Diesel Engine Reference Book

675 Pages·2005·35.49 MB·English

Diesel Engine
Reference Book
Second Edition
Edited by
Bernard Challen
Rodica Baranescu
pi U T T E R W O R TH
|g|E I N E M A NN
OXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHI
Butterworth-Heinemann
Linacre House, Jordan Hill, Oxford OX2 8DP
225 Wildwood Avenue, Woburn, MA 01801-2041
A division of Reed Educational and Professional Publishing Ltd
"O^ A member of the Reed Elsevier pic group
First published 1984
Second edition 1999
Chapter 6 © Reed Educational and Professional Publishing Ltd and
A.E. Joyce (System Studios) Ltd 1999
Section 11.2 © Lucas Ltd 1999
Section 11.3 © Robert Bosch Corp. 1999
Section 11.4 © Caterpillar Inc. 1999
All other chapters © Reed Educational and Professional Publishing Ltd 1999
All rights reserved. No part of this publication may be reproduced in
any material form (including photocopying or storing in any medium by
electronic means and whether or not transiently or incidentally to some
other use of this publication) without the written permission of the
copyright holder except in accordance with the provisions of the
Copyright, Designs and Patents Act 1988 or under the terms of a
licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham
Court Road, London, England, WlP 9HE. Applications for the
copyright holder's written permission to reproduce any part of this
publication should be addressed to the publishers
British Library Cataloguing in Publication Data
Diesel engine reference book. - 2nd ed.
1. Diesel motor - Handbooks, manuals, etc.
I. Challen, Bernard II. Baranescu, Rodica
629.2'506
ISBN O 7506 2176 1
Library of Congress Cataloguing in Publication Data
Diesel engine reference book/edited by Bernard Challen, Rodica Baranescu.
p. cm.
Includes bibliographical references.
ISBN 0750621761
1. Diesel motor. I. Challen, Bernard. II. Baranescu, Rodica.
TJ795.D437
621.43'6-dc21 98-55395
CIP
Typeset by Replika Press Pvt. Ltd., 100% EOU Delhi 110 040, India
Foreword
It is now 15 years since the Diesel Engine Reference Book first geometry components such as the turbocharger, inlet manifold
appeared and in the meantime the diesel engine industry has and valve-train.
undergone more product development than probably at any time The specific output of larger medium-speed diesel engines
in its 100 years history. It is very timely, therefore, that this continues to rise steadily. Despite increases in mechanical loading,
classic reference book should be updated to reflect the significant overhaul lives of 20 000 hours, or 1 million miles in locomotive
advances that have taken place in diesel engine design, improving applications, are being achieved with improved reliability and
performance and economy, environmental attributes, reliability lower manufacturing costs.
and durability. These advancements in the diesel engine have only been
The demand for the diesel engine continues to increase world- possible by the development of advanced fuel injection systems,
wide as it consolidates its position as the prime mover for tractors, generally with electronic control systems, offering higher injection
medium and heavy trucks, buses, locomotives, ship propulsion, pressures with much more accurate control of fuel metering and
auxiliary power generation and many industrial applications. injection timing. The unit injector is already well established,
Additionally, the diesel engine continues to challenge the gasoline and common rail fuel injection systems are expected to find
engine as the power unit for the passenger car market particularly widespread application especially in automotive engines,
in Europe although exhaust emissions legislation, and specifically providing additional benefits in noise reduction and design
limits on particulate emission, threatens the survival of the diesel flexibility—allowing greater freedom in selecting the number
in this sector in the USA and Japan. of cylinders and cylinder configuration.
Much of the advancement has been driven by exhaust and The engineer involved in diesel development is increasingly
noise emission legislation which is both increasing in severity under pressure to achieve a higher quality product in a shorter
and broadening from automotive engines to cover virtually all time frame. This has resulted in the rapid development of
applications. The impact of such legislation is extending from sophisticated analytical tools to enable greater optimization at
North America, Europe and Japan to cover most of the world, the design stage.
as other developing nations encounter serious environmental This new edition has been comprehensively revised and
problems. extended to cover these latest advances in diesel engine design
Fuel economy remains the prime factor favouring the and development.
application of the diesel in many markets. In the smaller engine I extend my congratulations to the joint editors Bernard Challen
sizes where the gasoline engine has made dramatic improvements and Rodica Baranescu who together with the impressive team
in economy through improved combustion, lean-burn operation, of world-renowned experts have succeeded in producing an
and advancements both in fuel injection equipment and electronic outstanding volume.
control systems, the diesel engine has been able to maintain its As a young apprentice engine designer at Ruston & Hornsby
advantage. This has been achieved principally by the development I found Pounder's original book of 1955 an invaluable aid; later
of the direct-injection combustion system for smaller and smaller the first edition of this book, which my old colleague Les Lilly
cylinder sizes, where traditionally the indirect-injection engine, was responsible for, embodied 30 years additional knowledge.
and particularly the Ricardo Comet system, dominated the market. I am sure this new edition, bringing us to the state-of-the-art at
Other trends in this sector are the move to 4-valve operation, the end of the century, will continue to be the essential reference
greater use of light alloy materials for the engine structure, charge book for all engineers involved in diesel engine design,
cooling, cooled EGR (exhaust gas re-circulation) and variable development and application.
JOHN MCCLELLAND
Managing Director
AVL Powertrain Engineering Ltd
Foreword
With the publication of this second edition the name of Leslie beside the engine, or with more discretion in front of it.'
Lilly will pass from the world of technical books, into obscurity. When he agreed to accept the challenge, I found myself working
And so, while the opportunity remains, please consider for a with a man of wisdom and a quite unmalicious humour, of
moment the achievement of a modest man whom I came greatly determined energy, and above all an integrity that enabled him
to respect. In many ways Leslie Lilly was the archetypal to assemble and earn the trust of an impressive cast of contributors
researcher, the 'back-room boy', tall, unassuming, but driven from the UK, Europe and America. From the diffidence of my
by an inner conviction to achieve what was to be achieved. He first meeting with this long-retired engineer, there emerged a
was well into retirement from Ricardos when I met him in the man who was discovering a second lease of life. Through firmness
late 1970s, singing in his church choir and active in the charitable and diplomacy, the massive manuscript of the first edition took
work that meant so much to him. I was commissioning for the shape, the work of more than thirty experts—and in the days
publisher Butterworths, following a trail that I hoped would before E-mail and personal word-processors. It was handed
lead to the rebirth of a classic that had been too long out-of- over on the agreed date, and the expertise of lifetimes became
print, C.C. Pounder's Diesel Engine Principles and Practice. I once more available to the diesel fraternity worldwide.
knew when the path eventually led to Lilly that there would be One of the rewards of publishing is its encounters with the
no snap decision, and that every consideration would be weighed authors and editors who emerge from the backrooms of technology
like every decision taken in the engine laboratories in which he to become the unforgettable personae of a working life. I am
had worked since 1928 when, as he recalled, '. . . parts not grateful to the publishers, my one-time employers, for this
infrequently flew out of the doors . . .' while one stood '. . . opportunity to pay tribute to Leslie Lilly.
DON GOODSELL
Preface to the
second edition
This edition represents the many changes that have appeared in authors, but many have played supporting roles of various types,
the diesel engine field. Not since Diesel's conception of the providing advice and guidance.
engine have there been so many substantial changes in diesel The linkage of this book with the original Pounder's Diesel
design and applications. Some of these are captured in this Engine Principles and Practice continues, with the chapter on
edition, so that readers will find most of the coverage from the marine engine applications reproduced here from the current
first edition but major new sections covering the impact of edition of Pounders.
electronics and modern control theory as well as the deve- One of the editors (Bernard Challen) was privileged to work
lopments in fuel injection systems. Some of the original with Leslie Lilly at Ricardo for many years and was pleased to
chapters have been revised, either by their original authors, or follow in his footsteps as an editor of this volume. Tribute is
by others. paid elsewhere to Leslie but the present editors would like to
The editors have attempted to include information relevant record their homage to him in providing a firm foundation on
to interested engineers, both those who are new to the field and which to extend and develop this book. They hope to have lived
also those who are long-term practitioners. Such is the diversity up to the original objectives to be useful and informative.
of knowledge required today, that the various specialisms require The editors hope that this revised edition will appeal—and
detailed study and the editors would like to express their sincere be useful—to a wide range of readers and so they have attempted
gratitude to the authors and their companies who have contributed to organize the material in logical sections, in addition to providing
to this revised edition. some of the most current material available. Some of this will
The editors are both past Chairs of the SAE Diesel Engine perhaps change rapidly, especially that affected by political
Committee and have a wide range of friends, colleagues and decisions, such as exhaust emissions and especially particulate
acquaintances who are active in the design, development and legislation. Apart from this area, the book contains much factual
application of diesel engines. We would like to recognize the and descriptive diesel material that will endure and provide
special efforts that many of these people have made to assist in help to many of us as we practise our profession. We trust that
the production of this new edition. Not all have been chapter you find the book both useful and enjoyable reading.
BERNARD CHALLEN
RODICA BARANESCU
Preface to the
first edition
This book was originally commissioned in order to provide a (rev/min) may be given also; fuel consumption is in grammes
modern version of Pounder's Diesel Engine Principles and per kilowatt hour (g/kW.h); and pressure is in bars (bar).
Practice and as an addition to the publisher's series of reference Since it is not possible to describe in the chapters concerned
books. In the event, it has ended up as a new book, since all the more than a few of the engine makes available, a list of
chapters have been rewritten, although some include still valid manufacturers and types of engines, arranged according to
material from the old book. The engines covered include all nationality, is given at the end of the book. A list of the various
types manufactured in Europe, the US A and Japan. The authors main institutions, associations and specialist firms particularly
of the various chapters have been drawn not only from the UK concerned with diesel engines is also included.
but from Europe and the USA and include many widely-known It is my hope that this new reference book will be useful to
authorities. Several new chapters have been added to cover the students and lecturers in universities and technical colleges, to
developments of the twenty-two years since the last edition of the personnel of manufacturing firms and research and
Pounder's book. development organizations, and to all diesel engine users and
Thermal and mechanical loads in cylinder heads, pistons and operators.
liners have increased dramatically because power from the same I would like to acknowledge and thank the directors of Ricardo
cylinder size has about doubled. The development of new cooling Consulting Engineers and my many friends in this firm for their
methods and new design techniques has been necessary to enable generous support and help without which this book would not
such higher loadings to be sustained. Therefore new chapters have been possible. I worked there for forty-eight years, and
on 'Thermal Loading' and on 'Pistons, Rings and Liners' have count myself fortunate to have arrived at a time when the diesel
been included. engine was only just starting to be applied to vehicles, and at a
The increasing worldwide concern with the control of un- time when Sir Harry Ricardo was experimenting with many
pleasant smoke and harmful emissions from the exhaust outlets single cylinder engines both single sleeve valve and poppet
of vehicle engines and also with the control of the noise level, valve. The fact that parts not infrequently flew out of the doors
has resulted in legislation to limit smoke, emissions and noise lent spice to the testing of these engines, especially since one
and in the setting up of standard test methods of measurement stood beside the engine or with more discretion in front of it,
in several countries, of which the USA was the first. These but not sitting in a sound-proofed control room as is today's
developments are explained fully in the chapters on 'Exhaust practice. A great variety of forms of combustion chamber were
Smoke Measurement and Regulation', 'Exhaust Emissions' and being patented at this time, among them the Ricardo 'Comet'
'Automotive Engine Noise'. The need to improve performance chamber which in an advanced form is now used in so many
whether as regards power output or as regards lower fuel passenger car engines. I think we were ahead of most other
consumption or preferably both, though they are not always people for we reached 21 bar b.m.e.p. before the commencement
found together, has led to research into other engine systems to of the second world war on two supercharged single cylinder
find out their potential. This research is covered in the chapter engines, one a single sleeve valve and the other a poppet valve.
on 'Compound and Other Engine Systems'. I am grateful that I have spent my working life with such a
The chapter on 'Modern Health Monitoring Methods' deals pioneering firm.
with the subject of the application of continuously recording I would like to make a special mention here of the late John
health monitoring equipment to marine two-cycle low-speed Hempson who died unexpectedly after a short illness only three
engines in large merchant ships in order to reduce manning years after retiring. It was he who suggested I might like to take
levels and maintenance costs. In fact, a more general interest in on the editing of this book. I am grateful for his help and for his
the application of health monitoring to smaller engines now chapter on 'Modern Instrumentation'. I would also like to thank
exists. all the authors for the very worthwhile chapters they have
The SI system of units is used throughout the book but with contributed and especially those who have undertaken the writing
some relaxations, as suggested by Ricardo Consulting Engineers, of several chapters. Many companies and establishments have
to bring them more into line with general worldwide usage. A supplied information and in some cases enabling chapters towards
list of those units in use in this book which differ from SI units, this book and I am very grateful for their contributions. I am
is given at the end of the book. For those units most commonly grateful also for receiving help and encouragement from the
employed, this means that power is expressed in kilowatts (kW), publishers and from Don Goodsell in particular. Finally I must
though horsepower (bhp) may also be quoted; rotational speed thank Miss M. C. Lines and Mrs. M. E. Holmes for the large
is in revolutions per second (rev/s), though revolutions per minute volume of secretarial work they have cheerfully carried out.
LRC LILLY
Contributors
Chapter 1 The theory of compression ignition engines Chapter 7 Computational fluid dynamics
Frank J. Wallace DSc PhD FIMechE FSAE Dr Rolf D Reitz (see Chapter 4)
Retired Professor of Engineering from Queen's University Belfast
and the University of Bath. His research interests have been in Chapter 8 Modern control in diesel engine management
the diesel engine field throughout his career and he has published Richard K. Stobart MA CEng MIMechE MSAE
widely. He has updated the chapter for this edition.
A graduate of Cambridge University, Richard Stobart has spent
time with British Rail and Ricardo. He now works for Cambridge
Chapter 2 The theory of turbocharging
Consultants Ltd/Arthur Little where he is the Automotive Business
Neil Watson PhD CEng MIMechE Manager, responsible for Electronic Control Development and
Design. He has presented and published numerous papers on
Deceased-Formally of Imperial College, London, he was res-
Control-related subjects in Europe and the United States.
ponsible for research in IC engines. He published numerous papers
on turbocharging and was the author of a reference book on this
subject. Chapter 9 Inlet and exhaust systems
Charles A. Beard CEng FIMechE MRAeS
Chapter 3 Compound and other engine systems Charles A. Beard was a senior consultant with Ricardo Consulting
Professor Frank J. Wallace (see Chapter 1) Engineers and worked in design and development. Bernard
Challen has updated the chapter.
Chapter 4 Diesel combustion and fuels
Chapter 10 Design layout options
Dr Jon Van Gerpen PhD PE
An Associate Professor of Mechanical Engineering at Iowa State Original chapters by Charles A. Beard. Bernard Challen has
University, he has been active in diesel combustion and emissions updated this chapter.
research, simulation and modelling engine processes.
Dr Rolf Reitz PhD FS AE Chapter 11 Fuel injection systems
Professor Michael Russell MSc CEng FIMechE
He is currently Wisconsin Distinguished Professor in the
Mechanical Engineering department at the University of Chief Research Engineer, Lucas Diesel Systems. Formerly
Wisconsin-Madison. Previously he was a research scientist at the Professor of Automobile Engineering at the Institute of Sound
Courant Institute of Mathematical Sciences in New York, Princeton and Vibration Research, Southampton, he has published widely
University and a staff research engineer at the General Motors on diesel injection and combustion characteristics, especially in
Research Laboratories. relation to noise.
Caterpillar Inc.
Chapter 5 Thermal loading
Dr Cecil CJ. French DSc(Eng) FEng FIMechE FIMarE Caterpillar Inc. is the world's largest manufacturer of construction
and mining equipment, diesel and natural gas engines and
A past President of IMechE and former director of Ricardo industrial gas turbines.
Consulting Engineers, now working as an independent consultant.
Max R. Lanz
He has presented and published numerous papers on a wide range
of engine-related subjects. He has updated the chapter for this Max Lanz is the Marketing Manager at Robert Bosch Corporation.
edition.
He was educated at the Eidgenoessische Technische Hochschule
in Zurich, Switzerland. The material is consolidated from various
Chapter 6 Thermodynamic mathematical modelling authors within Bosch.
Anthony Joyce BSc DCAe CEng CPhys MRAeS MInstP
Chapter 12 Lubrication and lubricating oils
Anthony Joyce is the MD of Systems Studies Ltd. He has been A.R. Lansdown MSc PhD Ccem CEng FRSC FIMechE FInstPet
responsible for developing models of automotive systems,
including drivelines and cooling systems. Dr Lansdown has worked in the Canadian petroleum industry
and in the Ministry of Aviation and the Ministry of Technology. Duncan Riding is Section Manager at Perkins Technology. He
He was Manager and subsequently Director of the Swansea has been involved with the development and refinement of
Tribology Centre for 20 years. He is the author of four books and many engines, working mainly from the finite element and
over thirty other publications on lubrication. analytical area.
Chapter 13 Bearings and bearing metals Chapter 21 Larger engine noise and vibration control
C. Evans PhD and J.F. Warriner CEng MIMechE MIMarE Stanley Walker
C. Evans has worked in all aspects of bearing development and
Stanley Walker is currently Principal Engineer, Truck Products,
manufacture. Co-author J.F. Warriner has worked on large engine
at Barry Controls. He is responsible for the design and development
development and is the author of several papers on engine bearings.
of diesel engine mounts, cab mounts, and isolation components
Reviewed by Mike Neale of Neale Consulting Engineers Ltd.
for Class 5 to Class 8 trucks worldwide.
Chapter 14 Pistons, rings and liners Chapter 22 Passenger car engines
Robert Munro PhD ARCST CEng MIMechE H.S.-H. Schulte Dr-Ing PhD Dipl-Ing (MSME)
Formerly Director of Engineering at Wellworthy Ltd, now a
consultant. He has presented many papers in the field of diesel Dr Schulte has worked at the Aachen Technical University, FEV
pistons, rings and liners. He has updated the chapter for this editon. Motorentechnik and at Mercedes-Benz. He is now the Executive
Vice President and Chief Technical Officer of FEV Engine
Technology in Auburn Hills, Michigan.
Chapter 15 Auxiliaries
Governors and Governor Gear—M. Davies, formerly with
Chapter 23 Trucks and buses
Woodward Governor.
David Merrion and K.E. Weber
Starting Gear and Starting Aids—D. Hodge CEng FIMechE
David Merrion has spent his entire career at Detroit Diesel
MIEAust, formerly with GEC.
Corporation. He is past president of the Engine Manufacturers'
Heat Exchangers—M.K. Forbes MA CEng FIMechE, formerly Association, a fellow of the SAE, a member of ASME, a
with Serk Heat transfer. Buckendale Lecturer and a member of the US Environmental
Protection Agency Technical Advisory Committee.
Chapter 16 Aircooled engines K.E. Weber has over 20 years experience in advanced heavy-duty
Dr LG. Killmann Dr techn Dipl-Ing MSAE MVDI and P. Tholen diesel engine design and development at General Motors and
Dipl-Ing Detroit Diesel Corporation. She is currently the manager of
Applications Documentation at DDC.
LG. Killmann joined Klockner-Humboldt-Deutz (KHD) in 1970
where he became Director of Research. He was made Vice Chapter 24 Locomotives
President of AVLK Prof List Ges. mbH in Graz in 1980 where he
Humphrey Niven BSc (Eng) CEng FIMechE
was responsible for engine research.
A specialist in research and development in the field of large
Paul Tholen started his professional career in 1950 at Klockner- engines, he formerly worked with Paxman Ltd. He is currently
Humboldt-Deutz (KHD). His work was mainly connected with with Ricardo Consulting Engineers where he is responsible for all
air cooled diesel engines. Before retiring in 1982 he was mainly aspects of large engine work.
engaged with advanced engine systems. This chapter was updated
by Rodica Baranescu. Chapter 25 Dual fuel engines
Roger Richards
Chapter 17 Crankcase explosions
Roger Richards is Principal Engineer with Ricardo Consulting
S.N. Clayton CEng FIMechE FIMarE
Engineers. He has worked on various engine areas, from Stirling
S.N. Clayton was formerly with Lloyd's Register. This chapter engines through alternative fuels and artificial intelligence applied
was edited by Rodica Baranescu. to condition monitoring. He is responsible for the development of
novel techniques for improving efficiencies and emissions of large
engines.
Chapter 18 Exhaust smoke, measurement and regulation
Contributed by Ricardo Consulting Engineers. Ricardo is an Chapter 26 Marine engine applications
independent consultancy, based at several locations in England
Doug Woodyard
and the US. Established in 1919, the Group's core business is
reciprocating engines and their related technologies. After experience as a seagoing engineer with the British India
Steam Navigation Company, Doug Woodyard held editorial
positions with the Institution of Mechanical Engineers and the
Chapter 19 Exhaust emissions
Institute of Marine Engineers. He subsequently edited The Motor
Contributed by Ricardo Consulting Engineers (see Chapter Ship journal for eight years before becoming a freelance editor
18). specializing in shipping and marine engineering.
Chapter 20 Engine noise Chapter 27 Condition monitoring
Raymond Farnell and Duncan Riding Michael Flint PhD CEng FIMechE and Tony Martyr
Raymond Farnell is Senior Noise Engineer at Perkins Technology. Michael Plint founded the company Plint & Partners and for the
He has been responsible for the noise engine reduction of many following 30 years was deeply involved with engine testing and
engines, combining practical testing and development techniques. the developing of test equipment. He held positions of visiting
Professor at Austrian and American universities. Michael Flint an independent consultant to the automotive industry worldwide.
died in November 1998. He has presented and published numerous papers covering various
aspects of engineering. He writes for several engineering publica-
Tony Martyr has worked extensively with marine and automotive tions, organizes and participates at engineering conferences and
engines. He is currently Operations Manager with Ricardo Test
workshops in Europe and the United States.
Automation. He is co-author with Michael Flint on a standard
work on engine testing. Dr Rodica Baranescu PhD MSc FSAE MASME
Dr Baranescu was previously Professor at the Technical University
Editors 'Polytehnica' Bucharest Romania. She moved to the US A in 1980
and joined Navistar International Transportation Corp. where she is
Bernard Challen MSc CEng FIMechE FIEE MIOA FSAE
chief engineer in the Engine Division. She is Chair of the Alternative
Former Technical Director, Ricardo Consulting Engineers, now Fuels Committee of the Engine Manufacturers' Association.