Automotive - Diesel Engine Reference Book.pdf - Automotive - mireklab

Diesel Engine

Reference Book

Second Edition

Edited by

Bernard Challen

Rodica Baranescu

pi UTTERWORTH

|g|E I NEMANN

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

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

licence issued by the Copyright Licensing Agency Ltd, 90 Tottenham

Court Road, London, England, WlP 9HE. Applications for the

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

appeared and in the meantime the diesel engine industry has

undergone more product development than probably at any time

in its 100 years history. It is very timely, therefore, that this

classic reference book should be updated to reflect the significant

advances that have taken place in diesel engine design, improving

performance and economy, environmental attributes, reliability

and durability.

The demand for the diesel engine continues to increase world-

wide as it consolidates its position as the prime mover for tractors,

medium and heavy trucks, buses, locomotives, ship propulsion,

auxiliary power generation and many industrial applications.

Additionally, the diesel engine continues to challenge the gasoline

engine as the power unit for the passenger car market particularly

in Europe although exhaust emissions legislation, and specifically

limits on particulate emission, threatens the survival of the diesel

in this sector in the USA and Japan.

Much of the advancement has been driven by exhaust and

noise emission legislation which is both increasing in severity

and broadening from automotive engines to cover virtually all

applications. The impact of such legislation is extending from

North America, Europe and Japan to cover most of the world,

as other developing nations encounter serious environmental

problems.

Fuel economy remains the prime factor favouring the

application of the diesel in many markets. In the smaller engine

sizes where the gasoline engine has made dramatic improvements

in economy through improved combustion, lean-burn operation,

and advancements both in fuel injection equipment and electronic

control systems, the diesel engine has been able to maintain its

advantage. This has been achieved principally by the development

of the direct-injection combustion system for smaller and smaller

cylinder sizes, where traditionally the indirect-injection engine,

and particularly the Ricardo Comet system, dominated the market.

Other trends in this sector are the move to 4-valve operation,

greater use of light alloy materials for the engine structure, charge

cooling, cooled EGR (exhaust gas re-circulation) and variable

geometry components such as the turbocharger, inlet manifold

and valve-train.

The specific output of larger medium-speed diesel engines

continues to rise steadily. Despite increases in mechanical loading,

overhaul lives of 20 000 hours, or 1 million miles in locomotive

applications, are being achieved with improved reliability and

lower manufacturing costs.

These advancements in the diesel engine have only been

possible by the development of advanced fuel injection systems,

generally with electronic control systems, offering higher injection

pressures with much more accurate control of fuel metering and

injection timing. The unit injector is already well established,

and common rail fuel injection systems are expected to find

widespread application especially in automotive engines,

providing additional benefits in noise reduction and design

flexibility—allowing greater freedom in selecting the number

of cylinders and cylinder configuration.

The engineer involved in diesel development is increasingly

under pressure to achieve a higher quality product in a shorter

time frame. This has resulted in the rapid development of

sophisticated analytical tools to enable greater optimization at

the design stage.

This new edition has been comprehensively revised and

extended to cover these latest advances in diesel engine design

and development.

I extend my congratulations to the joint editors Bernard Challen

and Rodica Baranescu who together with the impressive team

of world-renowned experts have succeeded in producing an

outstanding volume.

As a young apprentice engine designer at Ruston & Hornsby

I found Pounder's original book of 1955 an invaluable aid; later

the first edition of this book, which my old colleague Les Lilly

was responsible for, embodied 30 years additional knowledge.

I am sure this new edition, bringing us to the state-of-the-art at

the end of the century, will continue to be the essential reference

book for all engineers involved in diesel engine design,

development and application.

JOHN MCCLELLAND

Managing Director

AVL Powertrain Engineering Ltd

Foreword

With the publication of this second edition the name of Leslie

Lilly will pass from the world of technical books, into obscurity.

And so, while the opportunity remains, please consider for a

moment the achievement of a modest man whom I came greatly

to respect. In many ways Leslie Lilly was the archetypal

researcher, the 'back-room boy', tall, unassuming, but driven

by an inner conviction to achieve what was to be achieved. He

was well into retirement from Ricardos when I met him in the

late 1970s, singing in his church choir and active in the charitable

work that meant so much to him. I was commissioning for the

publisher Butterworths, following a trail that I hoped would

lead to the rebirth of a classic that had been too long out-of-

print, C.C. Pounder's Diesel Engine Principles and Practice. I

knew when the path eventually led to Lilly that there would be

no snap decision, and that every consideration would be weighed

like every decision taken in the engine laboratories in which he

had worked since 1928 when, as he recalled, '. . . parts not

infrequently flew out of the doors . . .' while one stood '. . .

beside the engine, or with more discretion in front of it.'

When he agreed to accept the challenge, I found myself working

with a man of wisdom and a quite unmalicious humour, of

determined energy, and above all an integrity that enabled him

to assemble and earn the trust of an impressive cast of contributors

from the UK, Europe and America. From the diffidence of my

first meeting with this long-retired engineer, there emerged a

man who was discovering a second lease of life. Through firmness

and diplomacy, the massive manuscript of the first edition took

shape, the work of more than thirty experts—and in the days

before E-mail and personal word-processors. It was handed

over on the agreed date, and the expertise of lifetimes became

once more available to the diesel fraternity worldwide.

One of the rewards of publishing is its encounters with the

authors and editors who emerge from the backrooms of technology

to become the unforgettable personae of a working life. I am

grateful to the publishers, my one-time employers, for this

opportunity to pay tribute to Leslie Lilly.

DON GOODSELL

Automotive - Diesel Engine Reference Book.pdf

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