Vehicle Design Lecture1

8/3/2019 Vehicle Design Lecture1

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Vehicle Design II

Vehicle Design II(Course Overview)

Dr. Nouby M. GhazalyAutomotive and Tractor Engineering Dept.

College of Engineering,Minia University-61111

[email protected]



Class Structure



Course Goals

• Contribute to future developments in automotivetechnology through design of engine components

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Course Topics

1. Introduction • Design philosophy, an overview of engine design, Applications of Computer aided

Design (CAD) and Finite Element Analysis (FEA) in Engine Design.

• History of automobile engines, Classification of engines, Principle of engine

operation (SI & CI). Engine support mountings. (8hrs) (2Q)

2. Design of Cylinders Block and Cylinder liners, details of water jacket, dry and wetliners, Design of Cylinder head, Cylinder arrangement. (4hrs) (1Q).

3. Design of Piston Assembly, piston rings, piston pin - stress analysis, methods of

manufacture, heat treatment, piston ring selection, limits of fit for pins. (4hrs) (1Q).

4. Design of Connecting rod assembly (small end- Big end- Shank ) (4hrs) (1Q).

5. Design of Crank shaft, firing order, balancing and torsional vibration analysis,

vibration dampers. (4hrs) (1Q).

6. Design of Flywheel; Camshaft - drives of cams, materials, Types. (4hrs) (1Q).

7. Design of Valve and valve mechanism, types of valve operating mechanisms, valve

springs, guides, push rods, rocker arms, tappets, valve timing diagrams. (4hrs) (1Q)•



REFERENCE BOOKS

1. Shigley J.E. “Mechanical Engineering Design” McGraw Hill, 2003.

2. Garrett T.K., Newton K. and Steeds W. “The Motor Vehicle” Reed Educational

and Professional Publishing, 2001.

3. Kolchin A., Demidov V. “Design of Automotive Engines” Mir Publishers, 1984.4. Willard W. Pulkrabek “Engineering Fundamentals of the Internal Combustion

Engine” Prentice Hall, 1997.

5. Richard D. Atkins “An Introduction to Engine Testing and Development” SAE

International, USA, 2009.



Lecture (1)

1. Design philosophy

• What is Design?

• How to design?

• Design Process

• Design process For Automotive

2. Applications of CAD/CAM/CAE

3. Finite Element Analysis (FEA) in Engine

Design.



Design Philosophy

• What is Engineering?

• Engineering is not usually considered a science. Science is about discovering

the natural. Engineering is creating the artificial.

• Engineers apply the principles of science and mathematics to developsolutions to problems.

• The main philosophy behind all of the engineering and engineering design

activities is to serve the people, society and mankind.

• This is why the engineering design is defined as an activity to satisfy a need.

A need is real only if it is defined and identified by a human.



What is Design?

• Design is a interaction between what we want to achieve and how we wantto satisfy them.

• Design is a process of converting information that characterize the needsand requirements for a product into knowledge about the product.

• Engineering design is creative at the beginning, and significance of creativitydecreases towards the end of the process,

• Engineering design is iterative during the whole design process.

Scientific Principlesand Technology

Design Information

Product

Work Feedback

DesignProcess Evaluation



How to Design?

• What does the customer want?

– Looks, safety, price, feeling, speed, Design, Efficiency, Features,

Performance, Handling, Size, Extra service, Capacity, User

reviews, Quality



How to Design?

• What do you want to achieve and how?

– Give people a vision about your car

– The car specifications

•

Engine, weight, efficiency, acceleration, topspeed, capacity



How to Design?

• car classification:

Supermini

Small family car

Large family carExecutive car

Roadster

Small Off-Roader

Large Off-Roader



Engineering Design

Process

Describe the challenge

to be solved, including

limits and constraints.

Test your solution.

Make your solution.

Use your knowledge

and creativity to

come up with many

solutions. Choose one

idea and draw or

make a model of it.

Research what

others have done.Discover what

materials are

available.

Identify the Problem

Explore Design

Create

Try It Out

Make It Better

Evaluate how the

solution worked and

think of how to

improve your design.



Engineering Design

Process• Recognition of a customer’s need

– Market research identifies customers and needs

– R&D creates ideas that are relevant to an organization’s capabilities

– Needs arise from dissatisfaction

– Technology push (examples : computers, audio)

• Definition of a problem or Task – Design specification

– Selecting product ideas

– Compiling the requirement list

– Acquire & apply technical knowledge

–Identify resources

– Prioritize design goals & continue to refine



Engineering Design

Process• Product definition

– Function

– Preliminary requirements list

– Solution requirements

– Cost target and budget

SOURCES

CONSUMER COMPANY

SITUATION ANALYSIS

PROCEDURE FOR SEARCH

DEFINE THE PRODUCT

QUALITATIVE DESCRIPTION

DESIGN



Engineering Design

Process• Conceptual design

– This phase looks at the function requirement of the Product. Thefunction are listed & complex functions are broken into simpler sub-functions.

– Determines the Principle of Solution.

–

It is preceded by a Decision• Procedure

– Abstract to identify essential problems

– Establish function structures

– Search for working principles to fulfill the sub-functions

– Combine working principles into working structures

– Select suitable combinations

– Evaluate against technical & cost criteria



Engineering Design

Process• Design embodiment

– It starts from the concept and develops the definitive layout for theproject

– Evaluate against Technical & Economic criteria

– Preliminary layout

– Optimize and complete form designs

– Check for errors and disturbing factors

– Prepare preliminary part list and production documents

• Embodiment design is characterized by repeated deliberation andverification.

• This requires approach that is progressive as well as iterative.

• The checklist – Function, Working Principle, Layout, Safety, Ergonomics, Production,

Assembly, Transport, Recycling, Maintenance, Costs, Quality control



Engineering Design

Process• Prepare production documents :

– Elaborate detailed drawings and parts list

– Complete production,assembly,transport and operatinginstructions

– Check all documents

• Design review – Review and redesign focuses on achieving the performance,

producibility, reliability and cost (As compared to what) objectives.

– Competitive benchmarking

– Reverse Engineering of competitor’s products

– Early bird gets the profit



BASIC STEPS IN MECHANICAL

DESIGN PROCESS

1) Problem DefinitionConstraints , Who’s the Customer?

Data gathering: What is known, what is not.

2) Literature Search: What are possible solutions?

3) Analysis , Modeling

4) Develop ideas for a solution

Solution Evaluation, Failure Mode Effect Analysis

Optimization, Design for Manufacturability

5) Prototype Fabrication

6) Testing, Modification

7) Volume Production

8) Continuous verification and Testing, Customer Feedback

9) Take data to verify your gains or improvements

Add this to your resume!



CAD/CAM/CAE

• Computer-Aided Design (CAD) is the technology• concerned with the use of computer systems to assist in

• the creation, modification, analysis, and optimization of a

• Design.

• Computer-Aided Manufacturing (CAM) is the technology

• concerned with the use of computer systems to plan,

• manage, and control manufacturing operations.

• Computer-Aided Engineering (CAE) is the technology

• concerned with the use of computer systems to analyze

• CAD geometry, allowing the designer to simulate and

• study how the product will behave.



Computer-Aided Design (CAD)

• Use of computer systems to assist

in the creation, modification,

analysis, and optimization of a

design

• Typical tools:

– Tolerance analysis

– Mass property calculations

– Finite-element modeling and

visualization

• Defines the geometry of thedesign



Computer-Aided Engineering

(CAE)

• Use of computer systems toanalyze CAD geometry

• Allows designer to simulate andstudy how the product willbehave, allowing for optimization

• Finite-element method (FEM)

– Divides model intointerconnected elements

– Solves continuous fieldproblems



Computer-Aided Manufacturing

(CAM)

• Use of computer systems to plan,

manage, and control

manufacturing operations

• Direct or indirect computer

interface with the plant’s

production resources

• Numerical control of machine

tools

• Programming of robots



Integrated

CAD/CAE/CAM Systems• Professional CAD/CAE/CAM Tools

• – CATIA (Dassault Systemes - IBM)

• – Unigraphics NX (Electronic Data Systems Corp - EDS)

• – I-DEAS (EDS)

• – Pro/ENGINEER (PTC)

• • Other CAD and Graphics Packages

• – AutoCAD Mechanical Desktop

• – SolidWorks (CATIA)

• – Solid Edge (EDS)

•

– MicroStation• – Intergraph



Pro/ENGINEER

• One of the CAD/CAM/CAE industry’s leading suppliers of

software tools from Parametric Technology Corp. (PTC)

• A pioneer of the new feature-based, parametrically driven

design paradigm in late 1980s, now industrial standard.

• A system used to automate the development of a mechanical product from its conceptual design through production.

• Offering integrated software technologies to reduce time to

market, improve engineering process, and optimize product

quality.

• One of the fastest growing companies in the mechanical design automation market

• Improved user’s interface in recent release.



Unigraphics- NX

• A full spectrum design modeling, analysis,simulation, and manufacturing CAD/CAE/CAM

software from

Unigraphics Solutions

• One of the older and well-established CAD/CAE

system.• A software of choice for a wide variety of

applications, especially in automotive and

aerospace product development.



CATIA

• A process-centric CAD/CAM software solution marketed

exclusively by IBM and developed by Dassault Systems

• A system used to design and manufacture many complex

3D products. Today, 7 out of every 10 airplanes and 4 out

of every 10 cars are designed using CATIA-CADAM

Solutions, making it the de facto standard for these

markets.

• A software of choice for a wide variety of applications

ranging from consumer goods and machinery to plant

design and shipbuilding.

• 300,000 CATIA users worldwide, nearly half in English

language markets



Finite Element Analysis in Design

• The continuum has an infinite number of degrees-of-freedom (DOF), while the

discretized model has a finite number of DOF. This is the origin of the name, finite

element method.

• The number of equations is usually rather large for most real-world applications of

the FEM, and requires the computational power of the digital computer. The FEM has little practical value if the digital computer were not available.

• Advances in and ready availability of computers and software has brought the FEM

within reach of engineers working in small industries, and even students

• Most commercial FEM software packages originated in the 1970s (ABAQUS,ADINA, ANSYS, MARK, PAFEC) and 1980s (FENRIS, LARSTRAN ‘80, SESAM

‘80.)

Fi i El A l i i



Finite Element Analysis in

Design• FEA programs simulate static, dynamic,

linear, nonlinear, thermal, modal, and

random vibrations, and more. FEA solves

many different problems out of which

structural and thermal problems are most

common for mechanical engineers."Structural analysis finds deformations,

strains, and stresses caused by structural

loads such as force, pressure, and gravity.

Thermal analysis finds temperatures,

temperature gradients, and heat flow

caused by thermal loads such as heat fluxor heat power. Boundary conditions such

as prescribed temperatures and

convection coefficients also affect results.



Finite element model of the

gasoline SI engine



Applications in FEA



Questions?

Documents

Vehicle Design Lecture1