PROJECT REPORT ON
“DESIGN AND ASSEMBLY OF A V6 ENGINE”
SUBMITTED BY: MCC 90TH BATCH
➢ SOURAV PAL
➢ SOURAV BISWAS
➢ SIBASHISH SATAPATHY
➢ KAMALENDU SAHU
➢ RANJAN KUMAR PATTASANI
➢ AJAY KUMAR MAJHI
➢ ROHANJEET SAHOO
➢ ABHISEK BALIARSINGH
➢ SAROJ KUMAR MAHALIK
➢ NAREN PUISTY
➢ SAHED JAMAL
➢ SANDEEP BEHURA
CENTRAL TOOL ROOM & TRAINING CENTRE
BHUBANESWAR
(A Govt. of India Society, Ministry of MSME)
Guided by: Mr. ANSUMAN MISHRA
ACKNOWLEDGEMENT
It is really a matter of great pleasure to acknowledge the all faculties of
MASTERS OF CAD/CAM department of Central Tool Room and
Training Centre, Bhubaneswar for their guidance and support with us
for completion of our project " DESIGN AND ASSEMBLY OF A
V6 ENGINE ".
We acknowledge our sincere gratitude to our guide Mr. ANSUMAN
MISHRA of training department, Central Tool Room and Training
Centre for all his sincere guidance and persistent encouragement during
the project.
We would also like to express our special gratitude and sincere thanks
to our course coordinator Mr. S. B. MISHRA (Senior engineer) of
MCC, Central Tool Room and Training Centre, Bhubaneswar for his
valuable suggestion and cooperation during completion of our project.
We take the opportunity to express our sincere thanks to Mr. L.
RAJSHAEKHAR (D.G.M.) of Central Tool Room and Training
Centre, Bhubaneswar for providing this chance to undertake this
project work.
We also place on record our sincere towards Sr. Manager, training Mr.
K.M. RAJAN, Central Tool Room and Training Centre, Bhubaneswar
for allowing us to do this project and his keen interest in our project.
We would like to express special thanks to all the persons who were
directly and indirectly associated with us for completion of our project.
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DECLARATION
We, do here by to declare that, the project report on “ DESIGN
AND ASSEMBLY OF A V6 ENGINE’’ submitted by us is original to the
best of our knowledge and belief. It has been prepared by us with our
own idea and creativity under direct supervision of our project guide
Mr. ANSUMAN MISHRA. It has not been presented anywhere else or
carried out by anyone else.
➢ SOURAV PAL
➢ SOURAV BISWAS
➢ SIBASHISH SATAPATHY
➢ KAMALENDU SAHU
➢ RANJAN KUMAR PATTASANI
➢ AJAY KUMAR MAJHI
➢ ROHANJEET SAHOO
➢ ABHISEK BALIARSINGH
➢ SAROJ KUMAR MAHALIK
➢ NAREN PUISTY
➢ SAHED JAMAL
➢ SANDEEP BEHURA
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ABSTRACT
In this project we will be designing various parts required for a 6-
cylinder engine using various CAD software. The type of cylinder
arrangement we will be designing is a V-motor. There are many parts
involved in operations of an engine. Some of the major parts are engine
block, cylinder block, piston, crankshaft, camshaft, valves etc. The
main outer body of an engine can be divided into 3 parts Cylinder head,
Engine Block and Crankshaft case. Cylinder head indeed holds
components such as valves, springs etc. Engine block acts as a
protection and casing for the pistons. The crankshaft case holds the
crankshaft and also collects the oil which is used for the lubricating the
engine parts.
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CONTENTS
SI. NO. CONTENTS PAGE NO.
1. Introduction to CTTC 6
2. Introduction to CAD/CAM/CAE 8
3. Need for CAD/CAM 12
4. Advantages / Disadvantages 13
5. Introduction to CAD Software 14
6. Introduction to V6 Engine 16
7. Working Principles 17
8. Components 18
9. Block Diagram 19
10. Components Parts Description 21
11. Drafting Sheets
12. Conclusion
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INTRODUCTION TO CTTC
Central Tool Room & Training Centre (CTTC), Bhubaneswar has been
set up by SIDO to meet the growing need of tooling in India and assist
MSME units. This Tool Room has been set up in the year 1991 with
the assistance of Government of Denmark and land/building and
infrastructure facilities have been provided by the State Government of
India.
OBJECTIVE OF THE TOOL ROOM
To assist MSME units in technological up gradation by providing
quality tooling. To increase efficiency of MSME units by providing
consultancy and common service facilities in the areas of design and
production of tools, jigs and fixtures molds& dies etc. To conduct long
term training courses in tool and die making, machining and fitting and
short-term courses on related subjects to personal working in the
industries.
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TRAINING FACILITIES AND SERVICES
AVAILABLE
CTTC, Bhubaneswar is equipped for comprehensive and integrated
service in Tool Engineering, state of the art leading edge technology in
CNC, CAD/CAM, precision Engineering, and Robotics and beyond,
modern teaching aids, technological support and consultancy where
mission is high degree precision and quality and steadily updating
design and development which will excel at every level.
Central Toll Room & Training Centre (CTTC), Bhubaneswar bags
ISO 14001:1996 Central Toll Room & Training Centre (CTTC),
Bhubaneswar has got ISO 14001: 1996 certification for its
Environmental Management system from M/s. NQAQSR Certification
Pvt. Ltd. The ISO 1400:1996 Certification demands very high level of
housekeeping cleanliness, judicious use of water, paper, air and other
precious gifts of natural as well as high level of discipline in disposing
off industrial and others wastes.
CTTC, Bhubaneswar executes expert order, designed, manufactured
and exported 2-cavity lid mold for Box components to Loblite
International Ltd, U.K. The mold has very complicated shape with very
close tolerance. The material of the carbonate was polycarbonate. The
component is used for Electronic Junction box. This is the third tool to
the same customer in last 2 years. This order was bagged after stiff
competition from other countries.
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INTRODUCTION TO CAD/CAM/CAE
The modern world of design, development, manufacturing so on, in
which we have stepped can’t be imagined without interference of
computer. The usage of computer is such that, they have become an
integral part of these fields. In the world market now the competition
in not only cost factor but also quality, consistency, availability,
packing, stocking, delivery etc. So are the requirements forcing
industries to adopt modern technique rather than local forcing the
industries to adopt better techniques like CAD/CAM/CAE, etc.
The possible basic way to industries is to have high quality products at
low costs is by using Computer Aided Engineering (CAE),
Computer Aided Design (CAD) and Computer Aided
Manufacturing (CAM) set up. Further many tools are been introduced
to simplify and serve the requirement CATIA, UG, SOLIDWORKS
are some among many.
This penetration of technique concern has helped the manufacturers to
➢ Increase productivity
➢ Shortening the lead-time
➢ Minimizing the prototyping expenses
➢ Improving Quality and better products
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CAD, CAM & CAE
CAD: -
Computer-Aided Design (CAD) refers to the use of computer tools to
assist engineers, architects and other design professionals in their
design activities. It is the main geometry authoring tool within the
Product Lifecycle Management (PLM) process and involves both
software and sometimes special-purpose hardware.
Current packages range from 2D vector based drafting systems to 3D
parametric surface and solid design modellers. CAD is sometimes
translated as “Computer-Assisted-Drafting”, “Computer-Aided-
Drafting”, or a similar phrase. Related acronyms are CAD, which
stands for “Computer-Aided Design and Drafting”; CAD, for
Computer-Aided Architectural Design”. All these terms are essentially
synonymous, but there are some subtle differences in meaning.
Basically, CAD is not just a drafting tool, it’s a very accurate and robust
design tool too. Due to the complexity of computations in design
methodology, the power of computers is leveraged to compute
solutions to complex problems like stress analysis, shear analysis,
thermal analysis and fluid flow analysis.
The CAD offers very simple, easy to use, less time consuming and
clean methods to study and evaluate the design process and arrive at a
close-to-perfect design. CAD and CAM can even be used in food
processing.
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CAM: -
Computer-Aided Manufacturing (CAM) refers to the use of
computer systems for the control of robotics and tools during the
product manufacture. Integrating CAM with CAD systems provides
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quicker and more efficient manufacturing processes. This method is
applied in different areas. In CNC manufacturing the CAM system is
used to simplify the machining and designing process. In most cases
the CAM system will work with a CAD design made in a 3D
environment.
The CNC programmer will just specify the machining operations and
the CAM system will create the CNC program. This compatibility of
CAD/CAM systems eliminates the need for redefining the work piece
configuration to the CAM system. In other words: CAM software
usually comes with a machine such as a lathe or chisel. The entire
system tends to be extremely expensive. (A lathe and computer system
with software will cost in excess of $ 1 million). CAD/CAM systems
offer the advantages of increased programming accuracy, geometric
conformance to design parameters, ability to make minor and often
major changes to part configuration and programming metrics within
the same system.
CAD/CAM systems utilize either “wireframe” or “solids” for the
part feature generation necessary for post-processing intermediate code
files derived from cutter tool paths into usable “Nc” code readable by
numerical control machines. Wireframe geometry can be either in two-
or three-dimensional planes, while solids are in 3D. CAD/CAM is used
widely across the world at schools and companies who design, innovate
and manufacture new products.
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CAE: -
Computer Aided Engineering Software used to analyse CAD
geometry tools that have been developed to support these activities are
considered CAE tools. CAE tools are being used, for example, to
analyse the robustness and performance of components and assemblies.
The term encompasses simulation, validation, and optimization of
products and manufacturing tools. In the future, CAE systems will be
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major providers of information to help support design teams in decision
making. Computer-aided engineering is used in many fields such as
automotive, aviation, space, and shipbuilding industries.
In regard to information networks, CAE systems are individually
considered a single node on a total information network and each node
may interact with other nodes on the network.
CAE systems can provide support to businesses. This is achieved
by the use of reference architectures and their ability to place
information views on the business process. Reference architecture is
the basis from which information model, especially product and
manufacturing models.
The term CAE has also been used by some in the past to describe
the use of computer technology within engineering in a broader sense
than just engineering analysis. It was in this context that the term was
coined by Jason Lemon, founder of SDRC in the late 1970s. This
definition is however better known today by the terms CAE and PLM.
CAE areas covered include: -
➢ Stress analysis on components and assemblies using Finite
Element Analysis (FEA);
➢ Thermal and fluid flow analysis Computational fluid
dynamics (CFD);
➢ Multi body dynamics (MBD) and Kinematics;
➢ Analysis tools for process simulation for operations such as
casting, moulding, and die press forming.
➢ Optimization of the product or process.
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NEED FOR CAD /CAM
Running a CAD/CAM system without procedures is similar to having
a highway system without a Highway Code and traffic signs.
Procedures provide the ground rules and framework for co-ordinating
activity at several different sources. Computer-aided design (CAD) is
the use of computer systems to aid in the creation, modification,
analysis, or optimization of a design. Computer-aided manufacturing
(CAM) is the use of software to control machine tools and related ones
in the manufacturing of work pieces.
Fueled by the need to beat short deadlines and minimize costs,
the manufacturing industry is always on the lookout for the best ways
of automating their processes. Apart from ability to avoid high
manufacturing costs brought about deep recession, companies that use
CAD services are capable of beating their rivals in the industry since
they get higher profits with less cost. While Computer-aided
manufacturing (CAM) applications have been used for years by
production companies for controlling machines, tools, and various
other manufacturing operations and are still the dominant way for CNC
machining programming, machine shops are always searching for
better technology to improve production.
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ADVANTAGES: -
1. Cut off of the designing time.
2. Cut off of the editing time.
3. Cut off of the manufacturing time.
4. High and controlled quality.
5. Reduction of process cost.
6. Consistency.
7. Maintenance of Universal accessing data
DRAWBACKS: -
1. Required skilled operators
2. Initial setting and assumption consume time
3. Setting cost is more
4. Over heads are high
5. Applicable if production is high
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Introduction to CAD Software
CAD (Computer Aided Design) is the use of computer software to
design and document a product’s design process.
Engineering drawing entails the use of graphical symbols such as
points, lines, curves, planes and shapes. Essentially, it gives
detailed description about any component in a graphical form.
Use of CAD
CAD is used to accomplish preliminary design and layouts,
design details and calculations, creating 3-D models, creating
and releasing drawings, as well as interfacing with analysis,
marketing, manufacturing, and end-user personnel.
CAD facilitates the manufacturing process by transferring
detailed information about a product in an automated form that
can be universally interpreted by trained personnel. It can be
used to produce either two-dimensional or three-dimensional
diagrams. The use of CAD software tools allows the object to be
viewed from any angle, even from the inside looking out. One of
the main advantages of a CAD drawing is that the editing is a fast
process as compared to manual method. Apart from detailed
engineering of 2D or 3D models, CAD is widely used from
conceptual design and layout of products to definition of
manufacturing of components. CAD reduces design time by
allowing precise simulation rather than build and test physical
prototypes. Integrating CAD with CAM (Computer Aided
Manufacturing) streamlines the product development even
more.
CAD is currently widely used for industrial products, animated
movies and other applications. A special printer or plotter is
usually required for printing professional design renderings. CAD
programs use either vector-based graphics or raster graphics
that show how an object will look.
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CAD software enables
• Efficiency in the quality of design
• Increase in the Engineer’s productivity
• Improve record keeping through better documentation and
communication
Today, the use of CAD has permeated almost all industries. From
aerospace, electronics to manufacturing, CAD is used in all
industry verticals. Since CAD encourages creativity and speeds
up productivity, it is becoming more and more useful as an
important tool for visualization before actually implementing a
manufacturing process. That is also one of the reasons CAD
trainings is gaining more and more importance.
Types of CAD Software
Since its introduction in late 1960’s, CAD software has improved by leaps and
bounds. A broad classification of CAD is:
• 2D CAD
• 3D CAD
• 3D Wireframe and Surface Modelling
• Solid Modelling
Examples of CAD Software
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Introduction to V6 Engine
Car engines have cylinders enclosing pistons which perform the pumping action.
This pumping aids in the conversion of fuel to the desired energy form. The
cylinders have an up & down movement on the crankshaft.
This movement action regulates the mixture of air and fuel for proper combustion.
The energy generated as a result of this combustion powers the vehicle.
Therefore, the number of cylinders in an engine dramatically contributes to the
performance of the car.
Four-cylinder engines usually take the inline configuration. Unlike four-cylinder
engines, six-cylinder engines can be arranged in shape resembling the letter "V".
For this reason, they are referred to as V6 Engines.
V6 engines have been common in cars, trucks, minivans, and SUVs for decades.
The V6 has traditionally served as a happy medium that’s more powerful than a
4-cylinder and more efficient than a V8.
Some advantages are:
• More powerful than a 4-cylinder — Generally speaking, more cylinders
and higher displacement result in more power. All things being equal in
terms of forced induction, V6 engines are more potent than 4-cylinder
engines.
• More efficient than a V8 — V8 engines are great for high horsepower
ratings and towing capabilities, but they’re usually inefficient. A V6 engine
delivers a good balance of power and efficiency, generally netting better
fuel economy ratings than V8 engines.
• Good towing capabilities — A V6 can have pretty muscular towing
capabilities. For example, the V6-powered Nissan Pathfinder can tow up
to 6,000 lbs.
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WORKING PRINCIPLES
A V6 engine is an internal combustion engine with six cylinders that
are arranged in a V-shaped formation. Using these six cylinders often
results in a higher horsepower rating compared to a 4-cylinder engine.
V6 engine works like any other internal combustion engine but the
difference is the way cylinders are arranged. Six cylinders are arranged
shaped in a “V” shape formation. The gas and air mixture enters the
cylinders through intake valves where the gas is compressed with the
help of pistons.
Then there is ignition where spark plugs are used to ignite the air fuel
mixture.
After ignition there is exhaust where fumes go out through the exhaust
valves, and the combustion process starts over.
Six cylinders are arranged in two-cylinder banks with three cylinders
with each meet in middle with all six pistons connecting to crankshaft.
The combustion process turns the crankshaft which converts the linear
motion to rotational motion which helps to send power to the
transmission. And finally, the transmission then sends power to the
wheel which makes the vehicle move.
It is believed that a 6-liter V6 engine is more powerful than a 4-cylinder
engine and has better fuel economy than one built with a six-liter
cylinder. V6 engines produce greater force than four-cylinder engines.
Unlike most engines, this one can use a lot of power without too much
noise being created.
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COMPONENTS
SL NO. PART NAME
1. Engine block
2. Crankshaft bushing
3. Crank shaft
4. Piston
5. Cylinder head
6. Cam shaft
7. Cam bushing
8. Camshaft retainer
9. Engine valve
10. Rocker arm spring
11. Oil pan
12. Engine side cover
13. Air filter
14. Air turbo
15. Exhaust manifold
16. Intake Manifold mirrored
17. Valves cover
18. Engine belt wheel
20. Hose
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BLOCK DIAGRAM
ISOMETRIC VIEW
FRONT VIEW
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RIGHT SIDE VIEW
TOP VIEW
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Components Parts Description
AIR FILTER:
This helps in sucking of fresh cold air into the engine
for combustion. It improves engine filtration and gas
mileage giving more power usually up to 20% as the
cold air pulls more oxygen into the combustion
chamber.
AIR TURBO:
Air turbo is a turbine driven forced induction device
that increases the efficiency of internal combustion
engine and power output by forcing extra compressed
air into combustion chamber.
ENGINE BELT WHEEL:
Engine belt wheel or also known as engine pully is
mounted to the engine of an automobile and is
responsible for driving all belts.
CAM SHAFT:
The camshaft is a mechanical component of an
internal combustion engine. It opens and closes the
inlet and exhaust valves of the engine at the right time,
with the exact stroke and in a precisely defined
sequence. The camshaft is driven by the crankshaft by
way of gearwheels, a toothed belt or a timing chain.
CRANKSHAFT:
A crankshaft is a rotating shaft which in conjunction
with the connecting rods) converts reciprocating
motion of the pistons into rotational motion.
Crankshafts are commonly used in internal combustion
engines and consist of a series of cranks and crankpins
to which the connecting rods are attached.
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CYLINDER HEAD:
In an internal combustion engine, the cylinder head sits
above the cylinders on top of the cylinder block. It
closes in the top of the cylinder, forming the
combustion chamber. This joint is sealed by a head
gasket. In most engines, the head also provides space
for the passages that feed air and fuel to the cylinder,
and that allow the exhaust to escape. The head can also
be a place to mount the valves, spark plugs, and fuel
injectors.
ENGINE BLOCK:
An engine block is the structure which contains the
cylinders, and other parts, of an internal combustion
engine. In an early automotive engine, the engine
block consisted of just the cylinder block, to which a
separate crank case was attached. Modern engine
blocks typically have the crankcase integrated with the
cylinder block as a single component. Engine blocks
often also include elements such as coolant passages
and oil galleries.
ENGINE VALVE:
Engine valves are located in the cylinder head. The
main function of the engine valves is to let air in and
out of the cylinders. That air is used to help ignite the
fuel which will drive the pistons up and down.
EXHAUST MANIFOLD:
Typically made of stainless steel, cast-iron or heavy-
gauge steel, the exhaust manifold directs exhaust
gases from multiple cylinders to a single exhaust. In
so doing, the exhaust manifold also helps to minimize
leakage of heat, air and gases.
ENGINE SIDE COVER:
It is used as a bracket to
hold the engine pully and
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INTAKE MANIFOLD:
In automotive engineering, an inlet manifold or intake
manifold is the part of an engine that supplies the
fuel/air mixture to the cylinders.
OIL PAN:
Oil pans are a major engine cooling system part. They
are usually constructed of thin steel and shaped into a
deeper section to fully perform its function. It is also
where the oil pump is placed. When an engine is not
running or at rest, oil pans collect the oil as it flows
down from the sides of the crankcase. In other words,
oil pans that are mounted at the bottom of the
crankcase serves as an oil reservoir. Engine oil is used
for the lubrication, cooling, and cleaning of internal
combustion engines.
PISTON HEAD:
The main purpose is to create a turbulence, for better
combustion so that to avoid knocking. Due to the
shape of a squish or quench area of piston, Incoming
air is set into rotation by the inlet valve being
positioned to one side of the cylinder head.
CONNECTING ROD:
A connecting rod, also called a con rod, is the part
of a piston engine which connects the piston to the
crankshaft. Together with the crank, the connecting
rod converts the reciprocating motion of the piston
into the rotation of the crankshaft. The connecting
rod is required to transmit the compressive and
tensile forces from the piston, and rotate at both
ends.
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DRAFTINGS OF ALL DESIGN PARTS
ASSEMBLY OF V6 ENGINE
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ROCKET ARM PARTS
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CONCLUSION
This project entitled "DESIGN AND ASSEMBLY OF A V6
ENGINE " was fully software based. Throughout this project we had
gone through various important tools of different CAD software like
SOLIDWORKS, CARIA V5 and CREO. We had also gone through all
the modules i.e., part modelling, assembly of those parts and then
drafting and detailing of individual parts.
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GROUP WORK ACTIVITY:
It is very important for an engineer to have a complete knowledge
about the task he is involved in for this, just having a theoretical;
knowledge is not enough. What is more important i.e., to do the work
practically. For this purpose, working in a group make the task much
easy and effective. A group must consist of sincere, hardworking,
dedicated, and intelligent individuals.
Our group consists of 12 members who have worked very hard
and have given their best effort in producing this product, a project on
"DESIGN AND ASSEMBLY OF A V6 ENGINE ".
Each one showed his active participation and was involved right
from preparing the format, collecting data "DESIGN AND
ASSEMBLY OF A V6 ENGINE " and its parts from various sources.
Designing these parts and assembling them using SOLID MODELING
SOFTWARE, drafting of the parts and producing the project report and
presenting it.
Each one deserves the credit for the efforts put by him in
completing this task within the time given and with high efficiency.
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