VII PTNSS Congress - 27th-29th June 2017
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Applying Reverse Engineering procedures to modernize a test engine cylinder head

In practical research sometimes a need arises to recreate an existing structural part which has been damaged or worn out, or requires major design changes, and there is no proper detailed design documentation. Such a problem arose at the Poznan University of Technology in connection with the necessity of making a new, modified cylinder head for single-cylinder research. The use of reverse engineering procedures was chosen for this purpose. The article presents the steps of manufacturing a new cylinder head, equipped with a valve timing control system and two-stage combustion system with a fuel spark jet ignition. The procedures for scanning the outer surfaces and determining the internal structure of the engine head with the use of computed tomography were discussed. The geometry of the head was obtained from those measurements in the form of a set of points, that were then imported into Geomagic Design X, and then used to develop a 3D model of the existing engine head, which was adapted for using the variable valve timing control system, and the gas-air mixture combustion in the divided chamber. The resulting model was used to design a casting core, which was used to cast the element. The crude casting was processed mechanically, the valve mechanism and the pad comprising a pre-combustion chamber a spark plug and gas supply inlet valve were mounted on the cast. The article concludes with a discussion of the effects of these measures and a short operational capacity description of the test engine equipped with a head produced this way. The possibility of further use of the head model and the combustion system for computer simulation of such an engine was also indicated.
Topic: Global trends in engine technology
Author: Wojciech Cieślik
Co-authors: Ireneusz Pielecha Krzysztof Wisłocki