Engine Model Mk3

One of the most ambitious projects completed so far, the knowledge acquired from every product designed previously has been implemented into this, the 3rd generation engine model. The powertrain has been created from scratch within an estimated timespan of 80 hours. It is inspired by the 1.6 litter Formula 1 engines of today, measuring at 80mm bore and 53mm stroke. The calculated compression ratio is equal to 13:1, alongside the total capacity numbering at 1598cc. This over squared setup allows for a high revving characteristic, configuring the engine to achieve peak power at a high RPM range. Parameters are as follows: DOHC, 24 valves (4 valves per cylinder), 6 cylinders arranged in a V with a 90° angle, a 4 – stroke combustion engine with direct injection weighing at 99.93 kg. Every component has been designed thoroughly with a high emphasis on attention to detail. All components, besides the ISO standard bolts, are created from scratch, allowing the engineer to have freedom in adjustability and reconfiguration if necessary. Engine block cooling ducts have been created so that an implementation of a water-based cooling system is possible. The block has been designed around the forged aluminium pistons, connecting rods, and crankshaft. The cylinder heads required extensive preparation, therefore most of the time was allocated for them and they’re parts. They are constructed of all components necessary to function accordingly, from valves, spark plugs, and gasket, all the way to cams, coil plugs and injectors. All measurements are thoroughly analysed, for the engine to experimentally be manufactured and operated reliably. The main materials used for this project are aluminium allocated for components such as the engine block, cylinder head housing and pistons, whereas steel constructed parts are represented by bolts, engine studs, and washers. Furthermore, gear ratio analysis and mathematical calculus have been conducted for the timing belt design. This project proves the ingenuity and dedication invested into making this F1 inspired internal combustion engine, thus extending the computer-aided design experience for future applications within the automotive industry.