The engine that was chosen to be developed and modified is Yamaha LC 135 Single Overhead Camshaft (SOHC) 4-valve 4-stroke 135cc liquid-cooled engine. The engine selection is based on the specification, rule and regulation in UTeM Formula Varsity 2012 (FV 2012). The engine performance is determined by engine operating characteristics. The engine air flow affects the filtration, intake and exhaust systems. The heat from the engine rejected to the surrounding through the active cooling system which has radiator and fan. The selection of the engine is based on weighted decision matrix which consists of reliability, operating and maintenance cost, fuel consumption and weight. The score of the matrix is formulated based on relative weighted factor among the selections. It been compared between Yamaha LC 135 Single Overhead Camshaft (SOHC) 4-valve 4-stroke 135cc liquid-cooled engine, Honda Wave 125 X Air Cooled, 4 Cycle Engine Overhead Camshaft (OHC) and Suzuki Shogun RR 4 stroke air cooled Single Overhead Camshaft (SOHC). The modification is applied to the engine through the simulation and tuning of Capacitor Discharge Ignition (CDI)

ABDULLAH, Mohd Azman

Manoharan, Tayalan

Rusnandi, Herdy

Samsir, Muhammad Afiq

Tamaldin, Noreffendy

English

Universiti Teknikal Malaysia Melaka (UTeM) Repository

This content has been downloaded from IOPscience. Please scroll down to see the full text.Download details:IP Address: 203.106.159.204This content was downloaded on 16/12/2013 at 12:17Please note that terms and conditions apply.Development and modification of a single overhead camshaft 4-valve 4-stroke 135 cc formulavarsity race car engineView the table of contents for this issue, or go to the journal homepage for more2013 IOP Conf. Ser.: Mater. Sci. Eng. 50 012005(http://iopscience.iop.org/1757-899X/50/1/012005)Home Search Collections Journals About Contact us My IOPscienceDevelopment and modification of a single overhead camshaft 4-valve 4-stroke 135 cc formula varsity race car engine  M A Abdullaha, N Tamaldin, H Rusnandi, T Manoharan and M A Samsir Centre for Advanced Research in Energy, Faculty of Mechanical Engineering, Universiti Teknikal Malaysia Melaka, Hang Tuah Jaya, 76100, Durian Tunggal, Melaka, Malaysia  E-mail: amohdazman@utem.edu.my Abstract. The engine that was chosen to be developed and modified is Yamaha LC 135 Single Overhead Camshaft (SOHC) 4-valve 4-stroke 135cc liquid-cooled engine. The engine selection is based on the specification, rule and regulation in UTeM Formula Varsity 2012 (FV 2012). The engine performance is determined by engine operating characteristics. The engine air flow affects the filtration, intake and exhaust systems. The heat from the engine rejected to the surrounding through the active cooling system which has radiator and fan. The selection of the engine is based on weighted decision matrix which consists of reliability, operating and maintenance cost, fuel consumption and weight. The score of the matrix is formulated based on relative weighted factor among the selections. It been compared between Yamaha LC 135 Single Overhead Camshaft (SOHC) 4-valve 4-stroke 135cc liquid-cooled engine, Honda Wave 125 X Air Cooled, 4 Cycle Engine Overhead Camshaft (OHC) and Suzuki Shogun RR 4 stroke air cooled Single Overhead Camshaft (SOHC). The modification is applied to the engine through the simulation and tuning of Capacitor Discharge Ignition (CDI).  1. IntroductionIn the previous researches, the development and modification of engine part were not presented [1][2]. Original and standard engine was used to drive the race car. In this research, the chassis is designed and developed [3-4] and in addition the engine is modified to increase its capability. The development and modification of Formula Varsity (FV) race car are performed in proper manner so that it will not harm the driver. The development and modification are performed with consideration of rake angle, gear ratios, carburettor type, vehicle weight, the number of cylinders and the brake and suspension systems [5-9]. Motorcycle that manufactured by manufacturer produced different power output based on displacement volume and engine setting whereby it is not always produce optimum performance due to improper design and manufactures error. However, in order to produce optimum engine performance, the engine needed to be analyzed via simulation. Lotus Single Engine simulation software is suitable for the engine performance analysis. Investigation on which parameters will produce optimum engine performance is carried out by modification of the engine specifications. Comparison is also performed for engine performance between actual and simulation by using parameters from manufacturer sources. The specifications of the engine are shown by table 1 [10].   2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP PublishingIOP Conf. Series: Materials Science and Engineering 50 (2013) 012005 doi:10.1088/1757-899X/50/1/012005Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distributionof this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.Published under licence by IOP Publishing Ltd 1Table 1. Yamaha LC 135 engine specifications. Specification Engine type Liquid-cooled 4-stroke, SOHC, 4-valve Cylinder arrangement Single cylinder Displacement 134.4 cm3Bore x stroke 54.0 mm x 58.7 mm Connecting rod length 125 mm Intake valve size 2 x 23.19 mm Exhaust valve size 2 x 20.13 mm Compression ratio 10.9:1 Maximum output 8.93 kW @ 8500 rpm Maximum torque 11.79 Nm @ 5500 rpm Starter Electric starter and kick starter Lubrication Wet sump Engine oil capacity 0.9 l Fuel tank volume 4.0 l Carburetion Mikuni BS25 x 1 Ignition DC-CDI 2. MethodologyLotus Single Engine Simulation is used to analyze by changing parameter such as bore size of piston to get the result which can sustain the engine for 30 Laps in Melaka International Motorsport Circuit (MIMC) for 48 km. The analyses of the engine include engine fuel consumption, engine heat rejection, and factor of safety. Through this theoretical proof modification is made on the engine precisely and accurately. The modifications are: i. Substitution of current Ignition Capacitor Discharge Ignition (CDI) to Capacitor DischargeIgnition (CDI) of Racing Rextor and unlimited Rotation per Minute (RPM).ii. Engine overhaul and increment of bore size of piston to 57 mm with new connecting rod.iii. Improvement of Carburetor with Throttle Position Sensor (TPS) and accelerator pump toUMA Racing Carburetor with Throttle Position Sensor (TPS) and accelerator pump (Main Jetsize 142 - Pilot Jet size 45). The modification follows the specification, rule and regulation that been fixed in UTeM Formula Varsity 2012 [9]. The engine is shown in figure 1. Figure 2 shows the software program (capacitor discharge ignition (CDI) of Racing Rextor Tuning Program) used to in the development and modification of the engine for Formula Varsity race car.   2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP PublishingIOP Conf. Series: Materials Science and Engineering 50 (2013) 012005 doi:10.1088/1757-899X/50/1/0120052Figure 1. Yamaha LC135 engine [10]. Figure 2. Concept design No. 2. 3. AnalysisThe Lotus Single Engine simulation program is used to simulate the performance of the engine by 3 basic steps: i. Construction of simulation model and engine specifications.ii. Data and test conditions are defined for the cycle simulation.iii. Calculation results for cycle-averaged data (volumetric efficiencies, brake specific fuelconsumption (BSFC), torque, power), and intra-cycle data (pressure, temperature, mass flowrate) [11-13] in the form of report quality summary sheet and through quick-to-use graphplotting.2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP PublishingIOP Conf. Series: Materials Science and Engineering 50 (2013) 012005 doi:10.1088/1757-899X/50/1/0120053 The engine performance is calculated theoretically with the new modified specifications from the simulation results (table 2) using Rextor tuning program. Table 2. Yamaha LC 135 engine modifications. Specification Bore, B x stroke, S 65.0 mm x 58.7 mm Compression ratio, rc 12.2:1 Maximum output power, P 8.45 kW @ 8500 rpm Maximum torque, T 11.65 Nm @ 5500 rpm The volume displacement is[13], Vd = 42SB(1) The engine torque is calculated at max power [14]. P  =  602 NT(2) The average piston speed at max power is [15], Up= NS (3) The volumetric efficiency is [16], pamave  (4) The thermal efficiency is calculated by [14], 23141TTTTthermal (5)  The results of the calculation and data gathering from engine trial are tabulated in Table 3. Throughout the modification process, the engine components are machined and amended according to the standard procedures of workshop and machining practices [17-21]. The engine trial is performed on the Melaka International Motorsport Circuit (MIMC). Table 3. Results and data of the modified engine. Engine Specification Value Engine Capacity 194.78 cc Engine Torque at maximum Power 29.8235 N.m Average piston speed@ max power 16.63  ⁄Bore-Stroke ratio (B/S) 1.1073 Volumetric Efficiency 0.878 @ 87.8% Engine Power at maximum Torque 26.55 kW @ 35.6 hp Thermal Efficiency 0.567 @ 56.7% 2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP PublishingIOP Conf. Series: Materials Science and Engineering 50 (2013) 012005 doi:10.1088/1757-899X/50/1/0120054Fuel flow rate 8.0952 ml/s Fuel per millage 0.2125 ml/m 4. Results and DiscussionThrough the simulation results obtained for original engine condition, the maximum torque is 10.23 Nm @ 5500 rpm and the maximum power is 8.80 kW @ 8,500 rpm. The compression ratio is 10.9 : 1. The comparison of performance summary between the original and modified engine is shown in figure 4. The simulation analysis result for the modification engine has established approving outcome interm of 194.78 cc of engine capacity, compression ratio 12.2:1, bore size of piston 65 mm, engine power at maximum torque 26.55kW @ 35.6hp, engine torque at maximum power 29.8235 Nm, and thermal efficiency of 56.7%. It is validated that the theoretical data calculated and the results are precise. With the modification of the engine, the performance is improved for endurance and racing. Figure 4. Performance summary comparison of original and modification. 5. ConclusionThrough the research, development and modification of FV race car engine is successfully performed. The parameters such as bore size, stroke length, compression ratio, valve timing give significant impact to the engine performance when modified. The simulation analysis result has established approving outcome in term of engine capacity, compression ratio, engine power at maximum torque, engine torque at maximum power and thermal efficiency. The engine is later assembled with power train and chassis for the FV racing competition. The validation of the results between simulation and theoretical calculation shows the availability and practicality of engine modification. Acknowledgments The authors gratefully acknowledged the financial support from Universiti Teknikal Malaysia Melaka and The Ministry of Higher Education, Malaysia (MoHE) under Exploratory Research Grant Scheme (ERGS), grant no.: ERGS/1/2012/TK08/UTEM/02/1/E00007.  2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP PublishingIOP Conf. Series: Materials Science and Engineering 50 (2013) 012005 doi:10.1088/1757-899X/50/1/0120055References [1] Shaharuzaman, M A, Abdul Munir F, Hassan M Z, Mohamad Zin M R, Boejang H, Muhammad Farhan, F H and Abdul Jamal A H 2010 Development of a Single Seat Race Vehicle for Educational Motorsport Engineering, 3rd International Conference on Science & Technology: Applications in Industry & Education, 16-17 December 2010, Universiti Teknologi MARA, Pulau Pinang Malaysia [2] Abdul Munir, Munir F, Shaharuzaman M A, Hassan M Z, Mohamad Zin M R, Mohd Azmi, M I and Mat Nuri N R 2011 Components Design of a Single Seat Educational Race Vehicle, Malaysian Technical Universities International Conference on Engineering & Technology (MUiCET 2011) 13-15 November 2011 UTHM Batu Pahat Johor [3] Abdullah M A, Mansor M R, Mohd Tahir M, Abdul Kudus S I, Hassan M Z and Ngadiman M N 2013 Analysis and Fabrication of Chassis Frame for UTeM Formula VarsityTM Race Car International Journal of Mining, Metallurgy & Mechanical Engineering (IJMMME) 1 75-77 [4] Abdullah M A, Mansor M R, Mohd Tahir M, Abdul Kudus S I, Hassan, M Z and Ngadiman, M. N 2012 Analysis and Fabrication of Chassis Frame for UTeM Formula VarsityTM Race Car, Proceeding for International Conference on Manufacturing and Industrial Engineering (ICMIE’12), International Scientific Academy of Engineering & Technology (ISAET), Kuala Lumpur, Malaysia, (December 29th to 30th, 2012) [5] SAE, 2012 Formula SAE Competition Rules and Regulations, Society of Automotive Engineers, USA [6] Kamal M, Rahman M M and Rahman A G A 2012 J Mech Eng Sci 3 291 [7] Nagarkar M P, Vikhe G J, Borole K R and Nandedkar V M 2011 Inter J Automot Mech Eng 3 364 [8] Kamal M, Rahman M M  and Rahman A G A 2013 Inter J Automot Mech Eng 7 912. [9] UTeM FV2012 2012 Formula Varsity Competition Rules and Regulations, Universiti Teknikal Malaysia Melaka, Melaka, Malaysia [10] Motomalaya 2012 Original Yamaha 135LC Big Valve Head. Retrieved 13 December, 2012, from http://motomalaya.net/blog/2010/09/17/original-yamaha-135lc-big-valve-head-intake-23-19mm-exhaust-20-13mm/yamaha-135lc-big-valve-head-ori-9/ [11] Nice K, 2012 How Camshafts Work Retrieved 12 December, 2012, from http://www.howstuffworks.com/camshaft.htm. [12] Auto-Ware 2012 Valve Timing & Performance. Retrieved 11 December, 2012, from http://www.auto-ware.com/combust_bytes/valvetiming.html. [13] Auto-Ware 2012 Cam Specs & Effects Retrieved 12 December, 2012, from http://www.auto-ware.com/combust_bytes/camspecs.html. [14] Pulkrabek WW 1997 Engineering Fundamental of Internal Combustion Engine (Prentice Hall: New Jersey) [15] Heywood J B 1998 Internal Combustion Engine Fundamental (McGraw Hill: New York) [16] Challengers 101, 2012. Exhaust and Intake Tuning. Retrieved 12 December, 2012, from http://www.challengers101.com/IntakeTuning.html. [17] Serope  Kalpakjian, Steven  Schmid 2006 Manufacturing Engineering and Technology (Canada: Prentice Hall) [18] Miller R And Richard M 2004 Machine Shop Basics All new (Wiley Publishing, Inc) [19] W. A. J. Chapman. 2001. Workshop Technology: Part 1, 5(United Kingdom. Edward Arnold Publishers Limited)  [20] Khurmi R S and Gupta J K 2008 Theory of Machines (14th ed.) ( Eurasia Publishing House) p 371 [21] Budynas R and Nisbett K 2006 Shigley’s Mechanical Engineering Design (8th ed.) (McGraw Hill) p 504 2nd International Conference on Mechanical Engineering Research (ICMER 2013) IOP PublishingIOP Conf. Series: Materials Science and Engineering 50 (2013) 012005 doi:10.1088/1757-899X/50/1/0120056

Development and Modification of a Single Overhead Camshaft 4-Valve 4-Stroke 135 cc Formula Varsity Race Car Engine

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Development and Modification of a Single Overhead Camshaft 4-Valve 4-Stroke 135 cc Formula Varsity Race Car Engine

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