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A Novel Engine Head Design Using a Rotary Valve System in Traditional Four-Stroke Internal Combustion Engines

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A Novel Engine Head Design Using a Rotary Valve System in Traditional Four-Stroke Internal Combustion Engines A NOVEL ENGINE HEAD DESIGN USING A ROTARY VALVE SYSTEM IN TRADITIONAL FOUR-STROKE INTERNAL COMBUSTION ENGINES A thesis presented to the faculty of the Graduate School of Western Carolina University in partial fulfillment of the requirements for the degree of Master of Science in Technology By Erik Paul Myers Director: Dr. Paul Yanik Associate Professor and Graduate Program Director School of Engineering and Technology Advisor: Dr. Tony Rizk Committee Members: Dr. Martin Tanaka, School of Engineering and Technology Dr. Yusef Fahmy, School of Engineering and Technology Dr. Hayri Sezer, School of Engineering and Technology © 2019 by Erik Paul Myers Acknowledgments I would like to acknowledge the part that God has played in my life and the blessing that it has been to be able to pursue higher education in research. I extend a special thanks to Dr. Tony Rizk, whose support in my ambitions helped me realize what I could accomplish through this thesis. I would also like to thank Dr. Tanaka, Dr. Fahmy, and Dr. Sezer, who’s presence on my thesis committee gave me the confidence and support to make this possible. My family and friends have played a major role in giving me constant support and encouragement during this time. I would like to thank my parents, and my sister and brother-in- law, and all those close to me for everything that they have done for me in life. I would also like to personally thank all of those in the graduate program with me, whose friendship made the impossible possible. Finally, I would like to give thanks to Western Carolina and the opportunity that was provided for me here to excel in my research. ii TABLE OF CONTENTS List of Tables ..............................................................................................................................v List of Figures ........................................................................................................................... vi List of Equations ..................................................................................................................... viii Abstract .................................................................................................................................... ix CHAPTER ONE: INTRODUCTION ..........................................................................................1 1.1 Internal Combustion Engine Design ................................................................................1 1.2 Improvements Made ........................................................................................................1 1.3 The Poppet Valve ............................................................................................................2 1.4 Design and Function of Poppet Valve systems .................................................................2 1.5 Rotor Valve Design .........................................................................................................3 1.6 Areas of improvement in the Rotor Valve Design ............................................................3 1.7 Purpose and Potential Gains ............................................................................................4 1.8 Automotive Manufacturing ..............................................................................................4 1.9 Performance and Efficiency Evaluation ...........................................................................5 CHAPTER TWO: LITERATURE REVIEW AND COMPARISON ...........................................6 2.1 Camless Valve Control ....................................................................................................6 2.2 Swirl Generation and Control ..........................................................................................7 2.3 Combination of Valve, Port, and Swirl Design.................................................................9 2.4 Engine Performance Affected by Engineering ............................................................... 10 2.5 Patent Approaches to Rotary Valve Design .................................................................... 11 CHAPTER THREE: DESIGN SPECIFICATION AND APPROACH ...................................... 14 3.1 Engine Design Selection ................................................................................................ 14 3.2 Basic System Modeling for the RVS .............................................................................. 15 3.3 Geometric Parameters of the Head Components ............................................................ 18 3.4 Selecting the Appropriate Modeling Environment ......................................................... 21 3.5 SolidWorks Drafting Specifics....................................................................................... 25 3.6 SolidWorks Cold Flow Simulation ................................................................................ 33 3.7 SolidWorks Combustion Simulation Background .......................................................... 37 3.8 Defining simulation constraints ..................................................................................... 44 CHAPTER FOUR: SIMULATION RESULTS ......................................................................... 47 4.1 Cold Flow Results from SolidWorks.............................................................................. 47 4.2 Velocity Cut Plot Comparisons ...................................................................................... 50 4.3 Issues with SolidWorks Cold Flow Analysis .................................................................. 56 4.4 Full Combustion Cycle Results ...................................................................................... 60 CHAPTER FIVE: Conclusions and Continuation of Work ........................................................ 73 5.1 Changes between the Traditional System and the RVS .................................................. 73 5.2 Future Work .................................................................................................................. 74 WORKS CITED ....................................................................................................................... 76 APPENDICES .......................................................................................................................... 80 Appendix A: SolidWorks Inlet/Outlet Cold Flow Conditions .................................................... 80 Appendix B: Solidworks Cold Flow Simulation Results – Traditional Model ............................ 82 Appendix C: SolidWorks Cold Flow Simulation Results – RVS Model ..................................... 82 Appendix D: Combustion Simulation Working Fluid Properties ................................................ 83 iii Appendix E: Combustion Simulation Flow COnditions ............................................................. 84 Appendix F: Traditional Combustion Simulation Results (Intake) ............................................. 87 Appendix G: Traditional Combustion Simulation Results (Combustion) ................................... 88 Appendix H: Traditional Combustion Simulation results (Exhaust) ........................................... 89 Appendix I: RVS Combustion Simulation Results (Intake)........................................................ 90 Appendix J: RVS Combustion Simulation Results (Combustion) .............................................. 91 Appendix K: RVS Combustion Simulation Results (Exhaust) ................................................... 92 Appendix L: Traditional COld Flow Velocity Cut Plots ............................................................ 93 Appendix M: RVS Cold Flow Velocity Cut Plots ...................................................................... 95 Appendix N: Traditional Combustion Velocity Cut Plots .......................................................... 97 Appendix O: RVS Combustion Velocity Cut Plots .................................................................. 100 Appendix P: Traditional Combustion Pressure Cut Plots ......................................................... 103 Appendix Q: RVS Combustion Pressure Cut Plots .................................................................. 106 Appendix R: Curvefit coefficients for k, µ, and Cp .................................................................. 109 Appendix S: Characteristics of Heptane .................................................................................. 110 Appendix T: Characteristics of O2 ........................................................................................... 111 Appendix U: Characteristics of N2 .......................................................................................... 112 Appendix V: Characteristics of H2O ........................................................................................ 113 Appendix W: Characteristics of CO2 ....................................................................................... 114 iv LIST OF TABLES Table 3.1. Table of Geometric Properties for the Agusta M4 Engine ......................................... 19 Table 3.2. Rotor Valve Timing Angles ...................................................................................... 20 Table 3.3. Simulation Boundary Conditions .............................................................................. 24 Table 3.4. Inlet and Outlet flow velocities for various CAD ...................................................... 35 Table 3.5.
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