This paper presents how the manufacturing technologies are designed for the assembly of a singlecylinder engine block, four strokes, air-cooled. It is presented, from the constructive and technological point of view, the design stages of the main element of the core of an engine, respectively, the engine block. This engine is currently used on light vehicle categories such as ATVs, quads, and motorcycles. In the researches, activities are developed such as the following: designing of various digital technologies to achieve virtual prototype, obtaining a prototype using additive manufacturing technologies, and manufacturing the engine block using CNC technologies, under a range of unique products or small series. Many of the designing activities are materialized in an original software system, named GENgine, developed by authors using Open DCL and Visual LISP programming environments.
This paper presents a method of finite element modelling used for thermal expansion analysis of the complex body assemblies. In this research, the assembly of complex body consists of single cylinder air cooling engine block and fixtures necessary for machining and assembling with cylinder casing. The assembly is loaded with an uniform distributed thermal field and the thermal expansion for internal sections of engine block is determined. The minimum section is used for assembling between engine block and cylinder casing by shrink fit technology. The paper also presents a comparison between results obtained using two different methods: linear thermal expansion and finite element method. The final results are implemented in a software tool, named GENgine, developed by the authors and used for digital manufacturing of engine block.
This paper presents a complex project, implemented in CATIA V5 environment, used for mechanical design and prototype obtaining of the single-cylinder engine block. The main features which are implemented allow reducing the time for design, using the end user design parameters for the prototype manufacturing, reducing the material consumption, optimization of the numerical control technology for milling process. The paper also presents a software system, developed with Visual Basic in CATIA environment, which can be used to automate the process of 3D model generating, creating the data files for rapid prototyping equipments, designing of CNC machining technology, and automatic generating of the numeric control files for the milling process using multi-axes machining centre. The NC files are verified using simulation capabilities of the virtual environment provided by CATIA V5.
This paper presents a method for designing of an engine group for motorsport automotive using the concept from the core to the periphery of the assembly. The core engine solution is an engine block with non-removable cylinder casing, 10 cylinders in V-normal at 72°, double overhead camshaft (DOHC) distribution solution. This powertrain solution is cooled with liquid in a pressurized cooling system. The method used is based in the first step on the modeling of the crankshaft assembly followed by, in the second step, the modeling the peripheral parts-engine assembly. In order to achieve the digital prototype of the engine group is used the CAD/CAM/CAE system named CATIA V5.
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