EXPERIMENTAL INVESTIGATION OF ALUMINIUM ALLOY ENGINE CYLINDER BLOCK IN TWO WHEELERS

Abstract

Automobiles have always been part of my life and I am sure they always will be. What is it about them that moves me? The sound of a great engine, the unity and uniqueness of an automobile’s engineering and coachwork, the history of the company and the bikes and cars and of course, the sheer beauty of the thing.” Attempts are never accomplished alone; there are constantly a few steady hands. This proposition is a careful aftereffect of direction of such individuals around me who have presented to me all through the way. Along these lines, I want to express gratitude towards them just for their nearness in my life throughout the work. I am to a great degree lucky to be required in a research work of this kind. It has advanced my life, giving me a chance to work in the territory of “Internal Combustion Engines”. This work upgraded my reasoning capacities and understanding ability. After the finish of my work, I encountered a sentiment self-delight. I might first want to express my profound feeling of appreciation to my guide Dr. Ravindra G. Tikotkar who is an exemplification of learning, consistent quality and resistance for his extraordinary course, recommendations, exceptional effort and support in the midst of my investigation work. Without his constant direction this postulation would not have been appeared. One can never wish for a superior guide and way creator in life. I might likewise want to offer my true thanks to Prof. S.B.Koulagi, Head, Department of Mechanical Engineering for his consolation and lighting up criticisms amid my exploration work. I am obliged to Dr.V.P.Huggi, Principal whose support and help required for carrying out experimental investigations. The present research work was completed in three stages, first the manufacturing and finishing of the cylinder block, second the assembly of the engine and third testing. I want to mention here the help from a number of persons who had helped me a lot during all these stages. The market survey regarding the present scenario in the use of material for the cylinder blocks was conducted to collect the data of engines from various manufacturers. The following persons shared their valuable time with me to build a strong foundation to initiate the research work, were Mr. Muralidhar Urane, M/S Badshah ‘BAJAJ’, Ichalkaranji; Mr. Sambhaji Patil, M/S DSK ‘HYOSUNG’, Kolhapur; Mr. Jagdish Powar, M/S Popular ‘HERO’, Ichalkaranji; Mr. Rohan Bijjargi, M/S Kaizan ‘HONDA’, Ichalkaranji; Mr. Manju Itagi, Belgaum ‘KAWASAKI’, Belgaum and Belgaum ‘KTM’, Belgaum; Mr. Sheetal Patil, M/S Sheetal vi Motors ‘MAHINDRA 2 WHEELERS’, Ichalkaranji; Mr. Nitin Kolekar, M/S Motor India, ‘ROYAL ENFIELD’, Kolhapur; Mr. Satish Hiralage, M/S Trio ‘SUZUKI’, Ichalkaranji; Mr. Raju Borgave, M/S Borgave ‘TVS’, Ichalkaranji; Mr. Avinash Nikam, M/S Nikam ‘YAMAHA’, Ichalkaranji; Mr. Tammubhai, M/S Perfect Motors ‘VESPA’, Sangli. The patterns were prepared by M/s A.P. INDUSTRIES, MIDC, Shiroli, Kolhapur. Tthe Castings were produced by Mr. Shrinivas Nilajikar of ‘PURVA METALS’, G.M. Industrial Estate, Miraj-Kupwad block. Further it was machined to get a finished and ready-to-fit block by M/s GANAPATI ENTERPRISES, Shivaji Udyamnagar, Kolhapur; Mr. Harshavardhan Patil of ‘CST TOOL MFG. INDUSTRY’, MIDC, Shiroli, Kolhapur followed by Mr. J. V. Pawar of ‘MACHINE TOOL WORKS’, Shivaji Udyamnagar, Kolhapur. I whole heartedly thank M/s INDRANI/MAHAXAMI HEAT TREATERS, Mahalaxmi Industrial Estate, A/P Nagaon, Kolhapur for helping to heat treat the newly developed cylinder block as per the requirements. CFD analysis is also playing important role in all these steps of manufacturing the block. So many persons helped me by taking a lot of efforts in modeling and analysis of the cylinder block. They are Mr. Nikhil, Mr. Akash, Mr. Pravin, Mr. Amit from M/s AXIS DESIGN SERVICES, Gokul Shirgaon MIDC, Kolhapur working in the field of 2D/3D inspection, CMM & tooling. Post treatment consists of analysis of the model to get the actual results. Mr. Pratik Patil of M/s SHRIVED SOLUTIONS PRIVATE LTD., Ichalkaranji was the person who had supported me to get the satisfactory results by careful analysis of the model. After getting the finished block which was ready-to-fit on engine, it was necessary to mount it on the engine. So, lot of spare parts were supplied by the following persons in re- construction of the engine and restoration of the test vehicle. In this phase, the persons helped me were Mr. Vinayak, Mr. Prakash, Mr. Dagadu, Mr. Omkar from M/s S. M. PATEL (Spare part dealer) from Ichalkaranji; Mr. Vinayak from M/s AUTO ANTARIKSHA (Authorised ‘Hero’ Spare Part counter), Shahupuri, Kolhapur; Mr. Harish Gaikwad, Mrs. Jagtap, Mrs. Sontakke, the spare part staff of M/s POPULAR AUTOMOBILES (HERO), Yadrav, Ichalkaranji; Mr. Patil, Mr. Gajanan, Mr. Sandip and Mr. Vishal of M/s MANISHA AUTOMOBILES (HERO), Jaysingpur. There was a very important role of two wheeler mechanics in fitting of newly developed block and assembly of the engine. So many aspects were discussed from time to time with them during the research work. Following persons helped me a lot by giving their precious advice.