The Diesel Necronomicon
Only Diesel Bombers Brings You - The Diesel Necronomicon - Book Of The NOTE 53MB http://www.dieselbookmarks.com/bombers/Diesel Engine Reference Book.zip Un Zip , Open and Behold the Vast Knowledge - The Most Informative Book of All Things Diesel BOOK 1 Theory The theory of compression ignition engines 1.1 Introduction 1.1.1 Historical 1.1.2 Classifications 1.2 Two-stroke and four-stroke engines 1.2.1 Two-stroke engines 1.2.2 Four-stroke engines 1.2.3 Evaluation of power output of two-stroke and four-stroke engines 1.2.4 Other operating parameters 1.3 Air standard cycles: constant pressure—constant volume—dual combustion 1.3.1 Theoretical expressions for air standard cycles 1.3.2 Further comments on air standard cycles 1.4 Basic thermodynamics of real gases 1.4.1 Gas properties 1.4.2 Combustion 1.4.3 Dissociation and reaction kinetics 1.5 Real diesel engine cyclic processes 1.5.1 Closed period 1.5.2 Open period 1.6 Detailed cycle analysis methods 1.6.1 Closed period 1.6.2 Open period (gas exchange process) 1.6.3 Completion of calculation sequence The theory of turbocharging 2.1 Introduction 2.2 Turbocharging 2.2.1 Turbochargers for automotive diesel engines 2.2.2 Small industrial and marine engine turbochargers 2.2.3 Large industrial and marine engine turbochargers 2.3 Turbocharger performance 2.3.1 Compressor and turbine efficiency 2.3.2 Non-dimensional representation of compressor and turbine characteristics 2.3.3 Compressor performance 2.3.4 Turbine performance 2.4 Turbocharging systems—principles 2.4.1 The energy in the exhaust system 2.4.2 Principles of constant pressure turbocharging 2.4.3 Principles of pulse turbocharging 2.4.4 Principles of pulse converter and other turbocharging systems 2.5 Charge air cooling 2.5.1 Charge cooling principles 2.5.2 Charge air cooling and engine performance 2.6 Turbocharger matching 2.6.1 Introduction 2.6.2 Air flow characteristics of engine and turbocharger 2.6.3 Matching for constant speed operation 2.6.4 Matching the marine engine 2.6.5 Matching for diesel-electric traction 2.6.6 Matching for other industrial duties 2.6.7 Matching the four-stroke vehicle engine 2.6.8 Matching the two-stroke vehicle engine 2.7 Changes in ambient conditions 2.7.1 Introduction 2.7.2 Operation under changing ambient conditions 2.7.3 Rematching to suit local ambient conditions Compound and other engine systems 3.1 Introduction 3.2 Gas generator and compound schemes compared with the turbocharged engine 3.3 Analysis of turbocharged and compound engine systems based on full cycle simulation 3.3.1 Analysis based on compression and expansion machines with fixed polytropic efficiencies of 85% and 80%, respectively 3.3.2 Analysis based on fully modelled system, including compressor, turbine and cooler characteristics 3.4 Other compounded or related engine schemes 3.4.1 The differential compound engine (DCE) 3.4.2 The differentially supercharged diesel engine (DDE) 3.5 Other turbocharged or pressure charging systems 3.5.1 Two-st=age turbocharging 3.5.2 Variable geometry turbocharging 3.5.3 The pressure wave supercharger Diesel combustion and fuels 4.1 Diesel combustion 4.1.1 Basic combustion theory 4.1.2 Ignition delay 4.1.3 Mixing controlled combustion 4.1.4 Combustion system design 4.1.5 Analysis of cylinder pressure data 4.2 Diesel fuels 4.2.1 Hydrocarbon types 4.2.2 Petroleum-derived fuels 4.2.3 Diesel fuel properties 4.2.4 Diesel fuel quality issues 4.2.5 Diesel fuel specifications 4.2.6 Alternative fuels Thermal loading 5.1 Introduction 5.2 Gross heat losses 5.3 Prediction of local heat flows 5.4 Heat transfer at coolant side 5.4.1 Stationary surfaces—liner 5.4.2 Moving components 5.4.3 Establishing temperature 5.5 Thermal stress 5.5.1 Thermal stress failures 5.5.2 Materials 5.5.3 Strongbacked constructions 5.5.4 Calculation of thermal 5.6 Limiting conditions in operation 5.6.1 To meet lubrication 5.6.2 For thermal strength 5.6.3 Fuel injector 5.7 Designing to meet thermal requirements 5.7.1 Cylinder head 5.7.2 Cylinder liner 5.7.3 Piston design 5.7.4 Injector cooling 5.8 Measurement of local temperature heat fluxes 5.8.1 Fixed thermocouples 5.8.2 Traversing thermocouples 5.8.3 Hardness recovery 5.8.4 Fusible plugs 5.9 Exhaust valves and seats |
Book 2 Engine design practice
Thermodynamic mathematical modelling 6.1 Introduction 6.2 Fundamentals and the energy equation 6.3 Gas properties 6.4 Pipe flows, valves, throttles and flow restrictions 6.5 Turbomachinery and charge air coolers 6.6 The cylinder 6.7 Injection and combustion 6.8 Heal transfer and friction 6.9 Model results and engine performance 6.10 Transient modelling 6.11 Other engine components 6.11.1 Turbomachinery 6.11.2 Control valves 6.11.3 Indirect injection and other fuellingmethods 6.11.4 Two-stroke engines 6.12 Energy equation, gas properties and combustion extensions 6.13 Gas dynamics Computational fluid dynamics 7.1 Introduction 7.2 Model description 7.2.1 Gas-phase modelling 7.2.2 Liquid-phase modelling 7 2.3 Ignition, combustion and emissions 7.3 Applications 7.3.1 Modelling the gas-exchange process 7.3.2 Combustion and emissions model validation 7.3.3 Effect of multiple injections 7.3.4 Use of CFD in engine design 7.4 Summary and conclusions Modern control in diesel engine management 8.1 What is the purpose of control 8.1.1 Fundamental components 8.1.2 The structure of a control 8.1.3 The shape of the future—control 8.2 The context of engine control 8.3 What a control system does 8.3.1 Sensors for control 8.3.2 Actuators for control 8.4 Current engine control technology 8.5 Algorithms for control 8.5.1 Predictors and filters 8.5.2 The Future 8.5.3 Modern control—an example 8.6 Designer’s guide 8.6.1 Developing control systems 8.6.2 General comments about development 8.6.3 Specifying functions |
BOOK 3 Engine sub-systems
Inlet and exhaust systems 9.1 Introduction 9.2 Gas flow 9.3 Four-stroke engines 9.3.1 Valve timings 9.3.2 Valve areas 9.3.3 Determination of flow coefficients 9.3.4 Engine breathing demands 9.3.5 Actual non-swirling port shapes 9.3.6 Swirl producing ports 9.4 Turbocharging 9.5 Two-stroke engine scavenging 9.5.1 Cross scavenging 9.5.2 Loop scavenging 9.5.3 Uniflow scavenging 9.5.4 Port areas and timings 9.6 Silencers Design layout options 10.1 Introduction 10.2 The balancing of engines 10.2.1 Consideration of the forces involved 10.2.2 Balance of a single-cylinder engine 10.2.3 Two-cylinder engines 10.2.4 Four-cylinder in-line engines 10.2.5 Three-cylinder engines 10.2.6 Six-cylinder engines 10.2.7 Vee engines 10.2.8 Two-stroke engines 10.2.9 Control of torque reaction 10.3 Torsional vibration 10.3.1 Simple systems 10.3.2 The solution of multi-cylinder crankshaft systems 10.3.3 Vibration dampers 10.3.4 Torsiographs and torsional vibration tests 10.4 General design practice and use of materials 10.4.1 Introduction 10.4.2 The design process 10.4.3 General properties of materials 10.4.4 Behaviour of materials under repeated loads—fatigue 10.4.5 Typical materials used in production Fuel injection systems 11.1 Introduction 263 11.2 Diesel fuel injection systems—Lucas Diesel Systems 11.2.1 Compression ignition combustion processes 11.2.2 Formation of nitric oxide by lean combustion 11.2.3 Unburned hydrocarbons 11.2.4 Origins of noise in diesel combustion processes 11.2.5 Particulate emissions 11.2.6 Traditional jerk pump 11.2.7 Unit injectors 11.2.8 DP rotary distributor pumps 11.2.9 Electronically controlled rotary pumps (EPIC) 11.2.10 Advanced rotary distributor pumps 11.2.11 Control of rate of injection with conventional FIE 11.2.12 Lubrication of fuel injection components 11.2.13 Common rail systems 11.2.14 Integrated fuel injection systems 11.2.15 Summary 11.2.16 Acknowledgement 11.3 Diesel fuel injection systems—Robert Bosch Corp. 11.3.1 Fuel-injection systems 11.3.2 Fuel-injection techniques 11.3.3 Pump-and-barrel assemblies (pumping elements) 11.3.4 Standard PE in-line injection pumps 11.3.5 PE in-line injection pumps for alternative fuels 11.3.6 In-line control sleeve fuel-injection pumps 11.3.7 Electronic Diesel Control (EDC) 11.3.8 Bosch—Single-plunger fuel-injection pumps 11.3.9 Innovative fuel-injection systems 11.3.10 Peripheral equipment for diesel fuel-injection systems 11.3.11 Bosch—Distributor injection pumps VE 11.4 Diesel fuel injection systems—Caterpillar Inc. 11.4.1 Caterpillar’s hydraulically-actuated electronic unit injector (HEUI) fuel system 11.4.2 Next generation: HEUI-B Lubrication and lubricating oils 12.1 Introduction 12.2 Lubricating oils 12.2.1 Mineral oils 12.2.2 Synthetic oils 12.3 Viscosity—its significance in lubrication 12.3.1 Viscosity and coefficient of friction 12.3.2 Viscosity measurement and units 12.3.3 Change in viscosity with temperature and pressure 12.3.4 Viscosity classification 12.3.5 Low-temperature viscosity and ease of starting 12.3.6 Viscosity at running temperatures;friction losses and oil consumption 12.4 Additives 12.5 Oil deterioration 12.6 Operational problems 12.6.1 Piston deposits 12.6.2 Engine wear 12.6.3 Bearing corrosion 12.6.4 Sludge 12.7 API classification 12.8 Engine tests and associated specifications 12.8.1 Engine test rating 12.9 Laboratory inspection tests 12.10 Spot tests Bearings and bearing metals 13.1 Introduction 13.2 Bearing designs 13.2.1 Wall thickness 13.2.2 Interference fit 13.2.3 Locating tangs 13.2.4 Free spread 13.2.5 Loading on crankpin and main bearings 13.2.6 Prediction of oil film thickness 13.2.7 Grooving configuration 13.2.8 Clearance 13.3 Bearing damage 13.3.1 Abrasion 13.3.2 Fatigue 13.3.3 Corrosion 13.3.4 Wiping 13.3.5 Cavitation 13.3.6 Fretting 13.3.7 Design faults 13.3.8 Incorrect assembly 13.3.9 Environmental factors 13.3.10 Geometric factors 13.4 Slow-speed engine crosshead bearings 13.5 Bearing metals 13.5.1 Fatigue strength 13.5.2 Scuff resistance 13.5.3 Wear resistance 13.5.4 Cavitation erosion resistance 13.5.5 Overlays 13.5.6 White metals 13.5.7 Copper-lead and lead-bronze alloys 13.5.8 Aluminium-tin alloys 13.5.9 Aluminium-silicon alloys Pistons, rings and liners 14.1 Introduction 14.2 Pistons 14.2.1 Introduction 14.2.2 Piston loading 14.2.3 Piston design 14.2.4 Piston types 14.2.5 Gudgeon pins 14.2.6 Piston design analysis 14.3 Rings 14.3.1 Introduction 14.3.2 Ring design 14.3.3 Ring types 14.3.4 Ring packs 14.3.5 Ring materials 14.3.6 Ring coatings 14.3.7 Oil consumption and blow-by 14.3.8 Scuffing 14.3.9 Ring research 14.4 Liners 14.4.1 Introduction 14.4.2 Dry liners 14.4.3 Wet liners 14.4.4 Liner shape and surface finish 14.4.5 Material 14.4.6 Bore polish Auxiliaries 15.1 Governors and governor gear 15.1.1 Introduction 15.1.2 Basic principles 15.1.3 Basic governing terms 15.1.4 Typical governors 15.1.5 Application requirements and governor selection 15.1.6 Typical applications 15.1.7 Conclusion 15.2 Starting gear and starting aids 15.2.1 Introduction 15.2.2 Unaided cold starting ability 15.2.3 Improving the unaided cold starting ability 15.2.4 Engine cranking requirements 15.2.5 Methods of starting 15.2.6 Starting aids 15.3 Heat exchangers 15.3.1 Introduction 15.3.2 Operating conditions 15.3.3 Water-cooled systems 15.3.4 Evaporative systems 15.3.5 Temperature control 15.3.6 Air-cooled systems 15.3.7 Heat transfer 15.3.8 Construction and design 15.3.9 Materials 15.3.10 Corrosion 15.3.11 Maintenance 15.3.12 Water treatment Aircooled engines 16.1 Introduction 16.2 Design features and functional aspects 16.2.1 Crankcase 16.2.2 Cylinder unit 16.2.3 Heat exchangers 16.2.4 Fan control 16.3 Cooling fan 16.3.1 General aspects 16.3.2 Layout and design of axial fans 16.3.3 Stators 16.3.4 Fan noise and its reduction 16.3.5 Other design considerations 16.3.6 Manufacturing considerations 16.4 Environmental aspects 16.4.1 Exhaust emissions 16.4.2 Engine noise 16.4.3 Noise characteristics of aircooled engines 16.4.4 Noise attenuation by secondary measures 16.5 Applications Crankcase explosions 17.1 Introduction 17.2 Oil mist in crankcases 17.3 Explosion effects 17.4 Incidence of crankcase explosions 17.5 Prevention of explosions 17.6 Design aspects 17.7 Explosion relief valves 17.8 Crankcase monitoring systems 17.9 Oil mist detectors 17.9.1 Graviner systems 17.9.2 Schaller Visatron systems 17.9.3 Location of sampling points 17.10 Practical aspects |
BOOK 4 Environmental aspects
Exhaust smoke, measurement and regulation 18.1 General considerations 18.2 Instrumentation 18.2.1 Comparators 18.2.2 Filter-soiling ‘spot’ meters 18.2.3 Opacimeters 18.3 Calibration and correlation of smoke meters 18.4 Optical system—spectral response 18.5 Opacimeter specifications 18.6 Visibility criterion—public objection 18.7 Test methods and procedures 18.8 Typical smoke regulations 18.8.1 Road vehicle applications 18.8.2 Regulations other than for road vehicles 18.9 Conclusions—future legislation Exhaust emissions Contents 19.1 Introduction 19.2 Legislation 19.2.1 USA 19.2.2 Europe 19.2.3 Japan 19.2.4 Concluding remarks 19.3 Analysers 19.3.1 Carbon dioxide 19.3.2 Carbon monoxide 19.3.3 Nitric oxide 19.3.4 Hydrocarbons 19.3.5 Oxygen 19.3.6 Particulates 19.4 Formation and control 19.4.1 Carbon dioxide 19.4.2 Carbon monoxide 19.4.3 Unburnt hydrocarbons 19.4.4 Nitrogen oxides 19.4.5 Odour 19.4.6 Particulates 19.5 Unregulated emissions 19.5.1 Aldehydes 19.5.2 Polycyclic aromatic hydrocarbons 19.5.3 Nitrated polycyclic aromatic hydrocarbons 19.5.4 Vapour-phase hydrocarbons 19.5.5 Particle size 19.6 Conclusions Engine noise Contents 20.1 Introduction 20.2 Theory and definitions 20.2.1 Amplitude 20.2.2 Effect of distance on sound pressure level 20.2.3 Frequency and wavelength 20.2.4 Sound power level 20.2.5 Addition and subtraction of sound sources 20.2.6 Averaging decibel levels 20.2.7 Calculating relative levels 20.2.8 Weighting curves 20.2.9 Noise dose level 20.3 Legislation 20.3.1 On-highway vehicles 20.3.2 Off-highway machines 20.4 Measurement and analysis of noise 20.4.1 Measurement environments 20.4.2 Equipment 20.4.3 Frequency analysis 20.4.4 Tracking analysis 20.4.5 Sound quality analysis 20.5 Noise characteristics of diesel engines 20.5.1 Engine overall noise levels 20.5.2 Assessment of combustion noise 20.5.3 Assessment of mechanical noise 20.5.4 Engine radiated noise 20.5.5 Vehicle and machine noise assessment 20.6 Methods for control of diesel engine noise 20.6.1 Combustion noise 20.6.2 Mechanical noise 20.6.3 Predictive analysis 20.6.4 Palliative treatments and enclosures 20.6.5 Vehicle and machine refinement 20.7 Conclusion Larger engine noise and vibration control 21.1 Introduction 21.2 Noise 21.3 Vibration |
BOOK 5 Applications
Passenger car engines 22.1 Introduction 22.2 Vehicle specific requirements 22.3 Current engine technology 22.3.1 Combustion systems 22.3.2 Design features 22.3.3 Fuel injection equipment 22.3.4 Exhaust gas aftertreatment 22.3.5 Electronic control systems 22.4 Performance and emissions characteristics 22.4.1 Power and torque 22.4.2 Fuel consumption 22.4.3 Exhaust emissions 22.4.4 Noise, vibration, and harshness 22.5 Future developments Trucks and buses 23.1 Market demands 23.1.1 Size and physical constraints 23.1.2 Weight 23.1.3 Cost 23.1.4 Durability and reliability 23.1.5 Performance 23.1.6 Fuel economy 23.1.7 Gaseous and noise emissions 23.1.8 Electronics 23.1.9 Product support 23.2 Starting point 23.2.1 Cylinder block and head 23.3 Cylinder kit components 23.3.1 Pistons 23.3.2 Piston rings 23.3.3 Cylinder liner 23.4 Connecting rod assembly 23.4.1 Connecting rods and bearing caps 23.4.2 Piston pin bearings and connecting rod-to-crankshaft bearings 23.5 Crankshaft assembly 23.5.1 Crankshaft 23.5.2 Crankshaft oil seals 23.5.3 Crankshaft main bearings 23.5.4 Crankshaft pulley 23.5.5 Crankshaft vibration damper 23.6 Camshaft assembly 23.6.1 Camshaft 23.6.2 Camshaft bearings and caps 23.6.3 Camshaft drive gear 23.7 Overhead components 23.7.1 Valve train assembly 23.7.2 Rocker assemblies 23.7.3 Rocker cover assembly 23.7.4 Engine retarders 23.8 Flywheel 23.9 Flywheel housing 23.10 Geartrain 23.11 Gear case and cover 23.12 Electronic control system 23.12.1 ECM 23.12.2 Sensors 23.12.3 Interconnections and wiring 23.12.4 Communications 23.13 Fuel injection system 23.13.1 Electronic fuel injection devices 23.13.2 Fuel (transfer) pump 23.13.3 Fuel lines 23.13.4 Fuel filters 23.13.5 Fuel heaters and coolers 23.13.6 Fuel and water separators 23.14 Air system 23.14.1 Turbocharger 23.14.2 Charge cooler 23.14.3 Intake and exhaust manifolds 23.15 Lubrication system 23.15.1 Oil pump 23.15.2 Regulator 23.15.3 Relief valve 23.15.4 Filters 23.15.5 Oil cooler 23.15.6 Dipstick 23.15.7 Oil pan 23.15.8 Crankcase ventilation 23.15.9 Oil quality 23.16 Coolant system 23.16.1 Coolant 23.16.2 Coolant filter and conditioner 23.16.3 Water pumps 23.16.4 Thermostats 23.17 Typical engines 23.17.1 Product overview 23.17.2 Caterpillar engines 23.17.3 Cummins engines 23.17.4 Detroit diesel engines 23.17.5 Mack engines 23.17.6 Mercedes-Benz engines 23.17.7 Navistar engines 23.17.8 VarityPerkins engines 23.17.9 Volvo engines Locomotives 24.1 Introduction 24.2 Development trends 24.2.1 Emissions 24.2.2 Engine weight 24.2.3 Reliability and durability 24.3 Engine descriptions 24.3.1 Caterpillar 3500 24.3.2 Caterpillar 3600 24.3.3 Dalian 240 ZD 24 3.4 General Electric 7FDL™ 24.3.5 General Electric 7HDL™ 24.3.6 General Motors EMD 645 and 710 24.3.7 General Motors EMD H engine 24.3.8 Kolomna D 49 24.3.9 MTU/DDC 4000 series 24.3.10 Paxman VP 185 24.3.11 Pielstick PA4 200 VG 24.3.12 Pielstick PA6B 24.3.13 Ruston RK215 24.4 Summary of engine design features and future trends 24.5 Railcar engines 24.5.1 Cummins 24.5.2 MAN 24.5.3 MTU 24.5.4 Niigata Dual fuel engines 25.1 What is a dual fuel engine? 25.2 Combustion in dual fuel engines 25.3 Gas properties and their effects 25.3.1 Heat value of a stoichiometric mixture volume 25.3.2 Net heating value (kJ/m3) 25.3.3 Anti-detonation properties 25.3.4 Pre-ignition tendency 25.3.5 Flame speed 25.4 Combustion system 25.4.1 The ‘conventional’ dual fuel engine 25.4.2 The ‘low NOx’ dual fuel engine 25.4.3 The ‘gas diesel’ engine 25.4.4 Other combustion systems 25.5 Air-fuel ratio control systems 25.5.1 Intake throttle 25.5.2 Exhaust by-pass 25.5.3 Compressor by-pass 25.6 Safety systems 25.7 Applications 25.7.1 Automotive 25.7.2 Locomotive 25.7.3 Stationary (power generation and mechanical drive) 25.7.4 Marine and offshore Marine engine applications 26.1 High speed engines 26.1.1 Caterpillar 26.1.2 Cummins 26.1.3 Deutz MWM 26.1.4 GMT 26.1.5 Isotta Fraschini 26.1.6 MAN B&W Holeby 26.1.7 Mitsubishi 26.1.8 MTU 26.1.9 MTU/DDC designs 26.1.10 Niigata 26.1.11 Paxman 26.1.12 SEMT-Pielstick 26.1.13 Wärtsilä diesel 26.1.14 Automotive-derived engines 26.2 Low speed engines 26.2.1 Introduction 26.2.2 Intelligent engines |
BOOK 6 Operation
Condition monitoring 27.1 Introduction 27.2 A typical condition monitoring system 27.3 Instrumentation for condition monitoring 27.3.1 Vibration monitoring 27.3.2 Temperature measurements 27.4 Instrumentation for condition monitoring indirect methods 27.5 Fuel monitoring 27.6 Exhaust emissions 27.7 Conclusion |
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