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Conceptual Cylinder Head CAD Project for Assessment

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2020 ASEE Virtual Annual Conference Content Access


Virtual On line

Publication Date

June 22, 2020

Start Date

June 22, 2020

End Date

June 26, 2021

Conference Session

Engineering Design Graphics Division Technical Session 4

Tagged Division

Engineering Design Graphics

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Eric Leonhardt Western Washington University

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I work with primarily undergraduate students in the area of vehicle design and construction. I have been involved with thirty student built vehicles, each named after the school's Viking mascot. We built Viking 32 to demonstrate carbon fiber honeycomb as an impact absorbing material for the Federal Highway Administration. Viking 32 also became the world’s first biomethane hybrid as we demonstrated “Cow Power to Horsepower”. We used Viking 25 and Viking 32, both hybrid electric vehicles that run on natural gas, to demonstrate technology to utilize Dairy cow derived renewable natural gas (RNG) as a transportation fuel. Viking 40 and Viking 45 were built to demonstrate lower cost and higher rate composite production processes for the body and monocoque chassis. Hybrid electric Viking 45 participated in the Progressive Automotive X Prize as the only U.S. university vehicle and hybrid vehicle to participate in the finals round. The vehicle achieved 172 MPGe for 100 km at 95 km/hr. The latest full size vehicle is Lyn Okse (Norwegian for "Lightning Ox"), a 1/4 ton electric pick-up truck with 300 mm of off-road ground clearance for campus grounds crews. The vehicle demonstrates the future of lower cost, more powerful electric motors and battery packs.

The Vehicle Research Institute operates as a technology development center that provides undergraduate students with opportunities for career specific training and research. Funding comes from a variety of sources including the Department of Energy, Department of Transportation, EPA, Paul Allen Family Foundation, BP, Washington State Department of Agriculture, Whatcom Public Utility District, Boeing, Janicki Industries, Northwest Porsche Club, Danner Corp. and Fluke. Past supporters include the Department of Defense, Fuji Heavy Industries (Subaru), PACCAR, Mazda, Ford, Bentley (parent company Audi), Alcoa, Conoco-Phillips, CNG Fuels of Canada, Chrysler, and DaimlerChrysler.

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A cylinder head design project is used to assess computer aided design skills during a capstone course sequence. The conceptual cylinder head design project is used to ensure that all students are assessed using a similar CAD project. The capstone course sequence generally features a large, multi-year project that may not have CAD components of similar complexity for all students. The geometric model is designed to support the creation of a physical prototype that may be used for airflow development models. Some of the models are printed using filament deposition printing techniques. The geometric model also supports the use of virtual airflow analysis using computational fluid dynamics. Earlier versions of the assignment utilized specifications of existing engine components--valves, valve springs, and valve seats--to guide the design of a four valve per cylinder suitable for compressed natural gas fuel in a long haul truck engine. Later versions of the assignment added the use of parametric tables to drive cylinder head geometry using a spreadsheet. During one capstone series, students designed and cast engine blocks for the prototype cylinder head. During this series, students also used engine simulation tools to predict the performance of the engine. The cylinder head CAD design project has allowed all of the program graduates to be assessed and to ensure that their CAD skills are marketable as they graduate.

Leonhardt, E. (2020, June), Conceptual Cylinder Head CAD Project for Assessment Paper presented at 2020 ASEE Virtual Annual Conference Content Access, Virtual On line . 10.18260/1-2--34323

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