Design and manufacture of a single cylinder, four stroke spark ignition engine using finite elements method

DESIGN AND MANUFACTURE OF A SINGLE CYLINDER, FOURSTROKE SPARK IGNITION ENGINE USING FINITE ELEMENTSMETHOD(Ph.D. Thesis)Melih OKURGAZI UNIVERSITYINSTITUTE OF SCIENCE AND TECHNOLOGYJanuary 2007ABSTRACTThe technological improvements and the increasing demand of the customershave lead the designers and the engine manufacturers to design andmanufacture various engines from model airoplane engines to giant marineengines.The design process is one of the most important stage of the production.Nowadays the primary objective of almost all engine makers is to reduce thedevelopment and manufacturing time and cost of engines parts and, at the sametime, to manufacture lighter and reliable products. Stresses and deformationson the parts, functions of the parts under loads, and acceptable deformationlevels have to be determined by the designers. And the most common tools of thedesigners are the computer based design and manufacturing softwares. Thecompetition of the design and manufacturing software companies resulted indifferent methods and package programs which has different advantagesagainst the others.In Turkey, the engines used in various areas such as agriculture, transportation,industry, universities and institutions, electrical power generation, etc.. are allforeign patents. Because of patent restrictions, it is not possible to furtherimprove these engines in Turkey. Therefore, the engine industry has difficultieson creating innovations, updating the knowledge and competing in theinternational market.A commercial type, single cylinder, spark ignited, four stroke 273 cc engine hasdesigned and manufactured in this thesis. ANSYS analysis programme was usedfor dimensioning and stress analysis of the critical engine parts. After serial loadtests and some refinements 3.26 kW output power was achieved at 2750 rpm.Higher power figures seems to be possible with the ignition and fuel systemmodifications.Science Code : 708.3.026Key Words : Engine design, engine loads, ANSYS, finite elementsPage Number : 160Adviser : Prof. Dr. Selim ÇETİNKAYA