Group 20 - GM V6 Engine - 1 - Revision history

M Devendorf: Group 20 - GM V6 Enginer - 1 moved to Group 20 - GM V6 Engine - 1: Corrected Typo in Title

2008-12-06T19:49:46Z

Group 20 - GM V6 Enginer - 1 moved to Group 20 - GM V6 Engine - 1: Corrected Typo in Title

UB08G20: /* Process */

2008-12-05T19:49:59Z

Process

UB08G20: /* Types of Material */

2008-12-05T19:46:10Z

Types of Material

UB08G20: /* Purpose and How it Works */

2008-12-05T19:45:05Z

Purpose and How it Works

UB08G20: /* CAD: Parts and Assembly */

2008-12-05T19:04:45Z

CAD: Parts and Assembly

UB08G21: /* Main Systems */

2008-12-05T19:02:22Z

Main Systems

UB08G20: /* Materials Used */

2008-12-05T18:18:16Z

Materials Used

UB08G21: /* CAD: Parts and Assembly */

2008-12-05T17:37:08Z

CAD: Parts and Assembly

UB08G21: /* Improvements */

2008-12-05T17:29:56Z

Improvements

UB08G20: /* CAD: Parts and Assembly */

2008-12-05T13:35:44Z

CAD: Parts and Assembly

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 ===How it Works===
 ====Process====
-The internal combustion engine, such as the General Motors V6 Vortec 4300 engine, works by transferring the chemical energy in gasoline into mechanical energy to move the vehicle.  To complete this process, a basic 4 stroke cycle called the Otto Cycle.  The four cycles of this process are as follows:<br>
+Internal combustion engines, such as the General Motors V6 Vortec 4300 engine, work by transferring the chemical energy in gasoline into mechanical energy to move the vehicle.  To complete this process, a basic 4 stroke cycle called the Otto Cycle.  The four cycles of this process are as follows:<br>
 .) '''The Intake stroke''' - In this stroke of the process, the piston is lowered, and the chamber or cylinder is filled with a fuel/air combination which is determined by the throttle.  <br> 2.) '''The Compression stroke''' - In this stroke, the piston is raised up while the openings on the cylinder head are closed, in order to compress the fluid to its desired compression to get ready for the next stroke.  <br> 3.) '''The Ignition stroke''' - Here the fluid is ignited by a spark plug, and the piston is forced down. <br>4.) '''The Exhaust stroke''' - In the final stroke of the cycle, the opposite intake opens and the byproduct (exhaust) is released.  <br>This process occurs in a few main components located inside of the engine.

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 ===Types of Material===
-We concluded that there are primarily four types of material used in this engine.  These are Steel, Plastic, Rubber, and Aluminum.  We concluded that these are primarily the four types because the different materials contain different alloys and types due to what the use is in the engine.
+We concluded that there are primarily four types of material used in this engine.  These are Iron, Steel, Plastic, Rubber, and Aluminum.  We concluded that these are primarily the four types because the different materials contain different alloys and types due to what the use is in the engine.
 ==Disassembly Procedure==

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 ===Purpose and How it Works===
-The gasoline engine is used to convert chemical energy in the form of a gasoline and air mixture to mechanical energy, which is used to make a vehicle move.  The engine generates this energy by the use of a combustion cycle obtained through a piston – cylinder system which is attached to the crank shaft.  The piston moves down letting an Air/Gasoline mixture enter the cylinder then the piston rises compressing the mixture.  Then the spark plug ignites creating a small explosion which drives the piston down to keep the cycle moving and releases the exhaust.  This constant cycle is rotating the crank shaft which eventually relates this energy to turn the tires.
+The gasoline engine is used to convert chemical energy in the form of a gasoline and air mixture to mechanical energy, which is used to make a vehicle move.  The engine generates this energy by the use of a combustion cycle obtained through a piston – cylinder system which is attached to the crank shaft.  The piston moves down letting an Air/Gasoline mixture enter the cylinder, then the piston rises compressing the mixture.  Then the spark plug ignites, creating a small explosion which drives the piston down to keep the cycle moving and releases the exhaust.  This constant cycle is rotating the crank shaft which eventually relates this energy to turn the tires.
 ===Types of Energy===

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 * Bearing
 [[Image:bearing cad.jpg|center|thumb|450px|]]
 ==Assembly==

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 ====Main Systems====
 Our engine contained components of some main systems of the vehicle. Although the full systems were not present on our engine, we felt it necessary to represent the system as it works on the vehicle for an understanding of why these components are present on the engine.<br><br>
-•'''Fuel Delivery''' - In order for combustion to occur, fuel and air must enter the engine during the intake stroke of each cylinder.  Fuel system components on the vehicle include the ECU, gas tank, fuel pump, and high-pressure fuel send and return lines.  The fuel pump creates enough pressure in the system for injection.  The fuel lines reach the central fuel injector, which is really six injectors together.  This injector is basically a series of valves that receives information from the Engine Control Unit(not a component of our engine but a component of the vehicle) so it can open the correct valves at the correct times.  When the injector allows fuel to flow through, it goes through a tube that leads through the intake manifold to the correct intake port in the cylinder head.<br>The most important part of the fuel system is the ECU because it determines when and how much fuel to inject by opening the valves in the fuel injector.  To maintain the proper air/fuel ratio sensors must be utilized to determine how much air is entering the engine and how much fuel is required.  The throttle position sensor determines the load on the engine, and the oxygen sensors determine if it is running rich or lean, for fine adjustments.  The crankshaft angle sensor tells the ECU what stroke each piston is in so that fuel can be added at the appropriate time. The Intake Manifold Absolute Pressure Sensor determines how much air is entering the engine.<br><br>
+• '''Fuel Delivery''' - In order for combustion to occur, fuel and air must enter the engine during the intake stroke of each cylinder.  Fuel system components on the vehicle include the ECU, gas tank, fuel pump, and high-pressure fuel send and return lines.  The fuel pump creates enough pressure in the system for injection.  The fuel lines reach the central fuel injector, which is really six injectors together.  This injector is basically a series of valves that receives information from the Engine Control Unit(not a component of our engine but a component of the vehicle) so it can open the correct valves at the correct times.  When the injector allows fuel to flow through, it goes through a tube that leads through the intake manifold to the correct intake port in the cylinder head.<br>The most important part of the fuel system is the ECU because it determines when and how much fuel to inject by opening the valves in the fuel injector.  To maintain the proper air/fuel ratio sensors must be utilized to determine how much air is entering the engine and how much fuel is required.  The throttle position sensor determines the load on the engine, and the oxygen sensors determine if it is running rich or lean, for fine adjustments.  The crankshaft angle sensor tells the ECU what stroke each piston is in so that fuel can be added at the appropriate time. The Intake Manifold Absolute Pressure Sensor determines how much air is entering the engine.<br><br>
-•'''Ignition''' - Our engine uses an electronic ignition system with a distributor.  The distributor spins with the crankshaft and sends a signal to the coil-pack.  The coil pack sends a spark to the spark plug via spark plug wires.  Since the distributor is in alignment with the crankshaft, spark is delivered at the correct time.  The firing order of our engine is 1-6-5-4-3-2. <br><br>
+• '''Ignition''' - Our engine uses an electronic ignition system with a distributor.  The distributor spins with the crankshaft and sends a signal to the coil-pack.  The coil pack sends a spark to the spark plug via spark plug wires.  Since the distributor is in alignment with the crankshaft, spark is delivered at the correct time.  The firing order of our engine is 1-6-5-4-3-2. <br><br>
-•'''Lubrication''' - In order to operate properly, any engine needs lubrication.  Our engine did not contain any fluids, but in order to function it needs motor oil.  Motor oil haas many functions.  It lubricates to reduce friction and wear, absorbs shock to reduce wear, cools, cleans, and inhibits oxidation for the prevention of rust.  Without proper lubrication, engine components will fail rather quickly.  If for example a car was traveling at 55 mph and a hole in the oil pan developed and all oil was drained in a matter of one minute, the engine would seize in just over a minute and catastrophic engine damage would occur.<br>Oil is added through a fill neck on one of the valve covers and sits at the bottom of the oil pan before entering the oil pickup tube which has a strainer on the end so that foreign particles are not circulated.  After entering the pickup, it goes through the oil pump which pumps it through passageways in the block to squirters that deliver it to moving components. It also flows to an external oil filter that is changed approximately every 3,000 miles with the oil, so that fine particles stay away from moving components. <br><br>
+• '''Lubrication''' - In order to operate properly, any engine needs lubrication.  Our engine did not contain any fluids, but in order to function it needs motor oil.  Motor oil haas many functions.  It lubricates to reduce friction and wear, absorbs shock to reduce wear, cools, cleans, and inhibits oxidation for the prevention of rust.  Without proper lubrication, engine components will fail rather quickly.  If for example a car was traveling at 55 mph and a hole in the oil pan developed and all oil was drained in a matter of one minute, the engine would seize in just over a minute and catastrophic engine damage would occur.<br>Oil is added through a fill neck on one of the valve covers and sits at the bottom of the oil pan before entering the oil pickup tube which has a strainer on the end so that foreign particles are not circulated.  After entering the pickup, it goes through the oil pump which pumps it through passageways in the block to squirters that deliver it to moving components. It also flows to an external oil filter that is changed approximately every 3,000 miles with the oil, so that fine particles stay away from moving components. <br><br>
-•'''Cooling''' - The cooling system contains a water pump driven by the crankshaft to circulate a mixture of water and anti-freeze through passageways in the engine and the radiator.  The thermostat contains wax which expands when heated so that it opens when the coolant is hot, allowing it to flow to the radiator for cooling by wind or fans.  The radiator cap keeps the system under pressure so that the boiling point of the coolant is increased.
+• '''Cooling''' - The cooling system contains a water pump driven by the crankshaft to circulate a mixture of water and anti-freeze through passageways in the engine and the radiator.  The thermostat contains wax which expands when heated so that it opens when the coolant is hot, allowing it to flow to the radiator for cooling by wind or fans.  The radiator cap keeps the system under pressure so that the boiling point of the coolant is increased.
 ====Functionality====

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 ) '''Aluminum'''- This material is used where a light weight, corrosion resistant material is needed.  For example, the compression rings are made of aluminum due to the wear exerted on them by the cylinder walls, and because the light weight of the aluminum rings will not impede the piston's motion.<br>
 ) '''Plastic'''- Plastics are used where the durability of metal is not required.  Also, it is used where the bulkiness of a component made of metal is not desired.  Plastics are used in the situation also because of the very cheap and effective processes that can be used to make plastic parts.<br>
-) '''Rubber'''- Rubber is very flexible and resistant and heat.  Therefore, it is used when a component must be able to move freely yet be resilient enough to withstand the intense heat produced by an engine. <br>
+) '''Rubber'''- Rubber is very flexible and resistant to heat.  Therefore, it is used when a component must be able to move freely yet be resilient enough to withstand the intense heat produced by an engine. <br>
 ===Sensors===

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 <br>• '''Create the engine block out of aluminum instead of cast iron.'''  The engine block is one of the largest and heaviest components of the engine, and a switch to a less dense material such as aluminum.  This aluminum would need to be developed to withstand the forces and heat created inside of the engine.  While switching out the engine block, other cast iron components such as cylinder heads could be replaced as well.  This would result in a reduction of weight, and an increase in efficiency.  Also, Aluminum is less corrosive, meaning it will survive longer.
-<br>• '''Change the angle of the cylinders from 90˚ to 60˚.'''  The angle of 90˚ is the most efficient angle for a V8 (8 cylinder) engine, but V6 engines can be configured to run this way.  Our V6 was made with a 90˚ angle because it is made in the same factories as V8 engines and it is economical to just configure the V6 at 90˚ so they can be made in a similar way.  However, the most efficient angle for a V6 is 60˚.  This angle change is significant,  as the engine can be made more compact, and this configuration is where the least amount of vibration occurs.
+<br>• '''Change the angle of the cylinders from 90˚ to 60˚.'''  The angle of 90˚ is the most efficient angle for a V8 (8 cylinder) engine, but V6 engines can be configured to run this way.  Our V6 was made with a 90˚ angle because it is made in the same factories as V8 engines and it is economical to just configure the V6 at 90˚ so they can be made in a similar way.  However, the most efficient angle for a V6 is 60˚. This angle change is significant,  as the engine can be made more compact mainly due to the elimination of the balance shaft, and this configuration is where the least amount of vibration occurs.
 <br>• '''Use all metric fasteners.'''  The fasteners used in this engine were not all the same system.  Some were English, come were Metric.  For assembly and disassembly purposes, or even upgrading and maintain the engine, it would be easiest if one whole system was used, and metric is used in all but 3 countries, which makes it the most sensible to use.

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 ===CAD: Parts and Assembly===
 [[Image:Cad1.png|center|thumb|450px|Piston in AutoCAD]]
 ==Assembly==