A SEMINAR RERPORT On

W ENGINES THE SUPER ENGINES

Submitted in partial fulfillment of award of BACHELOR OF TECHNOLOGY

By

Shubham Gupta
IIIrd year, ME, Section L Roll No- 1108240101 Session- 2012-2013

Seminar Incharge: Mr. (Assistant Professor) Mr. Rakesh Kr. Gangwar (Assistant Professor) Mr. Himanshu Agrawal (Assistant Professor)

Seminar Guide:Mr. Akhilesh Kumar (Assistant Professor)

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that the seminar entitled W ENGINES THE SUPER ENGINES Submitted by ANKIT CHAHAL Roll No. 0908240019 in partial fulfillment of the degree of Bachelor of Technology in Mechanical Engineering embodies the work done by him under my guidance.

Seminar Guide:-

Mr. HIMANSHU AGRAWAL

Assistant Professor Deptt. Of Mechanical Engg.

(i)

ABSTRACT
With the rising demands of power , better performance & fuel economy in automobile vehicles, engineers do many research & finally they got success in the form of a new breed of engines the W Engines. One of the first W engines was a three-cylinder (W3), built by Anzani in 1906 to be used in motorcycle. The 1917 Napier Lion aircraft engine was an early W12 engine. After many years of research Volkswagen Group created the first successful automotive W engine, with the introduction of itsW8 engine (as a testbed for W12). The W12 combines two narrow-angle VR6 engines around a single crankshaft for a total of four banks of cylinders. For this reason, the four-bank configuration is sometimes, and more accurately, referred to as a "VV" or "VR", to distinguish it from the traditional three-bank "W" design. Volkswagen Group went on to produce a W16 engine prototype which produced 465 kilowatts (624 bhp). A quadturbocharged version of this engine went into production in 2005 powering the 736 kilowatts (987 bhp). The major advantage of these engines is packaging; that is, they contain high numbers of cylinders but are relatively compact in their external dimensions. In 2006, the Volkswagen Group-owned Bugatti produced an impossible missile, the Bugatti Veyron EB16.4, a supercar; with an 8.0 litre W16 engine. This had four turbochargers, and it produces motive power output of 736 kilowatts (987 bhp) at 6,000rpm. It utilises four valves per cylinder, 64 valves total, with four overhead camshafts. This car is now the fastest production car of world with unbelievable speed of 432kph and may be it goes on in coming years.

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ACKNOWLEDGEMENT
It is the great pleasure and pride that I present that seminar report before you. At this moment of triumph, it is unfair to neglect those who helped me in the successful completion of that seminar report. First of all I would like to keep myself at the feet of GOD ALMIGHTY for his everlasting love and for the blessings that he gave to me, which made it possible to see in between turbulence and set up the right path. I would also like to thanks the H.O.D. of Mechanical Engineering Mr. PARUL GUPTA to providing the various types of facilities and equipments. I am grateful to my seminar guide: Mr.HIMANSHU AGRAWAL for his guidance and whole hearted support and unforgettable constructive special tips gave by him to me, which had driven the whole seminar successfully.

ANKIT CHAHAL ROLL NO:-0908240019

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TABLE OF CONTENT Chapter 1: -

Page No

Introduction.................................................................1 Chapter 2: W Principle.2 - 3 Chapter 3: Comparison- W & V....4 - 5 Chapter 4: Specifications...6 Chapter 5: Construction.7 - 8 Chapter 6: Latest W Engine........................................................9 Chapter 7: Why Called Super Engine.10 - 11 Chapter 8: Application12 Conclusion Reference

Tables
Table 1- Specifications of W8 Engine Table 2- Specifications of Bugatti Veyron SS

Diagrams
Figure 1- Showing W concept Figure 2- Modular design principle of W engine Figure 3- W8 & V8 design comparison Figure 4- W12 & V12 crankshaft comparison Figure 5- W engine crankcase Figure 6- W engine cylinder heads Figure 7- Cylinder head with valves and ports

Pictures
Picture 1- W16 engine at Volkswagen Research Centre Picture 2- Bugatti Veyron SS front Picture 3- Bugatti Veyron SS back & top

Chapter 1 - Introduction
The constantly rising demands regarding performance, running comfort and fuel economy have led to the advancement of existing drive units and the development of new drive units.

The new W8 as well as the W12 engines are representatives of a new engine generation the W engines. Large numbers of cylinders were adapted to the extremely compact dimensions of the engine. In the process, more attention was paid to lightweight design. With the aim of building even more compact units with a large number of cylinders, the design features of the V and VR engines were combined to produce the W engines.

As with the V engines, the cylinders are distributed to two banks. In the W engines, these banks of cylinders are aligned at a V-angle of 72 in relation to one another.

When the W engine is viewed from the front, the cylinder arrangement looks like a double-V. Put the two Vs of the right and left cylinder banks together, and you get a W. This is how the name "W engine" came about.

Figure 1- Showing W Concept

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Chapter 2 - The W principle

To illustrate the principle of the W engine cylinder arrangement, let first look at conventional engine types.

(a)The Inline Engine

Represents the earliest development level in engine development. The cylinders are arranged in-line vertically above the crankshaft. Advantage: Simple design Drawback: Large numbers of cylinders result in very long units unsuitable for transverse mounting.

(b)The V Engine
To make engines shorter, the cylinders in the V engines are arranged at an angle of between 60 and 120, with the centre lines of the cylinders intersecting with the centre line of the crankshaft. Advantage: Relatively short engines Drawback: The units are relatively wide, have two separate cylinder heads, and therefore require a more complex design and a larger engine compartment volume.

(c)VR Engines
The need for a powerful alternative suitable for transverse mounting for use in lower mid-range vehicles saw the development of the VR engine. Six cylinders, offset at a Vangle of 15, are accommodated in a fairly slender and very short engine block. Unlike previous designs, the engine only has one cylinder head.

(d)W Engines
The engines of the W family are a combination of two "VR banks" based on a modular design principle. The cylinders of one bank have an angle of 15 relative to each other while the two VR banks are arranged at a V-angle of 72.

(e)The Modular Design Principle of the W Engines

Two compact VR engines from the VR series are combined to produce a W engine. The result is a series of compact petrol engines ranging from the W8 to the W16. Numerous components of the VR and W series are identical, e.g.: - Valves, valve springs and valve seat inserts - Roller rocker fingers - Valve clearance compensating elements

Figure 2- Modular design principle of W engine With regard to the evolution of the 6-cylinder engine, the VR6 engine stands out due to its compactness. It is much shorter than the comparable inline engine, and narrower than the V engine. Combining two VR6 engines with a cylinder angle of 72 produces a W12 engine. A W16 engine is obtained by joining two cylinders to each cylinder bank of a W12 engine. Splitting the W16 in the middle leaves two W8 engines.
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Chapter 3 - Comparison (a)W8 & V8

When a conventional 8-cylinder V engine is compared to an 8- cylinder W engine, the latter particularly stands out due to its compact design and very small external dimensions. This is also reflected in a comparison of the crankshafts. The compact design of the 12cylinder W engine is highlighted by the fact that it has even smaller external dimensions than a conventional V8 engine. The W8 Engine The V8 Engine

W8 crankshaft
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V8 crankshaft

Figure3- W8 and V8 crankshaft

(b)W12 & V12

Comparing the 12-cylinder crankshaft of a conventional V12 engine with that of a 12cylinder W engine emphasizes the constructional advantage. Depending on the number of cylinders, the W principle therefore saves material, and hence also weight.

W12 crankshaft V12 crankshaft Figure 4- W12 and V12 crankshaft

Hence it is clear from the figure that W engines are always smaller in dimension than V engines.

Chapter 4 - Specifications (a) The W8 Engine

TABLE 1- Specifications of W8 engine Displacement [cc] Bore [mm] Stroke [mm] Number of cylinders Number of cylinder heads V-angle of cylinder heads [] of both banks V-angle of cylinders [] in a bank Number of valves Firing order Dimensions (l x w x h) [mm] Weight [kg] Max. output [kW] ([bhp]) Max. torque [Nm] Fuel Engine management system 3999 84 90.168 8 2 72 15 4 / cylinder 1-5-4-8-6-3-7-2 420 x 710 x 683 approx. 193 202 (275) 370 98 RON to DIN EN 228 Bosch Motronic ME7.1

Chapter 5 - Construction (a)The Crankcase

The crankcase comprises two components: the crankcase upper section and the crankcase lower section. The upper section contains, among other things, the cylinders and the upper bearing cover halves of the crankshaft. The crankcase lower section is designed as a bearing support and carries the lower bearing cover halves. The crankcase upper section The "aluminium" crankcase upper section is made of a hypereutectic aluminium-silicon alloy (AlSi17CuMg). Use of this alloy eliminates the need for additional cylinder liners or a plasma coating for the purposes of cooling and lubricating the cylinder surfaces as the material already has sufficient natural strength and thermal stability. The crankcase lower section The crankcase lower section is a bearing support with integral bearing seats. The bearing support is also made of aluminium. It serves as a frame structure for the lower crankshaft bearing covers. These bearing covers are made of grey cast iron and are also embedded when the bearing support is cast. They are located on the pressure side of the crankshaft and give the crankshaft bearing the strength it requires. The bearing support is attached to the crankcase upper section by 4 bolts per bearing cover.

Crankcase upper section

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Crankcase lower section Figure 5- W engine crankcase

(b) The Cylinder Heads

The W engines have two aluminium cylinder heads with two overhead camshafts apiece. The injectors are inserted into the cylinder heads.

Figure 6- W engine cylinder heads Each of the cylinder heads in the two W engines has an intake camshaft and an exhaust camshaft with camshaft adjusters attached to their end faces. Due to the cylinder arrangement, short and long valves as well as short and long inlet and exhaust ports alternate with one another.

Figure 7- Cylinder head with valves and ports

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Chapter 6 - Latest W Engine (a)The W 16 Engine A W16 engine is a sixteen cylinder piston internal combustion engine in a four-bank W configuration. All W16 engines consist of two double-row' banks of eight cylinders, coupled to a single crankshaft. Volkswagen Group is the only automotive manufacturer currently producing W16 engines. Volkswagen Group's design is a stretched form of its W12 engine, which is itself based on technology from its VR6 engine. In the W16, each side is made up of eight cylinders, but the 'bank' angle is increased to 90 degrees. The narrow angle of each set of cylinders allows just two overhead camshafts to drive each pair of banks, so just four are needed in total. For this reason, the engine is sometimes described as a WR16.

Picture 1- W16 engine at Volkswagen research centre

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Chapter 7 - Why Called SUPER ENGINE?

The Bugatti Veyron 16.4 is the fastest and most expensive street-legal production supercar in the world, with a proven top speed of over 400 km/h (407 km/h or 253 mph). The Bugatti Veyron features a super W16 engine16 cylinders in 4 banks of 4 cylinders. It reached full production in September 2005. It is named after racing driver Pierre Veyron, who won the 24 hours of Le Mans in 1939 while racing for the original Bugatti firm. Bugatti once again claimed the land speed record for production cars on July 4, 2010 with the Veyron Super Sport prototype. At the hands of Bugatti test driver Pierre Henri Raphanel, the Super Sport managed runs of 265.9 and 269.8 mph (approx 432kph).

Picture 2- Bugatti Veyron SS (front)

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(a)

Specifications- Bugatti Veyron SS

Table 2- Specifications of Bugatti Veyron SS

Price 0-100 kph Top speed Economy Kerb weight Engine layout Installation Power Torque Compression ratio Gearbox Length Width Height Wheelbase Fuel tank Front & Rear suspension Brakes Wheels Tyres

Rs 10.22 crore/ $ 144800 2.5 sec 432 kph 5.19 kpl 1838kg W16, 7993cc, quad-turbo, petrol Mid, longitudinal, 4WD 1184 bhp at 6400 rpm 152.77 kgm at 3000-5000 rpm 8.3:1 7-speed dual-clutch automatic 4462 mm 1998 mm 1190 mm 2710mm 100 litres Double wishbones, coil springs, anti-roll bar 400mm carbon-ceramic discs (f) 380mm carbon-ceramic discs (r) 20 in, magnesium alloy 265/35 R20 (f) 365/30 R20 (r)

Picture 3- Bugatti Veyron SS (back & top)

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Chapter 8 - APPLICATION
A 4.0 litre W8 engine producing 275 PS (202 kW) was introduced in 2001 in a

luxury version of the car Passat 5.5. This engine was intended to be a test bed for Volkswagen Group's new W engine technology. The engine was discontinued in 2004. This engine would later make an appearance on the W12 in the Phaeton and Audi A8, and the W16 engine in the Bugatti Veyron. The Volkswagen Group W12 engine is used in some high-end luxury models: Audi A8L W12 Bentley Continental GT Bentley Continental Flying Spur Spyker C12 LaTurbie Spyker C12 Zagato Volkswagen Phaeton W12 Volkswagen Touareg W12 The W16 engine was introduced with the Bentley Hunaudieres concept car, a midengined sports car, which was never intended for production. This W16 was later used in the Audi Rosemeyer (never produced) concept car. W16 engines are now currently employed in Bugatti Veyron, a mid engine sports car. W24 engine was used by General Motors in Allison V-3420 (aviation engine), from 1937-1944.

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Conclusion
W Engine with their successful story created a new era of powerful & efficient engines with better fuel economy. From 1906 to present there is a constant increase in power and performance of W engines. Volkswagen is the only car manufacturer in the world, currently producing W engines. Volkswagen working in this field since 1998 produced many W engines e.g. W8, W12 and then W16. W16 engine is currently the most powerful Engine in the world which when installed in Bugatti Veyron gives running speed of 432kph. So as centuries goes on peoples demand for supercars also increases which led many automobile companies to do research and produce more powerful engine. Hope the successful story of Volkswagen, in producing powerful engines continues in the coming years.

Reference
1. http://www.volkspage.net/technik/ssp/ssp/SSP_248.pdf 2. http://en.wikipedia.org/wiki/W_engine 3. http://www.eskimo.com/~riffraff/files/W_engines.pdf 4. Autocar India magazine 5. http://www.autozine.org/technical_school/engine/tech_engine_packaging.htm