Diesel Engine Reference Book

The Diesel Engine Reference Book, Second Edition, is a comprehensive work covering the design and application of diesel engines of all sizes. The first edition was published in 1984 and since that time the diesel engine has made significant advances in application areas from passenger cars and light trucks through to large marine vessels. The Diesel Engine Reference Book systematically covers all aspects of diesel engineering, from thermodynamics theory and modelling to condition monitoring of engines in service. It ranges through subjects of long-term use and application to engine designers, developers and users of the most ubiquitous mechanical power source in the world. The latest edition leaves few of the original chapters untouched. The technical changes of the past 20 years have been enormous and this is reflected in the book. The essentials however, remain the same and the clarity of the original remains. Contributors to this well-respected work include some of the most prominent and experienced engineers from the UK, Europe and the USA. Most types of diesel engines from most applications are represented, from the smallest air-cooled engines, through passenger car and trucks, to marine engines. The approach to the subject is essentially practical, and even in the most complex technological language remains straightforward, with mathematics used only where necessary and then in a clear fashion. The approach to the topics varies to suit the needs of different readers. Some areas are covered in both an overview and also in some detail. Many drawings, graphs and photographs illustrate the 30 chapters and a large easy to use index provides convenient access to any information the readers requires. Cover ......Page 1 Title ......Page 2 Copyright ......Page 3 Foreword......Page 4 Preface to the Second Edition......Page 6 Preface to the First Edition......Page 7 Contributors......Page 8 Part I. Theory......Page 11 1. The Theory of Compression Ignition Engines......Page 12 1.2 Two-Stroke and Four-Stroke Engines......Page 13 1.2.1 Two-Stroke Engines......Page 14 1.2.3 Evaluation of Power Output of Two-Stroke and Four-Stroke Engines......Page 15 1.2.4 Other Operating Parameters......Page 16 1.3.1 Theoretical Expressions for Air Standard Cycles......Page 17 1.3.2 Further Comments on Air Standard Cycles......Page 21 1.4.1 Gas Properties......Page 22 1.4.2 Combustion......Page 23 1.5.1 Closed Period......Page 25 1.5.2 Open Period......Page 27 1.6.1 Closed Period......Page 29 1.6.2 Open Period (Gas Exchange Process)......Page 30 References......Page 33 2. The Theory of Turbocharging......Page 35 2.1 Introduction......Page 36 2.2.1 Turbochargers for Automotive Diesel Engines......Page 37 2.2.2 Small Industrial and Marine Engine Turbochargers......Page 40 2.2.3 Large Industrial and Marine Engine Turbochargers......Page 41 2.3.1 Compressor and Turbine Efficiency......Page 42 2.3.2 Non-Dimensional Representation of Compressor and Turbine Characteristics......Page 44 2.3.4 Turbine Performance......Page 45 2.4.1 The Energy in the Exhaust System......Page 47 2.4.2 Principles of Constant Pressure Turbocharging......Page 48 2.4.3 Principles of Pulse Turbocharging......Page 51 2.4.4 Principles of Pulse Converter and Other Turbocharging Systems......Page 60 24.3 Engine Descriptions......Page 0 2.5.2 Charge Air Cooling and Engine Performance......Page 64 2.6.1 Introduction......Page 66 2.6.2 Air Flow Characteristics of Engine and Turbocharger......Page 68 2.6.3 Matching for Constant Speed Operation......Page 69 2.6.4 Matching the Marine Engine......Page 70 2.6.5 Matching for Diesel-Electric Traction......Page 71 2.6.7 Matching the Four-Stroke Vehicle Engine......Page 72 2.6.8 Matching the Two-Stroke Vehicle Engine......Page 74 2.7.2 Operation under Changing Ambient Conditions......Page 76 2.8 Closure......Page 77 Nomenclature......Page 78 3. Compound and Other Engine Systems......Page 79 3.2 Gas Generator and Compound Schemes Compared with the Turbocharged Engine......Page 80 3.3.1 Analysis Based on Compression and Expansion Machines with Fixed Polytropic Efficiencies of 85% and 80%, Respectively......Page 81 3.3.2 Analysis Based on Fully Modelled System, Including Compressor, Turbine and Cooler Characteristics......Page 83 3.4.1 The Differential Compound Engine (DCE)......Page 86 3.4.2 The Differentially Supercharged Diesel Engine (DDE)......Page 88 3.5.1 Two-Stage Turbocharging......Page 89 3.5.2 Variable Geometry Turbocharging......Page 90 3.5.3 The Pressure Wave Supercharger......Page 91 References......Page 92 4. Diesel Combustion and Fuels......Page 93 4.1.1 Basic Combustion Theory......Page 94 4.1.2 Ignition Delay......Page 95 4.1.3 Mixing Controlled Combustion......Page 96 4.1.4 Combustion System Design......Page 97 4.1.5 Analysis of Cylinder Pressure Data......Page 99 4.2.1 Hydrocarbon Types......Page 101 4.2.2 Petroleum-Derived Fuels......Page 102 4.2.3 Diesel Fuel Properties......Page 103 4.2.5 Diesel Fuel Specifications......Page 105 4.2.6 Alternative Fuels......Page 106 References......Page 107 5. Thermal Loading......Page 108 5.3 Prediction of Local Heat Flows......Page 109 5.4.1 Stationary Surfaces - Cylinder Head and Liner......Page 111 5.4.2 Moving Components - Pistons......Page 114 5.5.2 Materials......Page 115 5.5.4 Calculation of Thermal Stress......Page 116 5.6.1 To Meet Lubrication Requirements......Page 117 5.7.1 Cylinder Head......Page 118 5.7.4 Injector Cooling......Page 120 5.8 Measurement of Local Temperature Gradients and Heat Fluxes......Page 121 References......Page 122 Part II. Engine Design Practice......Page 124 6. Thermodynamic Mathematical Modelling......Page 125 6.2 Fundamentals and the Energy Equation......Page 126 6.3 Gas Properties......Page 128 6.4 Pipe Flows, Valves, Throttles and Flow Restrictions......Page 130 6.5 Turbomachinery and Charge Air Coolers......Page 133 6.7 Injection and Combustion......Page 138 6.8 Heal Transfer and Friction......Page 140 6.9 Model Results and Engine Performance......Page 143 6.10 Transient Modelling......Page 144 6.11.1 Turbomachinery......Page 145 6.11.3 Indirect Injection and Other Fuelling Methods......Page 146 6.12 Energy Equation, Gas Properties and Combustion Extensions......Page 147 6.13 Gas Dynamics......Page 148 References......Page 150 7. Computational Fluid Dynamics......Page 151 7.2.1 Gas-Phase Modelling......Page 152 7.2.2 Liquid-Phase Modelling......Page 153 7 2.3 Ignition, Combustion and Emissions......Page 156 7.3.1 Modelling the Gas-Exchange Process......Page 158 7.3.2 Combustion and Emissions Model Validation......Page 160 7.3.3 Effect of Multiple Injections......Page 163 7.4 Summary and Conclusions......Page 165 References......Page 166 Nomenclature......Page 168 8. Modern Control in Diesel Engine Management......Page 169 8.1.2 The Structure of a Control System......Page 170 8.1.3 The Shape of the Future - Model-Based Control......Page 171 8.3 What a Control System Does......Page 174 8.3.1 Sensors for Control......Page 176 8.3.2 Actuators for Control......Page 177 8.5 Algorithms for Control......Page 178 8.5.3 Modern Control - an Example......Page 183 8.6.1 Developing Control Systems......Page 184 8.6.3 Specifying Functions......Page 185 References......Page 189 Part III. Engine Sub-Systems......Page 191 9. Inlet and Exhaust Systems......Page 192 9.3 Four-Stroke Engines......Page 193 9.3.1 Valve Timings......Page 194 9.3.2 Valve Areas......Page 195 9.3.3 Determination of Flow Coefficients......Page 196 9.3.6 Swirl Producing Ports......Page 199 9.5.2 Loop Scavenging......Page 203 9.5.3 Uniflow Scavenging......Page 204 9.5.4 Port Areas and Timings......Page 205 9.6 Silencers......Page 206 References......Page 207 10. Design Layout Options......Page 208 10.2.1 Consideration of the Forces Involved......Page 209 10.2.2 Balance of a Single-Cylinder Engine......Page 212 10.2.3 Two-Cylinder Engines......Page 214 10.2.4 Four-Cylinder in-Line Engines......Page 215 10.2.5 Three-Cylinder Engines......Page 216 10.2.7 Vee Engines......Page 217 10.2.8 Two-Stroke Engines......Page 220 10.3.1 Simple Systems......Page 221 10.3.2 The Solution of Multi-Cylinder Crankshaft Systems......Page 225 10.3.3 Vibration Dampers......Page 232 10.3.4 Torsiographs and Torsional Vibration Tests......Page 235 10.4.2 The Design Process......Page 236 10.4.3 General Properties of Materials......Page 237 10.4.4 Behaviour of Materials under Repeated Loads - Fatigue......Page 238 10.4.5 Typical Materials Used in Production......Page 242 References......Page 250 11. Fuel Injection Systems......Page 251 11.2.1 Compression Ignition Combustion Processes......Page 252 11.2.3 Unburned Hydrocarbons......Page 255 11.2.5 Particulate Emissions......Page 256 11.2.6 Traditional Jerk Pump......Page 257 11.2.8 DP Rotary Distributor Pumps......Page 258 11.2.9 Electronically Controlled Rotary Pumps (EPIC)......Page 261 11.2.10 Advanced Rotary Distributor Pumps......Page 262 11.2.11 Control of Rate of Injection with Conventional FIE......Page 263 11.2.13 Common Rail Systems......Page 265 11.2.14 Integrated Fuel Injection Systems......Page 266 11.2.15 Summary......Page 268 11.3.2 Fuel-injection techniques......Page 269 11.3.3 Pump-and-barrel assemblies (pumping elements)......Page 271 11.3.4 Standard PE in-line injection pumps......Page 274 11.3.5 PE in-line injection pumps for alternative fuels......Page 279 11.3.6 In-line control sleeve fuel-injection pumps......Page 280 11.3.7 Electronic Diesel Control (EDC)......Page 281 11.3.8 Bosch—Single-plunger fuel-injection pumps......Page 283 11.3.9 Innovative fuel-injection systems......Page 285 11.3.10 Peripheral equipment for diesel fuel-injection systems......Page 286 11.3.11 Bosch—Distributor injection pumps VE......Page 289 11.4 Diesel fuel injection systems-Caterpillar Inc.......Page 290 11.4.1 Caterpillar's Hydraulically-actuated Electronic Unit Injector (HEUI) fuel system......Page 291 References......Page 293 12. Lubrication and Lubricating Oils......Page 295 12.2.1 Mineral Oils......Page 296 12.3.1 Viscosity and Coefficient of Friction......Page 297 12.3.4 Viscosity Classification......Page 298 12.3.5 Low-Temperature Viscosity and Ease of Starting......Page 299 12.5 Oil Deterioration......Page 300 12.6.2 Engine Wear......Page 302 12.8 Engine Tests and Associated Specifications......Page 303 12.9 Laboratory Inspection Tests......Page 310 Acknowledgement......Page 313 Abbreviations......Page 314 13. Bearings and Bearing Metals......Page 315 13.2.2 Interference Fit......Page 316 13.2.4 Free Spread......Page 317 13.2.6 Prediction of Oil Film Thickness......Page 318 13.2.7 Grooving Configuration......Page 319 13.3.1 Abrasion......Page 320 13.3.3 Corrosion......Page 321 13.3.7 Design Faults......Page 322 13.3.9 Environmental Factors......Page 323 13.4 Slow-Speed Engine Crosshead Bearings......Page 324 13.5.2 Scuff Resistance......Page 325 13.5.5 Overlays......Page 326 13.5.6 White Metals......Page 327 13.5.7 Copper-Lead and Lead-Bronze Alloys......Page 328 13.5.8 Aluminium-Tin Alloys......Page 329 References......Page 330 14. Pistons, Rings and Liners......Page 331 14.2.2 Piston Loading......Page 332 14.2.3 Piston Design......Page 333 14.2.4 Piston Types......Page 335 14.2.5 Gudgeon Pins......Page 339 14.2.6 Piston Design Analysis......Page 340 14.3.1 Introduction......Page 341 14.3.2 Ring Design......Page 342 14.3.3 Ring Types......Page 343 14.3.5 Ring Materials......Page 345 14.3.6 Ring Coatings......Page 346 14.3.9 Ring Research......Page 347 14.4.2 Dry Liners......Page 348 14.4.5 Material......Page 349 14.4.6 Bore Polish......Page 350 References......Page 351 15. Auxiliaries......Page 353 15.1.2 Basic Principles......Page 354 15.1.3 Basic Governing Terms......Page 356 15.1.4 Typical Governors......Page 357 15.1.5 Application Requirements and Governor Selection......Page 365 15.1.6 Typical Applications......Page 366 15.2.3 Improving the Unaided Cold Starting Ability......Page 369 15.2.4 Engine Cranking Requirements......Page 370 15.2.5 Methods of Starting......Page 371 15.2.6 Starting Aids......Page 380 15.3.3 Water-Cooled Systems......Page 384 15.3.5 Temperature Control......Page 387 15.3.6 Air-Cooled Systems......Page 388 15.3.7 Heat Transfer......Page 389 15.3.8 Construction and Design......Page 392 15.3.9 Materials......Page 401 15.3.11 Maintenance......Page 402 References......Page 403 16. Aircooled Engines......Page 404 16.1 Introduction......Page 405 16.2.2 Cylinder Unit......Page 407 16.2.3 Heat Exchangers......Page 413 16.2.4 Fan Control......Page 414 16.3.3 Stators......Page 417 16.3.4 Fan Noise and Its Reduction......Page 418 16.3.5 Other Design Considerations......Page 419 16.4.3 Noise Characteristics of Aircooled Engines......Page 420 16.4.4 Noise Attenuation by Secondary Measures......Page 421 16.5 Applications......Page 422 References and Bibliography......Page 426 17. Crankcase Explosions......Page 429 17.3 Explosion Effects......Page 430 17.7 Explosion Relief Valves......Page 431 17.9.1 Graviner Systems......Page 432 17.9.2 Schaller Visatron Systems......Page 433 References......Page 434 Part IV. Environmental Aspects......Page 435 18. Exhaust Smoke, Measurement and Regulation......Page 436 18.2.1 Comparators......Page 437 18.2.3 Opacimeters......Page 438 18.3 Calibration and Correlation of Smokemeters......Page 441 18.5 Opacimeter Specifications......Page 442 18.6 Visibility Criterion - Public Objection......Page 443 18.7 Test Methods and Procedures......Page 444 References......Page 446 19. Exhaust Emissions......Page 447 19.2.1 USA......Page 448 19.3 Analysers......Page 450 19.3.3 Nitric Oxide......Page 451 19.3.5 Oxygen......Page 452 19.4.1 Carbon Dioxide......Page 453 19.4.4 Nitrogen Oxides......Page 454 19.4.6 Particulates......Page 455 19.5.4 Vapour-Phase Hydrocarbons......Page 456 19.6 Conclusions......Page 457 Bibliography......Page 458 20. Engine Noise......Page 460 20.2.3 Frequency and Wavelength......Page 461 20.2.5 Addition and Subtraction of Sound Sources......Page 462 20.2.8 Weighting Curves......Page 463 20.3.2 Off-Highway Machines......Page 464 20.4.2 Equipment......Page 465 20.4.3 Frequency Analysis......Page 466 20.4.4 Tracking Analysis......Page 467 20.5 Noise Characteristics of Diesel Engines......Page 468 20.5.2 Assessment of Combustion Noise......Page 469 20.5.4 Engine Radiated Noise......Page 471 20.5.5 Vehicle and Machine Noise Assessment......Page 473 20.6.1 Combustion Noise......Page 475 20.6.3 Predictive Analysis......Page 476 20.6.4 Palliative Treatments and Enclosures......Page 479 Bibliography......Page 480 21. Larger Engine Noise and Vibration Control......Page 482 21.2 Noise......Page 483 21.3 Vibration......Page 484 References......Page 491 Part V. Applications......Page 492 22. Passenger Car Engines......Page 493 22.1 Introduction......Page 494 22.3.1 Combustion Systems......Page 499 22.3.2 Design Features......Page 504 22.3.3 Fuel Injection Equipment......Page 509 22.3.4 Exhaust Gas Aftertreatment......Page 510 22.4.2 Fuel Consumption......Page 513 22.4.3 Exhaust Emissions......Page 514 22.4.4 Noise, Vibration, and Harshness (NVH)......Page 516 22.5 Future Developments......Page 517 References......Page 520 23. Trucks and Buses......Page 521 23.1.6 Fuel Economy......Page 523 23.2.1 Cylinder Block and Head......Page 524 23.3.1 Pistons......Page 525 23.3.3 Cylinder Liner......Page 526 23.5.1 Crankshaft......Page 527 23.5.4 Crankshaft Pulley......Page 528 23.7 Overhead Components......Page 529 23.7.1 Valve Train Assembly......Page 530 23.7.4 Engine Retarders......Page 531 23.8 Flywheel......Page 532 23.10 Geartrain......Page 533 23.12.1 ECM......Page 534 23.12.2 Sensors......Page 536 23.12.4 Communications......Page 537 23.14 Air System......Page 540 23.14.1 Turbocharger......Page 541 23.14.2 Charge Cooler......Page 543 23.15.1 Oil Pump......Page 544 23.15.8 Crankcase Ventilation......Page 545 23.16.3 Water Pump......Page 546 23.17.2 Caterpillar Engines......Page 547 23.17.3 Cummins Engines......Page 548 23.17.6 Mercedes-Benz Engines......Page 549 23.17.9 Volvo Engines......Page 550 Bibliography......Page 553 24. Locomotives......Page 554 24.2.1 Emissions......Page 555 24.2.3 Reliability and Durability......Page 558 24 3.4 General Electric 7FDLTM......Page 563 24.3.7 General Motors EMD H Engine......Page 564 24.3.8 Kolomna D 49......Page 567 24.3.10 Paxman VP 185......Page 569 24.3.11 Pielstick PA4 200 VG......Page 571 24.3.12 Pielstick PA6B......Page 573 24.5 Railcar Engines......Page 575 References......Page 577 Further Reading......Page 578 25. Dual Fuel Engines......Page 579 25.3.3 Anti-Detonation Properties......Page 580 25.3.5 Flame Speed......Page 581 25.4 Combustion System......Page 582 25.4.2 The 'Low NOx' Dual Fuel Engine......Page 584 25.4.3 The 'Gas Diesel' Engine......Page 586 25.4.4 Other Combustion Systems......Page 587 25.6 Safety Systems......Page 591 25.7.1 Automotive......Page 593 References......Page 594 Bibliography......Page 595 26. Marine Engine Applications......Page 596 26.1.1 Caterpillar......Page 597 26.1.3 Deutz MWM......Page 598 26.1.4 GMT......Page 599 26.1.6 MAN B&W Holeby......Page 601 26.1.8 MTU......Page 604 26.1.9 MTU/DDC Designs......Page 608 26.1.12 SEMT-Pielstick......Page 615 26.1.13 Wartsila Diesel......Page 616 26.2.1 Introduction......Page 619 26.2.2 Intelligent Engines......Page 622 Part VI. Operation......Page 626 27. Condition Monitoring......Page 627 27.3 Instrumentation for Condition Monitoring......Page 628 27.3.2 Temperature Measurements......Page 629 27.4 Instrumentation for Condition Monitoring Indirect Methods......Page 630 References......Page 631 List of Units and Conversion Tables......Page 632 Index......Page 634

the Diesel Engine Reference Book, Second Edition, Is A Comprehensive Work Covering The Design And Application Of Diesel Engines Of All Sizes. The First Edition Was Published In 1984 And Since That Time The Diesel Engine Has Made Significant Advances In Application Areas From Passenger Cars And Light Trucks Through To Large Marine Vessels.

the Diesel Engine Reference Book Systematically Covers All Aspects Of Diesel Engineering, From Thermodynamics Theory And Modelling To Condition Monitoring Of Engines In Service. It Ranges Through Subjects Of Long-term Use And Application To Engine Designers, Developers And Users Of The Most Ubiquitous Mechanical Power Source In The World.

the Latest Edition Leaves Few Of The Original Chapters Untouched. The Technical Changes Of The Past 20 Years Have Been Enormous And This Is Reflected In The Book. The Essentials However, Remain The Same And The Clarity Of The Original Remains. Contributors To This Well-respected Work Include Some Of The Most Prominent And Experienced Engineers From The Uk, Europe And The Usa. Most Types Of Diesel Engines From Most Applications Are Represented, From The Smallest Air-cooled Engines, Through Passenger Car And Trucks, To Marine Engines.

the Approach To The Subject Is Essentially Practical, And Even In The Most Complex Technological Language Remains Straightforward, With Mathematics Used Only Where Necessary And Then In A Clear Fashion. The Approach To The Topics Varies To Suit The Needs Of Different Readers. Some Areas Are Covered In Both An Overview And Also In Some Detail. Many Drawings, Graphs And Photographs Illustrate The 30 Chapters And A Large Easy To Use Index Provides Convenient Access To Any Information The Readers Requires.

audience: Engine Designers And Developers.