital.18 (See page 489 ) Fig 24-3 Distribution of fracture-load cycles in an exhaust manifold (See page 704.) Fig 20-5 CFD simulation of the cooling air flow in the front section of a car (See page 557.) Fig 24-4 Distribution of acoustic velocities on the surface of an aggregate (See page 704.) Fig 24-6 Optimization of the geometry of a connecting rod: Plot of stress in initial state (left) and in optimized state (right) (See page 705.) A.lftl S C l JMI tS to0 lO;Ulll _, , u ,._, � lAYO) 1- •lU.tU 1M1 •.2TC4U Fig 24-10 -���· �� 1U.'74l 1n.5ot 11'7.111 11$.0)2 J)2.lt4 ao.SM 2t:l.)ll 21&.0'71 '"··· Temperature distribution in an automobile gasoline engine at design output (See page 708 ) 1100N .OLOTtOII - -· - ·111.12'7 •Jfl,JI4 Ut.ll' , ua n 2001 lhU111 U,t,50• Fig 24-11 l'U.Q 1ff.4'Jl 3Jl.4'M 2U.UI 3:11.411 1U.4 )11 ltl l41.1M Temperature distribution in an automobile diesel engine at design output (See page 708 ) Fig 24-13 page 709 ) Model for use for piston calculation (See , Aft 2"J 2001 111UtJ4 IIODAL IOLUTJC* ·-· IIQY (A'YO) Dll •• 151201 1111' •• n�n• Nlftl 5.'J An 2"J 2001 1Jrl"Jrn IMZ •• n1201 •-.1JN81 1111: •-.ONOI!J aa •114., .71'SJMo IIODAJ SOLUTIO 11.u1 l"J• , ,,.,, H ut us."' - uo.u• u, ,,, 1'S&.m Fig 24-14 Stresses and deformations in a piston under purely gas force (example) (See page 710.) IIODAL SOLUTIOII' ISQV (AW) UID 'So."J J"J 1001 10:40•18 Dll • 112'70t - •1.121 a •IS.IlJ 1.121 10.w IIODAL SOUITIC .,_, ,., , Qa • : UJ'JO!J Nll1la , An 21 2001 lOtU:JI - •-06002] llll • • ]11701 it • at.f.IK 1'7.AI u.ut H.IU M.tn 74 012 - n.au -� ztcfn l121ot Fig 24-15 Stresses and deformations in a piston under a purely thermal load (example) (See page 710.) IIODAJ SOLUTIO , , ISQV (A'YO) Qa • 2N"J41 - •1.151 1101: •11t.122 , ,,., T1 2001 10t4Jalt OO.U SOUITIO ._, ,., , UIYII �."J Aft J"J 2001 1010122 ma: • •unu ID • 2tn.OI 1111 •.nnu • o) NSfCn' , u Fig 24-16 Stresses and deformations in a piston (mechanical and thermal) example (See page 710 ) 2UOU � SOLU!lOII' ,_, u (A.9C) Dll •.3N'7Cl Allftl ,_., ua n 3001 l01Jl:lt � SOI.UTIO .,_, aY (AVQ) MlftS ,_., Aft 3'7 2001 10;.,1:21 11G • • JN7U 8lllf •-H.lOIIJ SKI •8t.271 •- lJ1 l12 1111 •65.476 61 222 Radial and tangential stresses in the hub boring (example) (See page 711.) Fig 24-17 IIOw.L SOLUTIO aan , , 3'7 2001 lO;.Utlt ., 11G •.2N'7Cl SIOI • 151 SIIX •Ut.lU - Fig 24-18 Stress intensity on a piston under mechanical and thermal load (example) (See page 711.) lfOOU SOLUTlCIII Sift N1SD 5.'7 Ull 27 1001 11:0];4.2 {AVC) Damage index using the critical plane method (See page 712.) Distribution of coefficients of heat transfer in valve engine (See page 717.) ma: • 214'74.1 SIG • • ,n•o' SIDI: • '510011 Fig 24-19 Fig 24-22 the vicinity of the exhaust ports in a four-cylinder, five Stratified combustion Comparative assessment between measurement and calculation CFD modeling LIF measurements 24' v OT 18' v OT Concentration distribution Reaction procilds 20' v OT Flame luminos�y Fig 24-26 Combustion with charge stratification; comparative assessment calculation vs measurement.20 (Seepage 721.) G.as.o 1ne fl a m e C e rwal spar� p l U g looatlot' lms':je Dblalned t'�rough the 1-""- s:ont Qf a ' 'gl ass -engJne" ��'1� 1111t, 01esel flame v,1e\Y through a con'ifbustwn mamber entJosc.np>e , � , , - · - - Applications: Combustion data, measurement of efficiency, energy balances, friction cheracteristics fields, lim� overshoot mon�oring, misfire detection, combustion noise, knocking detection, vibration excitation, tail gas measurement, EGR calibration, automatic characteristics field optimization, injection phase, mechanical loads Fig 25-5 Examples of piezoelectric sensors for measure ment of cylinder pressure (See page 726.) Fig 25-7 Flame photograph (See page 727 ) lnt 1/(ms) 14 1mme of flame arrival, evaluated on basis of intensity threshold Fig 25-11 Flame core generation, observation using a spark plug sensor The result illustrates the symmetry or asym Fig 25-12 Arrangement of a micro-optic sensor sys metry of the flame core and its predominant direction of propagation (See page 731.) tem in the cylinder-head gasket for tomographic flame reconstruction (See page 731.) Without swirl (i (i Wilh 900 SWirl -20 100 10 10 - OT 10 20 30 40 50 'CS � ,j !:; � Fig 25·13 DI gasoline engine: Flame tomography shows the local position of bright, soot-producing diffusion flames Swirling flow produces a significant improvement (See page 731.) Fig 25-14 Flame propagation: Tomograph with sensor system installed in the cylinder-head gasket The isolines indicate the progress of the flame front against Inlet side time The influence of internal flow Lateral elongation Influence of constricting surface 'CS 35 % Fig 25-15 Flame tomography supplies comprehensive documentation of flame propagation and knocking spot distribution (See page 732.) on flame propagation is clearly perceptible (See page 732.) Frequency Fig 25-16 Determination of knocking spots by a fan-type sensor, presentation of results: Single cycle and derived knock ing spot statistics (See page 733.) Fig 25-18 Gasoline direct injec tion: Fuel distribution in the injec tion process and after deflection from the pistons The stability of distribution states is determined from individual images using image statistics Green/red: Fuel vapor with increasing stability; blue/white: Fuel droplets with increasing stability (See page 734.) Internal C ombustion Engine Handbook Edited by Richard van Basshuysen and Fred Schafer "Although a large number of technical books deal with certain aspects of the internal combustion engine, there has been no publication until now that covers all of the major aspects of the topic." This statement, written by editors Richard van Basshuysen and Fred Schafer and taken from the foreword of this publication , exemplifies the need for the Internal Combustion Engine Handbook: Basics, Components, Systems, and Perspectives This essential resource illustrates the latest level of knowledge in engine development, paying particular attention to the presentation of theory and practice in a balanced ratio Almost 950 pages in length - with ,250 illustrations and nearty 700 bibliographical references - the Internal Combustion Engine Handbook covers all of this component's complexities, including an insightful look into the internal combustion engine's future viability An ideal publication for specialists in the automotive, engine, mineral oil, and accessories industries, this book will also prove to be useful for students, patent lawyers, the motor vehicle trade, government offices, journalists, and interested members of the public Chapter topics include: • • • • • • • • • a historical review thermodynamic fundamentals engine components lubrication friction supercharging of internal combustion engines combustion and combustion systems the powertrain sensors SAE lnternationar SI E M E N S V C O A u t o m o t i v e R-345 04 1 ISBN �78 - D7b8Dll3� - ...www.TechnicalBooksPDF.com Internal Combustion Engine Handbook Basics, Components, Systems, and Perspectives www.TechnicalBooksPDF.com Other SAE titles of interest: Direct Injection Systems: T he... http://store.sae.org www.TechnicalBooksPDF.com Internal Combustion Engine Handbook Basics, Components, Systems, and Perspectives Edited by Richard van Basshuysen and Fred Schafer s,ã.,E lnternationar... Cataloging-in-Publication Data Handbuch Verbrennungsmotor English Internal combustion engine handbook: basics, components, systems, and perspectives I edited by Richard van Basshuysen and Fred Schiifer p