Loughborough University Institutional Repository

Diesel engine 2-stroke versus 4-stroke cycle design in rail

traction

This item was submitted to Loughborough University's Institutional Repository by the/an author.

Additional Information:

• Two-stroke cycle and four-stroke cycle diesel engines are in use in rail trac- tion with four-stroke cycle design dominating the field. Cycle simulation by computer programmes have shown that the conventional two-stroke cycle is inferior to its four-stroke cycle counterpart in combustion effi- ciency and thermal loading. Research at Sulzer Brothers Ltd., to decide on the choice of cycle for production of a high power locomotive engine concluded that. conventional two-stroke cycle engine is not suitable for locomotive application. A report by Ricardo Ltd., based on a survey of engines in current production for traction application suggested that there are potentials in two-stroke cycle design . This research project is concerned with comparison of two well proven locomotive engines, one of two-stroke cycle and the other of four-stroke cycle. Performance, mechan- ical loading, thermal loading and vibration were chosen as parameters to be investigated to provide information about the status of the two cycles in relation to lower range, fuel consumption, reliability and durability, with a view to assist the users of locomotive engines to make the correct choice. Results and analysis of these findings are presented.

• A Master's Thesis. Submitted in partial fulfilment of the requirements for the award of Master of Philosophy of Loughborough University.

Metadata Record: https://dspace.lboro.ac.uk/2134/14389

Publisher: c© E.B.Mohammed Nabag

Please cite the published version.

https://dspace.lboro.ac.uk/2134/14389

This item was submitted to Loughborough University as an MPhil thesis by the author and is made available in the Institutional Repository

(https://dspace.lboro.ac.uk/) under the following Creative Commons Licence conditions.

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:1 .1

I

LOUGHBOROUGH UNIVERSITY OF TECHNOLOGY

LIBRARY AUTHOR/FILING TITLE

N~Q.AG- £ ~ M ---------- ------- __ __ J.. ______________ __________ ,

-- -- - - -- -- - --- -------------- -- -- --- ----- - - --"-- --- ACCESSION/COPY NO.

----------------- -Q ~_~_'t ':':.~ /~3.: ____________ _ ! VOL. NO. CLASS MARK i

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11 P,~ OAN 3 INKS

NLESS P~-e:;ALLE

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SCHOOL OF ENGINEERING

DEPARTMENT OF TRANSPORT TECHNOLOGY

DIESEL ENGINE 2-STROKE VERSUS 4-STROKE

CYCLE DESIGN IN RAIL TRACTION

by

E.B.Mohammed Nabag

S~pervisor: Dr.S.D.Haddad

Director of Research: Professor F.D. Hales

A Thesis submitted in partial fulfilment of

the requirements of the award of de~ree of

Master' of Philospuhy ..

UNIVERSITY OF TECHNOLOGY, LOUGHBOROUGH 1983

DEDICATION

In memory of my father, mother, brother and Un cle.

To .my wife Noor, my sons, Khali.d, Abu Bkr and Omer.

TABLE OF CONTENTS

Page

Synopsis i

Acknowledgement ii

Chapter 1 Introduction, Summary of Thesis, Chapters

and Ge neral Review of Reference 1

1.1 Introduction

1.2 A short summary of thesis chapters and a

general review of references

References

Chapter 2 Two stroke Vs Four stroke in Rail Traction

2.1. Introduction

2.2. P1'edicti,ve studies

2.2.1.Power output

2.2.5.Thermal loading

2.2.2.1. Aggregate heat transfer

2.2.2.2. Piston heat flow

2.2.2.3. Thermal stress criteria

2.2.2.4. Thermal stress

2.2.3. Turbocharged, compound and gas generation

arrangements

2.2.4. Indi~ated thermal efficiency

2.2.5. Comparison of engine types on basis of

power and thermal load , .

. 2.2.5.1. Fixed boost pressure ra ti,o and power

2.2.5.2. Fixed thermal load and power

2.2.5.3. Fixed bore and power

2.3. Test results from experimental engines

(Sulzer experience)

2.3.1. Comparison between 2-st1'o1

2.3.1.1. Comparing fuel consumption and

acceleration characteristics 27

2.3.1.2. Considering the thermal loading 29

2.3.1. Conclusions ~n the field of application

for 2 and 4 stroke cycle trunk

piston engines 29

2.3.2.1. ~vo stroke cycle 30

2.3.2.2. Four stroke cycle 30

2.4. Comparison of performance and design of

engines in current production 39

1. Thermal loading 40

2. Brake mean effective pressure 40

3. Piston speed 40

4. Specific weight and specific volume 41

Design factors

1. Pistons 42

2. Cylinder heads 42

Conclusions 45

References 46

Chapter 3. History! Development and Enhancement

of Design of Traction Diesel Eng!~

within General Motors and Ruston Diesels. 76

3. A. General Motors Corporation. 76

3.1. Evolution' of GM Series 567 Diesel Engine

3.1.1. Turbocharging

3.2. M6del 645 engine series 3.9.1. Fe,atures 9f hbdel 645 Engines 3.2.1.1. l?iston 3.2.1.2. Piston l~ings'

3.2.1..3. Cylinder liner 3.2.1. 4. Cy linCie]; -head

3.3. Features o:f Model 6-15EB engines.

76

92

95

95 95

96

97 97

98

3.3.1.

3.3.1.1.

3.3.1::·2.

3.3.1.3.

3.3.2.

3.3.2.1

3.3.2.2.

3.3.2.3.

3.4.

3.4.1.

3.4.1.1.

3.4.1.2.

Performance - related design features 98

Unit fuel injector 98

Turbocharger 99

Fuel Consumption 101

Reliabili ty - related design features 101

Silver wrist pin bearing 101

Cylinder liner 103

Cylinder head 104

Model F and F3A diesel engines la;

Model F3A engine performance objectives la;

Me chanical requirements for the model

F3A rating

Model F3A engine features

3.4.1.2.1. Fire ring piston

103

107

107

3.4.1.2.2. Rocking pin and bearing, cylinder liner

and cylinder hea~.

3.4.1.3.

3.4.1.4.

3.4.1.5.

3.4.1.6.

Turbocharger

Crankcase

Camshaft and rocker arm assembly

Engine performance

3.4.1.6.1. Improved cylinder scavenging

3.4.1.6.2. Improved fuel economy.

3.5. Model. 645EC and 645FB engines

3.5.1.

3.5.2.

3.5.2.1.

3.5.2.2.

3.5.2.3.

Structural design features

Performance features

Turbocharger

Fire ring piston

Model FB and EC engine performance.

3.5.2.3.1. Improved cylinder scavenging

108

108

109

110

110

llO

III

ll2

113

ll4

ll4

ll4

ll5

ll5

3.5.2.3.2. Model F

3.5.2.3.3. Model FA

3.5.2.3.4. Model Fb

3.6.

3.6.1.

3.B.

3.1.

3.1.1.

3.1.2.

3.1.3.

3.1.4.

3.1.5.

3.1. 6.

3.1. 7.

3.2.

3.2.1.

3.2.2.

3.2.2.1.

3.2.2.2

3.2.2.3.

3.2.2.4.

3.3.

3.3.1.

3.3.2.

3.3.2.1.

3.3.2.2.

The locomotive,and the engine

New diese 1 electric locomotive technology

Ruston Diesels Ltd.,

Background to the,English Electric V/RK

Mark 3.

Design Philosophy

Performance improvement

Design development

Serviceabili ty

Related matters

Performance of prototype

Endurance of the prototype

Development of analytical aspects of

diesel engine design

Introduction

Engj_ne performance and heat transfer

Turbodynamic model

Turbocharging model

geat release model

Fuel injection model

Deve lopmen t of Ruston 254 nun bore RK

Performance trend ' .... . -~ ... ,

Engine performance prediction

8RKC engine

12 RKC engine

115

116

116

117

117

118

118

120

122

124

126

127

128

129

132

132

133

133

134

135

137

139

139

139

140

142

3.3.3.

3.3.4.

3.3.5.

3.3.6.

3.4.

3.4.1.

3.4.2.

3.4.3.

3.4.3.1.

3.4.3.2.

3.4.3.3.

3.4.4.

3;4.4.1.

3.4.4.2

Chapter 4.

4.1. .

4.2.

Turbocharger efficiency

Compression ratio

Engine reliability

Finite element analysis and engine loading

143

144

144

144

RK engi ne.opera ting experience on Bri tish Rai 1 146

Selection of the prototype and test 147

User requirement, design modifications

and reliability

Performance assessment

First prototype 12 cylinder engine

12 cylinder