Department of Mechanical Engineering University of Canterbury Te Whare Wānanga o Waitaha Telephone: +64-3-366 7001 Private Bag 4800 Facsimile: +64-3-364 2078 Christchurch 8020, New Zealand Website: www.mech.canterbury.ac.nz MASTER OF ENGINEERING THESIS MODELLING A NOVEL ORBITAL IC ENGINE TO AID FURTHER DESIGN By Lindsay Muir BE (Hons) 31 August 2014 Requirements for the degree of MASTER OF ENGINEERING IN MECHANICAL ENGINEERING Approved by: Dr Dirk Pons, Project Supervisor 1 COPYRIGHT LINDSAY MUIR 24/10/2015 0 TABLE OF CONTENTS 1 INTRODUCTION ................................................................................................ 11 1.1 Scenario ............................................................................................................. 11 1.2 Purpose .............................................................................................................. 13 1.3 Scope ................................................................................................................. 14 2 BACKGROUND .................................................................................................. 15 2.1 The Radial and Rotary engine .......................................................................... 15 2.1.1 History ............................................................................................................. 15 2.1.2 Multi-row radials .............................................................................................. 18 2.1.3 Diesel radials .................................................................................................. 19 2.2 General Engine Operating Principles .............................................................. 20 2.2.1 Advantages of the Engine ............................................................................... 26 2.2.2 The operating principles for the 4 stroke engine (1st Prototype) ..................... 27 2.2.3 Second Generation, 2 Stroke Prototype ......................................................... 28 2.3 Risk analysis ..................................................................................................... 36 2.4 Research ............................................................................................................ 37 2.4.1 IC Engines used for Power Generation........................................................... 37 2.4.2 Fuels ............................................................................................................... 38 2.4.3 IC Engine Fundamentals ................................................................................ 39 2.4.4 Engine Development Strategies ..................................................................... 49 2.4.5 IC Engine Modelling ........................................................................................ 50 2.5 Modelling ........................................................................................................... 57 2.5.1 Ricardo Wavebuild .......................................................................................... 58 2.5.2 Model Setup .................................................................................................... 59 3 METHODOLOGY ............................................................................................... 62 3.1 Objectives .......................................................................................................... 62 3.2 Modelling of Four Stroke Prototype ................................................................ 64 3.2.1 Manipulating WAVE for alternative configuration. ........................................... 64 3.2.2 Main Screen Showing General Model Layout ................................................. 64 3.2.3 Constants Table .............................................................................................. 69 3.2.4 Engine General Panel ..................................................................................... 71 3.2.5 Friction and Dynamic Factors ......................................................................... 73 3.2.6 Heat Transfer and Conduction ........................................................................ 74 3.2.7 Combustion ..................................................................................................... 75 3.2.8 Fuel Delivery ................................................................................................... 76 3.2.9 Valves ............................................................................................................. 79 3.2.10 Tuning ............................................................................................................. 83 3.2.11 Output calibration ............................................................................................ 84 1 3.2.12 Validation ........................................................................................................ 87 3.3 Modelling of Two Stroke Prototype Stroke Engine ........................................ 88 3.3.1 Combustion ..................................................................................................... 90 3.3.2 Crankcase and Valves .................................................................................... 91 3.3.3 Scavenging ..................................................................................................... 92 3.3.4 Sensitivity and parameter Analysis ................................................................. 92 3.3.5 Gas Compressibility. ....................................................................................... 93 3.3.6 Squish ............................................................................................................. 93 3.3.7 Upstream breathing restriction investigation ................................................... 94 3.3.8 Uniflow Scavenging ........................................................................................ 94 3.3.9 Ignition timing, Combustion and Fuel Analysis ............................................... 95 4 RESULTS ........................................................................................................... 98 4.1 4 Stroke Performance ....................................................................................... 98 4.1.1 Validation ........................................................................................................ 99 4.2 2 Stroke Base Prediction ................................................................................ 100 4.2.1 Validation ...................................................................................................... 102 4.3 Investigation and optimization for performance predicting ........................ 103 4.3.1 Valve Sizing .................................................................................................. 104 4.3.2 Compression Ratio (CR) and Crankcase Ratio (CCR) ................................. 105 4.3.3 Figure: Fixing CCR at 2. CR changing: ......................................................... 106 4.3.4 Dwell ............................................................................................................. 108 4.3.5 TDC Dwell investigation ................................................................................ 109 4.3.6 Optimization of dwell ..................................................................................... 116 4.4 Optimizing 2 Stroke Engine ........................................................................... 124 4.4.1 Comparing To ICE Engine ............................................................................ 126 4.5 Performance prediction model ...................................................................... 129 4.5.1 Validation ...................................................................................................... 130 5 DISCUSSION .................................................................................................... 131 6 CONCLUSIONS ............................................................................................... 135 6.1 Recommendations .......................................................................................... 135 6.2 Technological Developments ........................................................................ 136 6.3 Commercial Developments ............................................................................ 137 6.4 System Developments .................................................................................... 138 6.5 Future Work ..................................................................................................... 138 2 APPENDICES Appendix A – Project Milestones Appendix B – 4 Stroke Property Constants Table Appendix C – 2 Stroke Property Constants Table Appendix D – Additional 4 Stroke Model Information Appendix E - Additional 4 Stroke Model Information Appendix F – Dynamometer Results of Original Prototype Appendix G – Piston Profile and Valve Timing Tables ANNEXES Annex A - Risk and Reliability Engineering, Application in Engine Design 3 FIGURES Figure 1 - Picture of Original Prototype 11 Figure 2 – Components that make up engine. 20 Figure 3 – Typical ICE Slider Crank Mechanism 21 Figure 4 – Lever dimensions on 2 stroke variant. 21 Figure 5 – Force and reaction path from combustion to the cam configuration for 2 stroke design 22 Figure 6 – Force Body Diagram of System 23 Figure 7 – Cam Detail of 2nd Prototype showing Maximum and Minimum Diameters 23 Figure