Group 2 - Gate 3

Gate 3: Product Analysis

Project Management: Coordination Review

Cause for Corrective Action

Our group functioned well while working on Gate 3. There were no major issues among members or with tasks assigned to members. There were also no disagreements over any topic directly related or not related to the gate. However, there were some issues that we would like to improve upon for the next gate.

The first was timeline of project completion. Our gate was finished very close to the deadline. We planned to work ahead and have some time to review our work thoroughly, but that time did not materialize. This can be attributed in part to midterms that group members had. During the week in which Gate 3 was due, there were several tests, often more than one on the same day. This affected when the group could work on the gate. For the next gate, we will attempt to complete the work needed ahead of time, so that issues like tests will not affect the group's performance on the gate.

A minor problem we ran into was that of communication. Our group did not communicate well enough while working on this gate. However, that was not a major detriment because even though communication was not perfect, we got work done well enough to finish ahead of the due date. We can improve this flaw by sending more frequent text messages to the group, and making phone calls to group members.

Product Archaeology: Product Evaluation

Component Summary

Name of Component	Function	Material Used	Manufacturing Process Used	Model or Part Number	Picture of Part
Throttle Body	Uses a valve to allow air into the engine.	Outer part made of cast iron, butterfly valve made of aluminum, some small plastic parts.	Method: Iron is die cast, aluminum is forged, plastic is injection molded. All parts are machined for detail. Evidence: The uneven weight distribution is a sign that the throttle body is made up of different types of material. Part lines around the outside of the throttle body suggest that it was cast in a die, the detail along the flat butterfly valve suggests that it was forged and the part lines along the plastic components suggest that injection molding was used. Material impact: Plastic was used for parts which had little to do with the functionality of the component as the plastic components are cheaper to make. Shape impact: The complexity in the function and shape of the throttle body made it so that multiple materials needed to be used to produce the part efficiently. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The quality of this component greatly influences the lifespan of the product. Environmental factor influence: little influence	617691-B	Figure 1: Throttle Body
Manifold Cover	Protective cover over the intake manifold that prevents damage.	Plastic	Method: Injection molding Evidence: Part lines can be seen along the Manifold cover as well as the fact that many plastic components are made by injection molding. Material impact: Due to the fact that the manifold cover does not have a high functionality, it does not need to be made of a sturdy material such as cast iron or cast aluminum. Shape impact: due to the low functionality of the component injection molding was the most efficient way to create the component Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: Plastic is cheaper to make and the most efficient to produce a plastic part in high mass is through injection molding. Environmental factor influence: little influence	17090544	Figure 2: Manifold Cover
Alternator	Converts mechanical energy into electrical energy.	Cast aluminum, plastic, steel	Method: Aluminum is die cast and machined, plastic part was manufactured through injection molded, the components were fastened together using screws and bolts. Evidence: part lines can be seen on the aluminum and plastic portions of the alternator. Screws can be seen which attach the plastic housing of the alternator components to the aluminum backing. Material impact: The housing of the alternator components are plastic due to the fact that the plastic would not affect the magnets in the alternator, aluminum also has a low magnetism making it a material which would not affect the alternator. Shape impact: Injection molding and casting are both geometrically capable of creating the parts necessary for the Alternator. Global factor influence: little influence societal factor influence: little influence Economic factor influence: These components were created using casting and injection molding because they were the most economically efficient ways to produce the parts. Environmental factor influence: little influence.	N/A	Figure 3: Alternator
Water Pipe	Brings water in to cool the engine.	Base is made of steel, pipe made of iron	Method: the Base of the water pipe forged, pipe is drawn, heated up and bent to desired shape. Evidence: Flash can be seen around the edges of the base which is a sign of forging. The thinness of the pipe and its length are both signs of something which has been drawn or pulled. the ridges along the bent parts of the pipe suggest that the pipe was initially straight and was then bent to meet the desired shape. Material impact: Iron is a sturdy material which can be easily drawn and bent making it the optimal choice for manufacturing. Shape impact: Due to the cylindrical pipe shape which pipes are generally made drawing was the most efficient way to create this part. The use of water to cool the engine is a very efficient and cheap way to prevent the engine from over heating Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: drawing is an efficient way of making pipes without wasting material. Environmental factor influence: little influence	N/A	Figure 4: Water Pipe
Water Valve	Allows the correct amount of water into the engine.	Aluminum	Method: The Disc-like parts of the water valve are forged, the springs are drawn and then heated up, and coiled in order to give then there elastic like properties. Evidence: The general shape of the component implies that forging would be the most efficient way to create the part. The spring is made of cylindrical wire which is often created through drawing and is then put through heated up and coils to give it its elastic properties. Material impact: The materials had very little influence as the materials were most likely chosen based upon the shapes needed. Shape impact:The shape of the component was most likely the influential factor which influenced why many of the parts were forged, this is largely due to the fact that many of the parts were thin cylindrical metal parts. Many wire shaped components are created using drawing or pulling operations. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: drawing is the most efficient way to make wires making it more economic. Environmental factor influence: little influence	92	Figure 5: Water Valve
Performance Sensor	Relays engine performance information to the user in the form of electrical signals	Plastic, iron, and aluminum	Method: Plastic parts were created using injection molded, the iron parts were forged and bent, and the aluminum parts were machined. The internal components of the Performance sensor could not be analyzed for method of manufacturing as taking apart the housing would result in destroying the function of the part. Evidence: The plastic components have part lines which is a sign of injection mold, the aluminum component which is a heat sink for the sensor is cut and finished and the iron portions of the housing have flash in areas. Material impact: The plastic components are most efficiently made using injection molding. shape impact: The shape of the heat sink which has multiple rows of aluminum plates all of which are connected appears difficult to create using something more efficient like casting or forging. Global factor influence: little influence. Societal factor influence: the heat sink on the performance sensor is designed to prevent the performance sensor from over heating. If the heat sink is made cheaply, performance sensor may overheat causing safety issues from a lack of knowledge of dangerous situations within the engine. Economic factor influence: little influence Environmental factor influence: little influence	N/A	Figure 6: Performance Sensor
Valve Cover	Plastic cover over the piston head for protection	Plastic with rubber seals	Method: Both the plastic cover and rubber seals were made with injection molding. Evidence: part lines can be seen on the outside of the cover and the rubber seal. Material impact: The valve cover material could be plastic and rubber due to the fact that the valve cover would not be exposed to such high temperatures that the plastic would melt. Shape impact: due to the simplicity of the parts injection molding is the most efficient manufacturing process to use Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: Injection molding is almost always the most cost effective way to produce plastic parts. Environmental factor influence: little influence	N/A	Figure 7: Valve Cover
Distributor	Channels electrical energy from the battery to the spark plug and ensure they fire in the right order	Composed of 8 different parts made of plastic, iron, and steel	Method: The metal shaft is forged and turned, the plastic cover is injection molded, and the gear at the bottom is cast and machined. Evidence: Since the metal shaft is symmetrically round, it is most likely that it is turned. Plastic parts are almost always made with injection molding, as can be seen by the parting lines on the cap. Gears are cast to give them good dimensional consistency. Material impact: material was chosen based upon the shapes which were needed. Shape impact: due to the complexity of the gears, casting and machining is the best choice for creating them. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: Due to the importance of the component it is necessary to make this part of a high quality to improve the lifespan of the product. Environmental factor influence: little influence	N/A	Figure 8: Distributor
Intake Manifold	Holds all the intake tubes in their correct places and covers the top of the engine	cast iron, plastic, rubber, aluminum, brass	Method: The iron part is forged, plastic and rubber parts are injection molded, aluminum parts are cast, and brass pipes are drawn Evidence: The pipe would need to be brass because it is a softer metal, which means it is less likely to cause sparks. This is especially important on and engine where a small spark would cause an explosion. Rubber and plastic parts are always injection molded, as evidenced by the parting lines. Material influence: most of the materials chosen were based upon the the shape and function of the part. shape influence: Most of the parts have simple geometry therefore the most efficient manufacturing process was used which were injection molding, casting and drawing. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The most efficient manufacturing process was used to create the parts for this component. Environmental factor influence: little influence	25170759	Figure 9: Intake Manifold
Serpentine Pulley 1	Translates motion from crankshaft to camshaft	Iron	Method: The general shape is forged and then turned to give it the ridges along the outside. Holes are drilled in place. Evidence: Part is turned because of the symmetric threads along the outside. Forging is recognized from it being made of iron as opposed to cast iron. Material impact: little impact shape impact: turning was used because it was an axial symmetric part. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: turning was used because it was the most efficient manufacturing process for the serpentine pulley. Environmental factor influence: little influence	10085754	Figure 10: Pulley 1
Serpentine Pulley 2	converts motion from the first pulley	Iron	Method: The general shape is forged and then turned to give it the ridges along the outside. Holes are drilled in place. Evidence: Part is turned because of the symmetric threads along the outside. Forging is recognized from it being made of iron as opposed to cast iron. Material impact: little impact Shape impact: turning was used because it was an axial symmetric part. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: turning was used because it was the most efficient manufacturing process for the serpentine pulley. Environmental factor influence: little influence	12550055	Figure 11: Pulley 2
Water Pump	Pumps water	Cast iron, steel, and aluminum	Method: Cast iron is cast and machined, steel is forged and machined, aluminum pipes are drawn Evidence: Smaller parts need to be more precise so they are forged and machined to give correct surface finish to allow for maximum efficiency. Aluminum pipes are used to prevent rusting, since steel or iron pipes would rust more quickly as water passed through them. Material influence: little influence Shape influence: The pipes were drawn because of the low thickness of pipes desired and the efficiency of drawing for pipes. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The most efficient process was always used for the water pump so that it would decrease the cost of production. Environmental factor influence: little influence	10238199	Figure 12: Water Pump
Mounting brackets	Support the engine when it mounted in the car	Iron, rubber	Method: Iron parts which were originally forged and were then bent and machined to meet the desired shape, the rubber parts were made using injection molding. Evidence: There are many holes in the product which have signs of drilling as well as being bent and shaped. The rubber padding has part lines which are an obvious sign of injection molding. material impact:Injection molding is almost always the cheapest way to mass produce the detailed rubber component. Material had little impact on the iron components though. Shape impact: Because of the shape and function of the part, which is to support the engine when mounted in the car, the part had to be structurally strong. Although cast iron may have been cheaper to use to make the part, cast iron parts can have structural weaknesses due to how the material flowed into the cast. s. Global factor influence: little influence. Societal factor influence: Due to the function of the part the part must be extremely strong in order to guarantee the stability of the engine in the car and the safety of the user. Economic factor influence: The most efficient way to the rubber padding would be injection molding Environmental factor influence: little influence	N/A	Figure 13: Mounting Bracket
Valve head (3 on each side)	Translates movement of the push-rod to the movement of the valve	Iron	Method: Forged and machined in order to create desired shape. Evidence: No part lines which would have implied cast iron, around the edges there are cut marks and a decent finish which is a sign that grinding was used. Material influence: material had little impact Shape influence: Because of the constant pressure that this component is under while the engine is functioning forging was chosen to be used over die casting because forging is often more structurally strong. This implies that the reliability of the part is important to the life span of the engine, making it a economic factor considered by the industry. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The component must be well made to insure the lifespan of the product. Environmental factor influence: little influence	N/A	Figure 14: Valve Head
Push rod (6 on each side)	Translates movement of camshaft into movement of valve heads	Iron	Method: Rod is forged and then turned to give its smooth finish Evidence: The rod is symmetrical all the way around one axis, making it very likely that it was turned. Forging would be the most efficient way to make these, as 12 are needed for each V6 engine. Material influence: little influence shape influence: The shape must be structurally sound therefore forging would be a good choice. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The quality of this component greatly influences the lifespan of the product. Environmental factor influence: little influence	N/A	Figure 15: Push-rod
Cylinder cover (1 on each side)	Covers the cylinders, holds the valves in place (valves let in fuel and air, and let out exhaust)	Cast iron, steel	Method: Actual body is cast, while springs are made of steel that is heated and coiled Evidence: The body has parting lines on it, making it clear it was cast. The method for making springs involves drawing the steel through a die to make a wire, and then heating up the steal until it is pliable. Then it is coiled around a form and cooled to give it its shape. material impact: the material has very little impact on manufacturing process used. Shape impact: The springs are drawn and then wrapped coiled around an object to give it its shape which is the most efficient way to make the spring shape. Global factor influence: little influence. Societal factor influence: the quality of this component greatly influences the performance of the engine. Economic factor influence: little influence Environmental factor influence: little influence	772	Figure 16: Cylinder Cover
Lifters (6 on each side) a	Lifters lubricate the engine	Steel	Method: Each piece is individually forged and machined for a smooth surface finish and assembled. Evidence: The pieces need to be smooth so as to be able to move with the moving pistons and supply lubrication to the pistons. Material impact: little impact Shape impact: Because of precision necessary for each piece and the geometric simplicity forging and machining is the best choice for manufacturing. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: This piece needs to be of a high quality because of its impact on the lifespan of the product. Environmental factor influence: little influence	N/A	Figure 17: Lifter
Lifter Covers (2)	Hold lifters in place	Plastic	Method: Cover is injection molded Evidence: Component has parting lines where the mold was pulled apart. Also, injection molding is the most efficient and cost effective way to make plastic parts. Material impact: Injection molding is the most efficient way to make a plastic component. shape impact: simple geometry of component made injection molding a good choice. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The cheapest way to make a plastic component is using injection molding. Environmental factor influence: little influence	N/A	Figure 18: Lifter Cover
Oil Pan	Collect oil	Iron	Method: Oil pan is forged out of iron and then machined to add inner details Evidence: Since the part is important to the function of the engine, and a failure in the oil pan would cause a catastrophic failure of the engine, it would be forged since cast parts may have weaknesses based on the flow of the metal into the mold. material impact: had little impact. Shape impact: due to weaknesses caused by casting the oil pan would be forged due to the forces acting on it when the product is performing. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The quality of this component can have a large impact on the lifespan of the product. Environmental factor influence: little influence	N/A	Figure 19: Oil Pan
Oil filter	Filters impurities out of oil	Cast iron, steel	Method: The base of the oil filter was made through die casting, the pipe was most likely drawn and then bent to meet the desired shape, pan is forged and thh mesh is woven steel wire, the steel wire is most likely drawn. Evidence: The oil filter base has part lines, a clear cast if die casting. The pipe is most likely drawn in order to get the low thickness of the walls. The steel wires were drawn which can be seen by their thickness and shape. Material impact: Die casting is also the most economicly efficient way to make a part out of iron, assuming it is allowed through geometric limitations and structural strength. Shape impact: The shapes of the various parts of this component are what most greatly influenced the manufacturing processes used. Pipes and wire are most efficiently made through the drawing process and then bending or weving the material to get its desired shape. Global factor influence: little influence. Societal factor influence: The part is made of high quality due to the importance of the part on the performance to the engine. Economic factor influence: little influence Environmental factor influence: little influence	N/A	Figure 21: Oil Filter
Crankshaft caps (2 on each side)	Hold the crankshaft in place	Cast iron	Method: The crankshaft caps were manufactured using Die casting and grinded and drilling to finish the product. Evidence: The weight of the part suggests that it is made of iron, the part was then greatly machined using grinding to give the part its smooth finish and drilling to create the holes for the bolts. Material impact: little influence shape impact: The shape of the part most likely played the most influential role in the type of manufacturing process used. Because of the other parts that it would be rubbing against it would require a very smooth surface finish. Global factor influence: little influence. Societal factor influence: The low coefficient of friction on the crankshaft caps is necessary to improve the performance of the engine Economic factor influence: Casting is the most efficient way to create the crankshaft caps. Environmental factor influence: little influence	N/A	Figure 22: Piston Cap
Piston (3 on each side)	Moves up and down in different stages of combustion to produce rotatory motion of the crankshaft	Cast iron, steel	Method: Die cast, machined and assembled, steel piston rings forged Evidence: The piston has part lines and a rough material found on the surface. The steal piston rings forged for strength and for large scale production. The piston needs to be made accurately so to minimize friction, this result in machining processes to be made such as turning and milling. Material impact: Factor that might affect the way the piston is made are the tolerance that the piston must achieve due to the intense pressure experienced in the cylinder. This would result in strong but not brittle materials needed to withstand the force. Shape impact: Because of the precision needed in the piston head the part needs to be machined in order to guarantee a tight seal. Global factor influence: little influence. Societal factor influence: The piston needs to be of a high precision and quality in order to guarantee the performance of the engine. Economic factor influence: little influence Environmental factor influence: little influence	Different on different pistons	Figure 23: Piston
Engine block	It holds all engine components in place	Cast Iron	Method: Die Casting iron Evidence: Part lines on the outside of the engine block are signs of Die casting. Material impact: Iron's good fluidity and castability makes die casting the favored method of manufacturing. shape impact: The geometric shape of the engine block makes it a suitable fit for die casting. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: The high volume of engine blocks that the industry will produce also make die casting the best economic choice for manufacturing. Environmental factor influence: little influence	090G-4	Figure 24: Engine Block
Exhaust manifold (1 on each side)	Channels exhaust gases away from the engine	Cast iron	Method: the exhaust manifolds were manufactured using die casting and holes were drilled for bolts. Evidence: The part lines on the exhaust manifold suggests that it was made using die casting and the holes were most likely drilled. The rough finish of the exhaust manifold also suggests that die casting was used. Material impact: The material used, cast iron, most likely was the dominatinating factor in using die cast to make the part. The hot exhaust required a material with a high melting point to be used for the exhaust manifold to insure the shape of the component and the saftey of the consumer. Shape impact: the geometric shape of the exhaust manifold made it so that die casting can be used. Global factor influence: little influence. Societal factor influence: A material had to be used with a high melting point in order protect the user from the hot exhaust. Economic factor influence: little influence Environmental factor influence: little influence	125501220	Figure 25: Exhaust Manifold
Crankshaft	It translates the vertical motion of the pistons into rotatory motion	Iron	Method: The crankshaft was Forged and then grinded for finishing properties. Evidence: Lack of part lines suggests that the crankshaft was not die cast. the texture of the surface of the crankshaft also suggests that it was forged and then grinded to give the product it's finish. Material impact: little influence Shape impact: Due to the large forces which are going to be applied to the crankshaft die casting cannot be used as the material flow into the cast often creates material weaknesses. Global factor influence: little influence. Societal factor influence: little influence Economic factor influence: Forging has a greated structural integrity and is used for the Crankshaft because the durability of this piece greatly affects the lifespan of the engine. Environmental factor influence: little influence	N/A	Figure 26: Crankshaft
Gear train, chain	Change the ratio of the rotatory motion of the drive shaft	Iron	Method: Gears are manufactured through investement casting, the chain links are forged for the chain and the pins are drawn and grinded for finish, the components are then assembled together using the pins as fastners. Evidence: Gears are detailed and have parts which would have been unable to achieve through die cast due to the precision of die casting. The chains links are clearly forged due to their two dimensionality and the mass production that would need to be used to make the chains. The pins are most likely drawn into solid wire due to the symmetry of each part. Material impact: little influence Shape impact: The shape of the parts used to make up the chain link and sproket is what most greatly influenced the manufacturing process used. The gears require a very high precision in order to ensure the accuracy of the chain link and sproket systems, this could only be done through investment casting. Global factor influence: little influence. Societal factor influence: The precision of this component greatly influences the performance of the engine. Economic factor influence: little influence Environmental factor influence: little influence	N/A	Figure 27: Gear Train

Table 1: Component Summary

Product Analysis

Engine Block

Component Function	Provides the base for all other components of the engine houses the cylinders Environment: The Engine functions under the hood of a car.
Component Form	Engine block is a large, axial symmetric, hexagonal component made out of cast iron Roughly 2.5 ft x 1.5 ft x 1.5 ft and 400 lb Shape is wider at the top to hold cylinders, and tapers down towards the bottom Cast iron was chosen as the material to reduce cost, as cast iron engine blocks and cast aluminum engine blocks perform roughly the same way, but it is much more cost effective to use cast iron Shape and function: Because the engine block houses so many of the components it needs to be large and sturdy. It has 6 holes each of which one of the cylinders fits into.
Aesthetics	Aesthetic properties: The engine block is a dark Gray color with a rough outer surface finish and raised part numbers on the surface Aesthetic purpose: The part numbers can be used to identify the part Component color: The engine block is dark gray most likely because this is the color of cast iron, the material which the engine block is made of. Component surface: The outside of the engine block is rough because this is what the surface texture is following the casting process. The inside of the piston cylinder are smooth serving a functional purpose of allowing the pistons to move with less friction.

Table 2: Engine Block

Crankshaft

Component Function	Attached to the pistons via bearings and allows the pistons to rotate shaft Attached to flywheel to reduce pulsation Involved in the flow of energy from the pistons to powering the vehicle Environment: Rests in the center of the engine and is attached to each of the six pistons at its six crankpins.
Component Form	A rod with offset "crank-pins" that the piston bearings attach to Roughly 2.5 ft long and weighing about 75 lb Made of forged steel, which has lower weight, better dampening, and more compact dimensions than die cast counterparts Shape influence function: each of the crankpins are offset from the center of the axis so that the pistons fire at different times. the counterweights are designed to counteract with the firing of each piston.
Aesthetics	Aesthetic properties: Crankpins are a reflective silver color and a similar color where it sits in the engine block. parts which do not require a low friction coefficient are a dark grey color. Aestheitc purpose: None. Component color: silver reflective where on crankpins and where it sits on the engine block, other parts were a dark grey color. The part is this color because this is the color of the material after it has gone through its manufacturing process. Component surface: The surface is smooth on the crankpins and where the crankshaft touches the engine block. The smooth finish is for the functional purpose of decreasing the friction of moving parts while the engine is running.

Table 3: Crankshaft

Camshaft-Distributor

Component Function	Camshaft attaches to the balance chain which makes sure it turns in sync with the crankshaft and balancing shaft Distributor uses the gear connected to the camshaft to send electrical signals to the spark plugs so they fire in the correct order Directly involved in the Otto Cycle which produces power for the vehicle Environment: The distributor sits on top of the engine block while the camshaft is located near the bottom of the engine and pushes against the valves.
Component Form	Camshaft is a 2 ft long rod with gears at both ends, one for the distributor and one for the balancing chain Distributor is a light, 1 ft long shaft with a plastic piece on top (which handles sending out the electrical impulses) and a gear on the bottom which meshes with the camshaft Both parts are axially symmetric Both shafts are forged and machined to their final shape, most likely through CNC machining to get precise measurements Both parts need to be completely in tune with one another, so measurements must be consistent and precise for the parts to function correctly shape influence by function: The camshaft has a gear at one end so that it rotates as the crankshaft is turning. the bumps on the camshaft, push the valves up and down to let air and fuel in and out at the precise times.
Aesthetics	Aesthetic properties: The Camshaft is a silver metal rod with bumps on it which form a functional purpose and a gear on the end. The distributor is black with electrical component housed in a black disk shaped plastic on one end, and a gear on the other. Aesthetic purpose: None Component color: The distributor is black because that is most likely the uniform color that the company chose and the color of the plastic that all the components are injection molded in. The camshaft is silver because this is the color of the material used. Component surface: The camshaft is very smooth in order to decrease the friction between it and the other components it is rubbing against. The distributor has neither an extremely smooth nor rough surface as it holds not functional or aesthetic value.

Table 4: Camshaft-Distributor

Water Pump

Component Function	Pumps water from the bottom of the radiator pan through the engine's water jacket to keep it cool One of the most important systems to keeping your engine from overheating, it only deals with the flow of coolant around the engine Environment: located on the outside of the engine block.
Component Form	Heavy turbine shaped component, measuring about 10 in x 6 in and weighing 20 lb Axially symmetric Casing made of cast iron, while internal parts are made of forged steel Internal parts have to be lighter and more resistive to rust since they will have water passing over them shape and function: The water pump has a fan like structure within it in order to pump the water around the engine. The pump is large in order to handle the pressure of the water flowing through the pump
Aesthetics	Aesthetic properties: The outside of the water pump is black with a rough surface finish and raised numbers on the outside. Aesthetic purpose: The part number helps to identify the part. Component color: Black because of the heat resistant engine paint on the outside. Component surface: the surface is rough, largely due to the heat resistant paint on the outside. The function of this paint is to protect the engine from corrosion.

Table 5: Water Pump

Intake Manifold

Component Function	Provides the correct mixture of air and fuel to the cylinders using the Vortec process Deals with the flow of fuel and air into the engine and optimizes it for optimal engine performance Environment: Located on top of the engine and houses the intake tubes.
Component Form	Rectangular base with varying heights on top Fuel injector sits on top of intake manifold Approximately 1.5 ft x 1 ft, weighs about 35 lb Mostly made of cast iron Sized to fit perfectly atop valve covers Shape and function: Due to the low functionality of this component it does not require extremely detailed. There are six holes located in it in order to house the intake tubes.
Aesthetics	Aesthetic properties: gray color, with raised numbers on the surface of the manifold by each intake hole. aesthetic purpose: the raised number by each hole are located there so that the correct fuel injector tube is inserted into its correct slot. Component color: The intake manifold is gray due to the color of that the plastic and iron components are when they leave the cast. The plastic components of the fuel injector are black due to color preference by the company. Component surface: The intake manifold has a rough surface and the fuel injector is smooth black plastic. The finish surface serves no aesthetic or functional purpose.

Table 6: Intake Manifold

Piston

Component Function	Most important component to the Otto Cycle. Goes out when air-fuel mixture is ignited in the cylinder and in when its counterpart on the other side goes out, causing the cycle. Environment: The six pistons are each located in their respective cylinders of the engine block and are connected to the crankshaft.
Component Form	Cylinder has a circular head with long trapezoidal bearing attached to it. Head is designed to fit perfectly in the cylinder. Head is die cast since casting has high dimensional accuracy, and that accuracy is important so there is no extra friction between the piston and the cylinder. The surface of the piston head must be ground with a grinder so it is perfectly smooth shape and function: The pistons are cylindrical shaped due to the optimal size for piston firing efficiency. They pivot on the connecting rod so that they can move up and down.
Aesthetics	Aesthetic properties: The piston was black before the paint chipped off of it and was smooth around the outside, where the connecting rod has a varying degree of surface finish. Where the connecting rod meets with the crank pin is always very smooth. Aesthetic purpose: None Component color: Piston head is black due to the piston coating, the piston coating reduces friction between the piston and cylinder wall and improves durability of piston. Component surface: The outside of the piston and the surface where the connecting rod would meet the crankpin are both very smooth. This is for the functional purpose of reducing friction while the engine is running.

Table 7: Pistons

Exhaust Manifold

Component Function	Collects exhaust from all the cylinders and funnels it through the muffler and eventually out the exhaust pipe Involves the flow of waste materials from the Otto Cycle Environment: There are two exhaust manifolds, one located on each side of the engine block.
Component Form	Pipes with 3 inputs and 1 output Roughly 2 ft long with 1 in diameter pipes, weighs about 25 lb Component is made out of iron to prevent melting since the exhaust gases traveling through are at a very high temperature Shape and function: The exhaust manifold is heavy and hollow so that it can handle the hot exhaust coming out of the engine.
Aesthetics	Aesthetic properties: Burnt orange color and rough finish most likely due to casting. Aesthetic purpose: None Component color: Burnt orange and brown, this is most likely due to rusting. Component surface: The surface is rough, most likely due to rusting, the surface serves no aesthetic or functional purpose.

Table 8: Exhaust Manifold

Alternator

Component Function	Converts mechanical energy into electrical energy that can charge the battery and run the electrical components of the vehicle Environment: located on the top of the engine.
Component Form	Heavy cylindrical piece with a triangular plastic piece at one end About 6 in long with a diameter of 3 in, weighs about 15 lb Heavy cast iron shell encloses smaller, more detailed components for energy conversion, such as an electromagnet Could not get first hand look at interior because of lack of tools Shape and function: The Alternator is small and its housing is made of non-magnetic material so that its housing does not influence the electric charge it creates through magnets.
Aesthetics	Aesthetic properties: Small with black, brown and grey components, most of which are smooth. Aesthetic purpose: None. Component color: The majority of the alternator housing is a brownish gray color. This color is most likely due to the material chosen which must be resistant to magnetism and electric current. Component surface: The component surface is smooth but holds no aesthetic or functional purpose.

Table 9: Alternator

Oil Filter

Component Function	Filters impurities out of the oil used to lubricate the engine Oil flows in and is cleaned before being returned into circulation in the oil pan Environment: Located in the oil pan at the bottom of the engine.
Component Form	Major part is a rectangular cast iron piece, making up most of the total weight of the component (about 5 lb) Has a series of tubes that transport the oil through the filter at the top Small gears on the inside of the filter provide suction to pull the oil through the filter Shape and environment: The end of the oil filter has thin woven wires to filter out large impurities in the oil. It then is a curved pipes to pump the oil to the filter and the n release it back into the engine.
Aesthetics	Aesthetic properties: The majority of the oil filter is smooth brass piping and partially made of mesh. The base is made of cast iron which has been coated to prevent corrosion. Aesthetic purpose: None. Component color: Brass color mostly due to the material it is made of. Component surface: The surface is a smooth brass finish. Brass is a soft metal which makes it less likely to spark and cause an explosion whcih is important because most of the time it is sitting in oil making giving the surface finish a functional purpose.

Table 10: Oil Filter

Throttle Body

Component Function	Takes the human input from the accelerator to open or close the throttle The more the throttle is open, the more air is let in, which leads to more air-fuel mixture being added to the engine, leading to higher power output Environment: Located on the top of the engine block
Component Form	Circle with a diameter of 3 in mounted on top of a square piece 4 in x 4 in Actual valve made of aluminum to make it lighter and stronger Lighter valves are easier to open and close, thus making acceleration more precise Valve has a smooth finish to allow air to pass more easily over it while open Shape and function: The throttle body is cylindrical shape and controls the amount of air let into the engine. It is spring loaded so that when the accelerator is not pressed, there is no air allowed into the engine
Aesthetics	Aesthetic properties: It has the appearence of a complicated component, with a metalic exterior with parts of it made of plastic. Aesthetic purpose: None. Component color: metalic grey because of the material it is made of. Component surface: Smooth interior surface and rough exterior surface. The interior surface may be smooth to serve the functional purpose so that the throttle can form a more perfect seal when not letting air in.

Table 11: Throttle Body

Complexity Scale

Value	Complexity	Interaction Complexity
1	A component is given a complexity rating of 1 if it appears to have a relatively simple geometry making it simple to manufacture. i.e. only die casting or injection molding is used.	A component is given a interaction complexity of 1 if Performs a very simple action and directly interacts with 2 or less components
2	A component is given a complexity rating of 2 if it has a significantly more complex geometry and requires multiple steps to manufacturing process or requires assembly of parts to create the component	A component is given an interaction complexity of 2 if it Performs a complex action but interacts with very few components or performs a simple action but directly interacts with multiple components
3	A component is given a complexity rating of 3 if it has Complex geometry and requires many steps in the manufacturing process possibly including assembly	A component is given an interaction complexity of 3 if it Performs a very complex action and interacts with many of the components in the engine directly.

Table 11: Complexity Scale

Component	Complexity	Reasoning	Interaction Complexity	Reasoning
Engine Block	1	Engine blocks are easily made using die casting, and do not require much machining afterwards to make them useable	3	Every system in the engine is tied in one way or another to the engine block, whether it be the cooling process or the actual creation of energy to power the vehicle
Crankshaft	2	Involves some extra machining after the original forging to make the offset crank-pins	2	Though the motion is very simple (just a turning motion) it interacts with many parts of the engine such as the camshaft, pistons, and push-rods
Camshaft-distributor	2	Simple geometry made by forging, however there are many parts to manufacture and then assemble	2	Motion is simple (just 2 spinning shafts) but the interaction with each other, as well as the spark plugs, crankshaft, balancing chain, and balancing shaft make it more complex
Water Pump	2	Outside is not difficult to cast, but the small, very dimensional specific inner parts, such as the turbine blade, are more difficult to make since they require multiple processes	1	Only performs the simple task of drawing water and distributing it throughout the engine to keep it cool
Intake Manifold	1	Can easily be cast	2	Though it seems much more complicated, the only components the intake manifold interacts with are the pistons, and the only input materials it deals with are air and fuel
Piston	2	Part needs to be ground down after it is originally forged to make it smooth enough	3	The piston interacts with many other components, such as the crankshaft, camshaft, distributor, and intake manifold. It also has a complex motion, as the piston system as a whole must fire in a very specific order to power the engine
Exhaust Manifold	1	Part would just be cast, one of the easiest manufacturing processes	1	Only interaction is with the pistons, as it take away the exhaust produced
Alternator	2	The visible part is easy to make through casting, however the internal components that we cannot see could be more difficult, leading to a higher ranking	2	The conversion process is fairly complicated, even though it seems very direct
Oil Filter	2	Outside part is not difficult to cast, but the small gears on the inside as well as the filter itself involve some more complex manufacturing processes	1	The oil filter only interacts with the oil pan and only uses a mesh to filter and gears to create a vacuum, none of which are very complicated processes.
Throttle Body	1	The parts are either forged or cast, meaning very easy manufacturing	2	The throttle needs to handle the human input from the accelerator and open the clutch accordingly, providing the power the vehicle needs to work

Table 12: Component Complexity

Solid Model Assembly

For our solid modeling, we used Inventor to draw the components of the piston and crankshaft system. We chose this system because it is the central system of the engine, and has many interconnecting components.

As stated before these components were chosen because they provide the driving force of an engine. After the piston are initially started by an external force they proved the linear energy to turn the crankshaft and provide rotary energy. The piston fasteners connect the piston to the crankshaft that allow this transfer of energy to take place. In order for the engine to provide reliable energy and minimize energy loss through vibrations the crankshaft must be secured in away that allows it to rotate. The crankshaft fastener must be secure enough to support the crankshaft but also minimize friction and vibrations.

These parts were built using Autodesk Inventor Professional 2011(Student Version). The reason we decided to use this program was the experience that some members of the group had with this program. In the past on high school projects and during personal projects Autodesk Inventor has been an efficient and successful modeling tool. Being familiar with the system and features of the program allowed the the solid modeling assembly become an easier task. Inventor also has very useful features such as Inventor Studio and Presentation which allows the user to render pictures with customizable lighting and graphics. The presentation feature also allows the user to disassemble a system and reassemble it.

These are the 8 components that went into the assembly drawing of our engine:

Figure 28: Crankshaft

Figure 29: Crankshaft Bolt

Figure 30: Crankshaft Fastener

Figure 31: Piston Head

Figure 32: Piston Journal Bearing

Figure 32: Piston Rod

Figure 33: Piston Bolt

Figure 34: Piston Fastener

This is how the model would be assembled:

Figure 35: Diss-assembly of the components

This is the final assembly drawing of these components on our engine:

Figure 36: Assembly Drawing

Engineering Analysis

Figure 36: Layout of Pistons

Figure 37: V6 Engine Running

A very important characteristic of engine performance is firing order of the cylinders. The firing order of the cylinders refers to the order in which sparks are introduced into the cylinders of the engine. This determines when combustion occurs in every piston, which further determines when the crankshaft is given an additional boost of power due to movement of the piston following combustion.

Before firing order is determined, it is important to number the cylinders correctly. This enables engineers to properly determine and communicate the firing order to other personnel in the design, development and manufacture divisions. Our GM 4.3L V6 Vortec engine uses the following numbering.

Each engine produced in the market has a specific requirement. It is produced to meet requirements such as but not limited to high top speed of the vehicle, high torque (pulling and weight hauling power), or high efficiency. Often, the best engine to suit a specific requirement has a combination of more than one of these factors. Engineering analysis in this case can be used to determine the firing order of the engine by analyzing what parameters of engine performance are affected by the firing order.

In the problem statement of this analysis, the engineer should list the required characteristics of the engine as given information. An engineer who performs this analysis will know whether the engine whose firing order is to be determined is going to be used for its performance (in the case of a race car - top speed - or a van - pulling capability) or its efficiency and smoothness (family sedan). The firing order of the engine can significantly impact these characteristics. The problem statement will also include the information to be determined. In this analysis, although the result should be an appropriate firing order, the engineer should determine how many cylinders should fire at a given instant.

The system diagram will contain the general layout of the engine. In this case, the GM engine is a V6. This presents the engineer with a general idea of how the pistons are arranged and helps him or her visualize how they should move. A flow diagram can also be included to show the output of power when cylinders fire. A piston produces power only in the combustion stroke, but consumes power in the intake, compression and exhaust strokes. This has to be taken into consideration when determining the firing order. A flow diagram of the functioning of a single piston can be drawn. This diagram can then be placed in parallel with itself, because pistons work in parallel. How these flows are placed in parallel will determine when firing occurs and in which piston in occurs.

In this analysis, most of the information the engineer uses is determined in the calculations, or is provided.

The most important equations used in the calculations are -

1. Crank angle = 720˚ / Number of cylinders in the engine (720˚is because each piston completes its 4 step cycle as the crankshaft rotates 720˚)

2. Number of pistons required for a complete rotation = 360˚ / Crank angle

3. Number of cylinders at top dead center = Total number of pistons / Number of pistons required for a complete rotation

The discussion for this analysis problem should have all the explanation necessary for the reader to understand how the firing order is determined. Each piston finished the 4 steps of the piston cycle as the crankshaft rotates twice. The total number of pistons for each cycle can be found, and the number of pistons at the top dead center can be found. The top dead center is the position of the piston at which it is located farthest from the crankshaft, so cylinder volume is minimum. In the piston cycle, this occurs twice - once just before ignition, and once after the exhaust has been expelled. At this stage, the engineer has calculated the number of pistons at the top dead center. The engineer now makes a decision on how many pistons at the top dead center fire at the same time. This firing at the same time leads to greater power because more than one piston is in its power stroke at that given time. However, this also causes greater vibrations. This choice will be based on the engine requirements. Alternately, the engineer can choose to let just one piston fire at a time. This leads to smooth power delivery and lower noise, but leads to less power also. This can be done by redesigning the cam shaft and distributor circuit.

Several examples of alteration of firing order to improve performance exist. One example is performance oriented improvement of firing order in NASCAR.

The firing order of the engine we are working on is 1-6-5-4-3-2.

Design Revisions

1) Change from Single Point Fuel Injection to Direct Fuel Injection

Single point fuel injection vs. direct fuel injection

Though direct injection is more expensive to add (since it is made of materials that can withstand higher temperatures and pressures), it is worth it. Direct injection injects fuel at a higher pressure with more precise air fuel mixtures based on the driving conditions, which increases efficiency. This decreases emissions and, in the long run, makes up for the increased price by saving the driver money on gas.

2) Change cylinder bank angle from 90 degrees to 60 degrees

The advantages of a 60 degree cylinder bank angle for a V-6 engine are explained.

90 degree V6 engines, such as the 4.3 Liter V6 engine we are analyzing are often prone to high vibrations due to the large width of the engine. Many 90 degree V6 engines are based on the design of similar V8 engines which simply have taken two pistons taken out of the design of the cylinder block. This creates an unneccesarily large width which in turn causes high vibration, these high vibrations can cause damage to engine parts and can make the ride uncomfortable for the passangers. If the cylinder bank angle were to be decreased to 60 degrees we can minimize the width of the engine and decrease the vibrations caused by the pistons firing.

3) Add turbocharger

Above is a diagram of how a turbo charger works

A turbocharger would allow this V6 engine to output power at a V8 clip while keeping V6 fuel economy. This would mean higher miles per gallon, which leads to fewer emissions. It would also expand the market into the large truck category, where the only engine available was the V8. This would improve GM's profits and put them on level ground with Ford.

References

[1] "2002 GMC S15/T15 Jimmy 2WD 4.3 liter V-6 VIN "W"." . N.p., n.d. Web. 18 Nov 2011. <http://autorepair.about.com/library/firing_orders/bl-fo-1573.htm>.
[2] "Engine smoothness." . N.p., n.d. Web. 18 Nov 2011. <http://www.autozine.org/technical_school/engine/smooth3.htm>.
[3] "What determines engine firing order?." . N.p., n.d. Web. 18 Nov 2011. <http://www.hotrodders.com/forum/what-determines-engine-firing-order-103531.html>.
[4] "The physics of: engine cylinder block angles." . N.p, n.d. Web 18 Nov 2011. <http://www.caranddriver.com/features/the-physics-of-engine-cylinder-bank-angles-feature>.
[5] Parker, Akweli "How Direct Injection Engines Work". N.p,n.d. Web 15 Dec 2011. <http://auto.howstuffworks.com/direct-injection-engine1.htm>.
[6]"Turbocharger Diagnosis & Repair" . N.p, n.d. Web 15 Dec 2011. <http://www.aa1car.com/library/turbo_repair.htm>.