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Dissertations / Theses on the topic 'Balancing crankshaft'

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Published: 4 June 2021
Last updated: 9 February 2022

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1

Angelopoulos, Vasileios. "A model-based design approach to redesign a crankshaft for powder metal manufacturing." Thesis, KTH, Maskinkonstruktion (Inst.), 2015. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-183006.

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A crankshaft is a component which is used to convert a reciprocating movement into rotating or vice versa. Through the past years classical manufacturing techniques did not leave space for a new approach regarding manufacturing this component. Powder Metallurgy provides a manufacturing technique which can revolutionize this procedure and make it more economical and more efficient. In order for this to be achieved, the crankshaft must be produced in different pieces. Webs, counter-webs and journal shafts must be produced individually and assembled together. The main challenge in this thesis is to understand if the crankshaft’s counter webs could be manufactured all in the same pieces or in as less pieces as possible. This thesis deals mostly with the technical requirements and proposing a new modular design. A kinematic-kinetic analysis is performed by using the values from the existing crankshaft which has been scanned and converted into a CAD model. The numerical values from the kinetic-kinematic analysis in Matlab are compared with a MBS model from Adams. Then the balancing of the crankshaft is analyzed and it is investigated how the counterweights should be arranged in space and what should be the mass and the geometrical properties of them. From the component’s design specifications, several models are generated and evaluated with the Pugh matrix. The original and the new proposed models are compared as far as concern the mass, center of mass, mass moment of inertia and natural frequencies.
En vevaxel är en motorkomponent som används för att omvandla den fram- och återgående rörelsen hos kolv och vevstake till en roterande rörelse. De klassiska metoderna att tillverka vevaxlar har varit dominerande och inte gett någon plats för alternativa tillverkningsmetoder. Powder manufacturing är en metod som kan revolutionera produktionens effektivitet och ekonomi. För att denna tillverkningsmetod ska vara möjlig måste vevaxeln tillverkas i delar. Webs, counter-weights och journal shafts måste produceras individuellt för att sedan sammanfogas. Den största utmaningen för denna avhandling är att förstå om vevaxelns counter webs kan tillverkas med samma form eller med så få olika former som möjligt. Denna avhandling handlar främst om att fastställa dessa tekniska krav och föreslå en ny, modulär design för PM. En kinematisk-kinetisk analys utförs med hjälp av en befintlig vevaxel som skannats och omvandlats till en CAD-modell. De numeriska värdena jämförs med en MBS-modell från Adams. Vevaxeln analyseras med avseende på balansering då motvikternas placering, massa och geometriska egenskaper undersöks. Nya modeller som följer de tekniska krav som krävs skapas och utvärderas med Pugh-matris. De nya föreslagna modellerna jämförs med den ursprungliga utformningen med tanke på massa, masscentrum, MMOI och egenfrekvenser.
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2

Svoboda, Radim. "Kontrola vyvážení klikového mechanismu maloobjemového traktorového motoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2013. http://www.nusl.cz/ntk/nusl-231005.

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The purpose of this thesis is determinate the forces in crankshaft mechanism acting on new design engine from company Zetor, assessment of the state of balance, design modifications balancing units, calculation of modal analysis, stress analysis and strain control. The content of the work is the creation of technical documentation for the newly modified balancer shafts.
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3

Hillerborg, Per. "Dynamic Model of a Diesel Engine for Diagnosis and Balancing." Thesis, KTH, Reglerteknik, 2005. http://urn.kb.se/resolve?urn=urn:nbn:se:kth:diva-107535.

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To monitor and control the combustion in a diesel engine one can study the speed signal from the flywheel. The idea is that if individual cylinders give different amount of torque this will lead to variations in the flywheel speed. A model which describes the cylinder torque based on flywheel speed can be used to estimate the torque from individual cylinders. With this new knowledge of the individual performance of each cylinder the engine can be balanced. The balancing aim at making the speed of the flywheel more even but also required a model with estimated cylinder torque as input. This model may also be used for testing new control algorithms easily and gaining understanding of the dynamics. In this thesis a time dissolved model is constructed to describe the cylinder pressure-, crankshaft-, flywheel and damper dynamics. The model is based on a physical point of view by approximating the system into nodes containing mass, stiffness and friction. The inputs into the model are injection data from the engine management system (EMS) and a torque from a drive line. Ways to reduce the complexity of the model are investigated in order to invert the model to estimate the injection data based on flywheel speed measurements. Measurementsare done in a test bed to receive data required for model simulation and validation. The result is that the main behavior of the dynamics is caught. The self oscillation behaviors in some operating points are however not caught which indicates that the model can not explain all behaviors. A reduced model works almost as well but of course looses more of the non stiffness behavior. As expected, the model equations can not be solved in real time. The result of the inverted reduced model depends on the flywheel signal. When the signal contains little non stiffness behavior the result is good. An observer model based on the reduced model is suggested and tested in order to estimate the indicated torque from flywheel data. The observer manages to detect errors in the injection.
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4

Richter, Tomáš. "Dvouválcový zážehový motor pro osobní automobil." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2012. http://www.nusl.cz/ntk/nusl-230157.

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The purpose of this thesis is two-cylinder in-line four stroke petrol engine design based on input parameters. The work consists of different variations of designed crankshaft balancing and balancing unit. Calculation method of torsion vibration and crankshaft fatigue failure solution based on stress analysis are included.
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5

Drápal, Lubomír. "Hnací ústrojí šestiválcového leteckého motoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2008. http://www.nusl.cz/ntk/nusl-227900.

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The purpose of this thesis is design of a six-cylinder engine arrangement with given main parameters (bore, stroke, etc.), powertrain design, possibilities of firing order, balancing inertia forces and its moments, in case of need, balancing shaft design and calculation of torsion vibrations.
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6

Balash, Ievgen. "Tříválcový řadový zážehový motor." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2014. http://www.nusl.cz/ntk/nusl-231050.

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The main aim of this master’s thesis is to design the powertrain of turbocharged threecylinder in-line gasoline engine based on given parameters. The work introduces three variants of balancing of inertia moment of rotating masses and balancer unit of first order moment of inertia of reciprocating parts. The thesis also presents calculation of torsion vibration of the powertrain and structural design of the rubber damper. In conclusion a stress analysis of the crankshaft is submitted with and without torsion vibration damper.
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7

Briš, Tomáš. "Tříválcový vznětový motor pro užitková vozidla." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2017. http://www.nusl.cz/ntk/nusl-318523.

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The diploma thesis deals with a design of a crankshaft for a three-cylinder diesel engine for commercial vehicles. The engine is a member of a unified line of engines with the number of cylinders from two to six. The main points of the work are a draft of the crankshaft configuration, the balance of inertial forces and the moments in the crank mechanism, creation of drawings of the crankshaft and finally carrying out a strength analysis of the part, taking into account torsional vibration. The aim is formation of a part – crankshaft for potential usage in the automotive industry.
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8

Josefíková, Kateřina. "Návrh klikového mechanismu leteckého vznětového motoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2010. http://www.nusl.cz/ntk/nusl-229179.

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The purpose of this thesis is design of a crank mechanism for diesel aircraft engine. Next then appropriately balance crank mechanism, strength tests and calculation of crankshaft torsional vibration. Developing of drawings documentation of crankshaft.
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9

Fáber, Filip. "Zážehový motor pro malá osobní vozidla." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2012. http://www.nusl.cz/ntk/nusl-230346.

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The aim of this master’s thesis was to define force progression in crank-type mechanism from the set parameters of the cylindrical unit. Furthermore, the design of the possible balance of this crank-type mechanism with one balancing shaft was realized. The calculations of torsional vibration and stress analyses of the designed crank-type mechanism were realized too.
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10

Nilsson, Magnus. "Modelingflywheel-Speed Variations Based on Cylinder Pressure." Thesis, Linköping University, Department of Electrical Engineering, 2004. http://urn.kb.se/resolve?urn=urn:nbn:se:liu:diva-2333.

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Combustion supervision by evaluating flywheel speed variations is a common approach in the automotive industry. This often involves preliminary measurements. An adequate model for simulating flywheel speed can assist to avoid some of these preliminary measurements.

A physical nonlinear model for simulating flywheel speed based on cylinder pressure information is investigated in this work. Measurements were conducted at Scania in a test bed and on a chassis dynamometer. The model was implemented in MATLAB/Simulink and simulations are compared to measured data. The first model can not explain all dynamics for the measurements in the test bed so extended models are examined. A model using a dynamically equivalent model of the crank-slider mechanism shows no difference from the simple model, whereas a model including a driveline can explain more from the test-bed measurements. When simulating the setups used at the chassis dynamometer, the simplest model works best. Yet, it is not very accurate and it is proposed that optimization of parameter values might improve the model further. A sensitivity analysis shows that the model is fairly robust to parameter changes.

A continuation of this work might include optimization to estimate parameter values in the model. Investigating methods for combustion supervision may also be a future issue.

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11

Jadrný, Jan. "Výpočtový model vyvažovací jednotky řadového pětiválcového motoru v multi-body systému." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2008. http://www.nusl.cz/ntk/nusl-228008.

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The diploma thesis deals with a calculation and a construction concept of a balancing unit of a strait five cylinder combustion engine. The thesis contains the calculation and the construction concept of the balancing shafts. Also the concept of the calculation model of a driving mechanism with the balancing unit in MSC Adams – Engine is included.
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12

Dragoun, Jan. "Dvouválcový čtyřdobý plochý zážehový motor." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2013. http://www.nusl.cz/ntk/nusl-230626.

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This thesis deals with the possibilities for realization of the crankshaft-cylinder four-stroke gasoline engine is flat, usable in the urban vehicle. In the work described stresses exerted on the crank mechanism can balance the crankshaft, torsional stress and strength calculation method of control. In the final part of this work is outlined proposal for implementation of the crankshaft.
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13

Vaculík, Tomáš. "Hnací ústrojí nekonvenčního vidlicového vznětového šestiválce s vyvažovacím hřídelem." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2011. http://www.nusl.cz/ntk/nusl-229884.

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The aim of this thesis is to design a powertrain of unconvential V-6 diesel engine with balancing shift with angel of cylinders’s axis 90 degrees and crank pin ofset of 30 degrees. The thesis provides an analysis of balance of inertial forces and their moments, layout of counterbalances on crankshaft and balancing shaft. It also provides a layout of discrete model of torsional cranksaft mechanism and layout of rubber damper of torsional oscillations.
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14

Štefaňák, Petr. "Pětiválcový řadový vznětový motor s vyvažovací jednotkou." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2011. http://www.nusl.cz/ntk/nusl-229887.

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The purpose of this work is design of a five-cylinder in-line diesel engine with the given initial parameters. The work will be analyzed by balancing the engine, remove the effects of unbalanced masses by the unbalance of the crankshaft and separate balancing unit. It will also be analyzed driveline torsion vibration, followed by reducing the effects of torsion vibration by using rubber torsion vibration dampers. At the conclusion will be modal and stress analysis of the crankshaft using the FEM program.
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15

Hejda, Tomáš. "Hnací ústrojí nekonvenčního vidlicového vznětového šestiválce s viskózním tlumičem." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2011. http://www.nusl.cz/ntk/nusl-229894.

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The purpose of this thesis is design an unconventional powertrain V-6 engine with cylinder opening lines offset 90 degrees and 30 degrees of crank pin offset. It is an analysis of the balance of the crank mechanism, proposed unbalance, build a model of discrete torsion system, design of viscous torsional vibration damper, compares the results of the calculation of strength without crankshaft damper and with damper.
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16

Kovář, Pavel. "Hnací ústrojí tříválcového řadového vznětového motoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2011. http://www.nusl.cz/ntk/nusl-229920.

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This master’s thesis describes design and comparison of three variants of the crankshaft in-line diesel engine for commercial vehicles. The work focuses on working with programs for 3D modelling and analysis proposed models, to be able to work under difficult conditions. Part of this work is a computational modal and strength analysis.
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17

Masnica, Pavel. "Pětiválcový řadový vznětový motor s pryžovým tlumičem." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2011. http://www.nusl.cz/ntk/nusl-229470.

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The purpose of this thesis is design of five-cylinder in-line diesel engine with rubber dumper, with given main parameters, powerstrain design, balancing inertia forces and its moments, modal analysis, calculation of torsion vibrations and design of rubber dumper.
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18

Ošmera, Petr. "Hnací ústrojí osmiválcového leteckého motoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2008. http://www.nusl.cz/ntk/nusl-227899.

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Configuration of the powertrain of a flat-eight engine with ordered basic parameters is the theme of this thesis which name is Powertrain design of an eight-cylinder aircraft engine. This thesis occupies with configuration design of the crank mechanism and firing order, balancing of centrifugal and reciprocating forces and their moments, conceptual design of crankshaft and its stress calculation. This thesis also puts mind to calculation of torsional vibrations.
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19

Kopřiva, Martin. "Hnací ústrojí desetiválcového leteckého motoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2008. http://www.nusl.cz/ntk/nusl-228009.

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Configuration of the powertrain of a flat-engine with ordered basic parameters is the theme of this final thesis which name is Powertrain design of ten-cylinder aircraft engine. This thesis is occupied with configuration design of the crank mechanism and firing order, balancing of centrifugal and reciprocating forces thein moments, conceptual design crankshaft and its stress calculation of torsional vibrations.
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20

Bečka, Petr. "Hnací ústrojí nekonvenčního vidlicového vznětového šestiválce s pryžovým tlumičem." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2011. http://www.nusl.cz/ntk/nusl-229883.

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The aim of this work is to design the crankshaft fork unconventional six-cylinder with offset pivots, the torque balance, modal analysis, vibration analysis of torsional and torsional vibration damper design, stress analysis using FEM.
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21

Ducheček, Martin. "Čtyřválcový řadový vznětový motor s excentrickým klikovým mechanismem pro užitková vozidla." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2015. http://www.nusl.cz/ntk/nusl-232116.

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The purpose of this thesis is to evaluate the influence of eccentricity of crank mechanism to the force between the piston and the cylinder liner for appointed crank mechanism. Furthermore the influence of eccentricity to balancing crankshaft is verified and for selected value of eccentricity is realized balance. For the construction check was realized stress analysis of crank mechanism included torsion vibration.
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22

Pecka, Luboš. "Hnací ústrojí čtyřválcového vidlicového motoru." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2010. http://www.nusl.cz/ntk/nusl-229282.

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This thesis is focused to design of powertrain V-four gasoline engine. It compares crank-pins configuration, firing sequence and bank angle with a view of crankshaft stress and torsional vibration. The thesis also includes crankshaft balancing design.
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23

Procházka, Miloslav. "Pětiválcový řadový vznětový motor s viskózním tlumičem." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2012. http://www.nusl.cz/ntk/nusl-230246.

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The aim of this diploma work is to design moving parts of the five cylinder inline diesel engine with given parameters, then to balance centrifugal forces and moments and design viscous torsional vibrations damper and calculate forced oscilations without the damper as well as with the damper. The designed parts are put to stress analyse by finite elements method. My design is based on similar construction of four cylinder engine Zetor.
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24

Navrátil, Zdeněk. "Pětiválcový řadový vznětový motor s vyvažovací jednotkou." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2011. http://www.nusl.cz/ntk/nusl-229671.

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his diploma work themed: Five-cylinder in-line Diesel engine with balancing unit is dealing with analysis of balancing possible alternatives of arranging crankshaft, analysis of arranging counterweight, concept of balancing shaft, engineering design of crank-shaft, calculation of frequency, computational control of crank-shaft in light of torsional oscillations and proposal of dynamic pendulum damper.
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Jurík, Juraj. "Torzní kmitání tříválcového motoru s vyvažovací hřídelí." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2017. http://www.nusl.cz/ntk/nusl-318532.

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Content of this master thesis is analysis of torsional vibration of the three cylinder engine with balancing shaft. In theoretical part of the thesis the kinematic and dynamic description of the cranktrain mechanism is included. The formation of unbalancing of the engine and methods of balancing are described in the theoretical part as well. In practical part of the thesis the analytical calculation of torsional vibration is provided. Simulation of the engine model in multibody software Adams/Engine was used as the other way of torsional vibration analysis. In the result part of the thesis the comparison of the both way of analysis were discussed. Last step of the thesis was design proposal of the torsional vibration damper done by the analytical calculation.
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Steigl, Vladimír. "Čtyřválcový zážehový motor s vypínáním válců." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2017. http://www.nusl.cz/ntk/nusl-318839.

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The aim of this diploma thesis is design of configuration and balancing of crankshaft which is determined for four-cylinder gasoline engine. The thesis investigates kinematics, dynamics and possible ways of balancing the inertial forces and moments of the rotating and sliding parts of the central crank mechanism. Subsequently, the 3D CAD model is designed according to the presented drawing. It is transformed into a spare torsion system, from which the calculations of its own and forced torsional vibrations are based. The proposed 3D CAD model is then spatially transmitted in the FEA software Ansys Workbench and modified (boundary conditions, etc.) in the FEA software Ansys Mechanical APDL so that it can be calculated according to the selected LSA method. From the selected results of the LSA method, the crankshaft safety factor against fatigue damage is calculated.
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Parchański, Martin. "Pětiválcový řadový vznětový motor." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2010. http://www.nusl.cz/ntk/nusl-229101.

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The purpose of this thesis is design of in-line a five-cylinder diesel engine arrangement with given main parameters, power train design, balancing centrifugal and inertia moments and calculation of torsion vibrations. The proposed engine must be based on four-cylinder diesel Zetor engine.
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Domský, Viktor. "Tříválcový řadový vznětový motor s excentrickým klikovým mechanismem pro užitková vozidla." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2015. http://www.nusl.cz/ntk/nusl-232051.

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The goal is to investigate the influence of eccentricity on the force between the piston and the cylinder liner and the influence on balancing of the crank mechanism. For a selected eccentricity suggest a balancing method and perform stress analysis of crankshaft considering torsional vibration. Eccentricity is chosen by the ratio of centric and eccentric mechanism of friction work. The paper shows the effect of eccentricity on the selected kinematics values. Stress analysis is done in the software ANSYS. Using selected eccentricity the friction work was reduced by 10 %.
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Nikolaychuk, Yaroslav. "Čtyřválcový vznětový motor pro užitková vozidla." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2018. http://www.nusl.cz/ntk/nusl-377457.

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The diploma thesis focuses on the design of the crankshaft for a four-cylinder diesel engine for commercial vehicles, the main task of this work are the design configuration of the crankshaft balance inertia forces and torques at the crank mechanism, drawing documentation crankshaft design strength check considering torsional vibration.
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Švarc, Marek. "Pětiválcový vznětový motor pro užitková vozidla." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2017. http://www.nusl.cz/ntk/nusl-318711.

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The aim of this diploma thesis is the design of the configuration and the method of balancing the crank mechanism with the specified parameters. For a particular configuration, a crankshaft drawing is processed and a strength analysis, considering the crankshaft torsional vibrations is performed in Ansys FEM software. At the end of the thesis, an ideological design of the torsional vibration damper and its effect on the crankshaft stress in the Ansys FEM software is performed.
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Rejnuš, Miroslav. "Modifikace tříválcového vznětového motoru na zkušební jednoválec." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2021. http://www.nusl.cz/ntk/nusl-449787.

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The master thesis deals with the design of a single-cylinder diesel piston internal combustion test engine by modifying the initial mass-produced three-cylinder engine. The first part of the thesis is devoted to the introduction to the problems of diesel and experimental single cylinder engines. Subsequent chapters focus on the adaptation of the baseline engine itself, including balancing of inertial forces. Furthermore, the crankshaft operability is checked, including the determination of safety against high-cycle fatigue. The last chapter deals with the design of the connection of the adapted unit to the dynamometer.
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32

Pulava, Oleksandr. "Šestiválcový vznětový motor pro užitková vozidla." Master's thesis, Vysoké učení technické v Brně. Fakulta strojního inženýrství, 2018. http://www.nusl.cz/ntk/nusl-378397.

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The aim of this diploma is to design a crankshaft for a six-cylinder commercial vehicle, which is one of the unified motors. The main parts are the design of the crankshaft configuration, the crankshaft balancing method for forces and moments, the crankshaft design documentation, and the crankshaft strength verification. The design of torsional vibration damping characteristics is also made and its effect on torsional vibration and crankshaft strength is determined.
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33

Tseng, Ming-Hsuan, and 曾明鉉. "Investingation of Precise Balancing of Crankshaft." Thesis, 2001. http://ndltd.ncl.edu.tw/handle/97829324866665950217.

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Lourenço, Carlos Eduardo Ribeiro. "Contribuição para o fabrico de motor de ciclo sobre-expandido." Master's thesis, 2012. http://hdl.handle.net/1822/22676.

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Abstract:
Dissertação de mestrado integrado em Engenharia Mecânica
Desde o aparecimento dos primeiros motores de combustão interna, estes têm sido constantemente alvo de evoluções em função das necessidades do meio ao qual se destinam, seja a procura por melhor fiabilidade, por maiores potências ou mesmo pela otimização dos mesmos de modo a tornar o seu custo de produção mais sustentável. Atualmente existe uma crescente preocupação pelos problemas ambientais, bem como pela escassez das reservas de petróleo, o que associado à crise económico-financeira vivida torna a procura por uma maior eficiência energética dos motores de combustão interna, o principal campo de evolução dos mesmos. Neste contexto, surge o conceito de motor sobre-expandido, sendo este um tipo de motor que apresenta rendimentos superiores aos motores convencionais, permitindo deste modo registar valores de consumos e emissões de poluentes francamente inferiores aos dos motores convencionais. O presente trabalho tem como finalidade o fabrico de um motor de combustão interna, mais concretamente o UMotor. Este é um motor de ciclo sobre-expandido que vem sendo desenvolvido há já alguns anos no Departamento de Engenharia Mecânica da Universidade do Minho e que se destina a equipar o EconomicUM. O trabalho apresentado faz inicialmente um enquadramento teórico acerca dos motores de ciclo sobre-expandido, dando a conhecer a sua origem, o seu principio de funcionamento e o seu papel na sociedade atual. Posteriormente, o trabalho é focado no desenvolvimento e fabrico de alguns componentes do UMotor, tais como o cárter, a árvore de cames, os balanceiros, a cambota e o coletor de admissão. Ao longo do trabalho apresentado são dadas a conhecer as diferentes fases no desenvolvimento dos componentes, desde o projeto dos mesmos utilizando ferramentas CAD/CAM, aos processos de fabrico utilizados bem como os procedimentos a ser adotado de modo a que no futuro se concretize a realização de um protótipo funcional do motor.
Since internal combustion engines made their early appearance, continuous evolutions took place in order to fulfill the requests of their application domains, whether pursuing reliability improvement, higher engine power or even manufacturing optimization and cost sustainability. Nowadays there is a growing concern about environmental issues, including oil reserves shortage, economic and financial crisis impact, so driving critical increase of energetic efficiency in internal combustion engines, as a field of study. In this context arises the concept of over-expanded engine, for it shows higher efficiency, allowing less fuel consumption and lower polluting emissions than conventional engines. The present work describes the manufacturing constraints and solutions of an experimental internal combustion engine, the UMotor. This is an over-expanded cycle engine under development in the Department of Mechanical Engineering of University of Minho, to equip the EconomicUM, a formula Shell® prototype vehicle. A theoretical overview is presented about the over-expanded cycle engines, describing its principles of operation and their possibilities in the society. The work is focused on the development and manufacturing of components of the engine, including the crankcase, the camshaft, the rocker arms, the crankshaft and the intake manifold. The work presents an overview of the actual stage in the development of components, including modifications to the project using CAD/CAM tools, and describes the manufacturing processes and procedures to be undertaken in the near future to achieve a fully functional prototype engine.
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