Group 10 - GM V-6 Engine 1

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Executive Summary

The following report analyzes the GM V-6 engine through the reverse engineering process. The analysis is composed of 4 main steps or gates; planning, dissection, analysis and explanation.

    Gate 1
      The first gate consists of the work proposal and the overall plan for the dissection of the engine, as well as general information on use, energy flows, complexity and materials used. Before the engine was taken apart, speculations were made on the tools to be used for dissection. These speculations got the group thinking and planning for future tasks. The group members were analyzed and given roles and responsibilities to be held throughout the analysis process. A time frame for different tasks necessary to the project was also proposed in the first gate. This gate went very well, no actual mechanical work had to be done so there was minimal difficulty involved.
    Gate 2
      The second gate provides step by step documentation on the dis-assembly of the engine. The difficulty of each step is given based on a number scale devised to describe the effort needed at each step of the process. The dissection process is given as a table, providing notes, photos, tools used, number of bolts removed, and the difficulty rating for each step. Following the dis-assembly process is a written report on the connection of the engine's subsystems, describing in detail the interaction of each subsystem and how they work together to perform the overall function. A flow chart is also provided, which breaks down the engine into its subsystems and describes the energy input required at each subsystem level. The energy input results in an engine output, which is documented in the chart. This gate posed some difficulty to the group. Now the engine actually had to be disassembled so the cumulative knowledge and experience of the group was used. The main difficulty was that Group 11 had taken apart the engine before all of Group 10 had seen it together. The first task was to completely reassemble the engine from parts in trash bags. Everything was very well labeled, but one had to know what every part was before it could be properly installed.
    Gate 3
      The dissection process provided information necessary for analysis of the engine, which is documented in gate 3. Problems that were encountered during the previous steps are given, along with proposed solutions. The analysis begins with pictures of the main components of the engine, as well as a high speed video of the assembly of the engine. The pictures are followed by a chart describing the function of each part, as well as the energy flows required for each part to perform the required task. Each part of the engine is connected and relies on an adjacent part to provide this energy. Each part is then analyzed and details are provided describing the manufacturing method used to make it. The global, economic, environmental and societal factors that were taken into account when designing each part are also given. Each part was then given a number value (based on a scale provided) indicating its complexity and the complexity of the interaction between it and adjacent parts. A generalization of the shape of each part is also documented along with the reason given for the shape. The weight, material used, and aesthetic properties of each part are also given. This gate also provides proposed design revisions to improve the performance of the engine. A solid model of the piston, crankshaft, connecting rods and camshaft is provided to show the interaction between these parts. Given the choice of an engineering analysis problem a section was also dedicated to show the thermal efficiency in the pistons of our engine.
    Gate 4
      The final gate for the analysis gives further explanation of the engine. Step-by-step instructions are given for the engine's re-assembly. A scale similar to the one provided for the dis-assembly process is given for re-assembly. The assembly process is summarized in a table listing the part installed, the difficulty of installation, tools used, the number and size of bolts required, notes further describing the process, and pictures to aid in re-assembly. The final proposal for design revisions are given describing what could be changed and how this change could improve the performance of the engine. The proposed revisions are variable valve timing, increased pressure ratio of the cylinders, and the use of overhead cams.



    • Sam Pierangelo
    • Jared Prosser
    • Jim Hickel
    • Ben Kuch
    • Ed Bishop

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