Abstract
Tier 4 Emission control versus conventional engine design is what every design engineer’s challenge to be dealt with. To design an engine to current market standards and requirements has become very intricate. In order to make such an explicit design which meets the standards, every component of the engine plays as a vital role. Every component design and development to current engineering standards pushes the envelope of manufacturability to new limits, which constraints the cost of the product across the ease of manufacturability of it. In consideration of the complexity to be attained, every component design contributes to the existence of a complete standardized engine, such as integrated valve cover. With the new tier 4 final regulations for engine manufactures, every new engine produced needs to meet those regulations. Caterpillar Inc regulated to produce tier 4 final compatible engines for the market. The new drive for development of new engines identified the objective of this project to design a new integrated breather valve cover for large power engines. Valve Cover, the noun by name explains it covers valves. In explanation to the definition of the valve cover, it covers the cylinder head mechanism;this is a high speed operating valve. Valve Cover not only covers the head mechanism and should also be persistent to pressure, stress and heat dissipated during the operation of the engine. Valve cover design initiates and explains the intricacy of a complete engine design. All the functional requirements of valve cover would be designed, analyzed and validated in this project, that drive the process of execution of the project to several phases of product development. Process identified for execution initiates with correct manufacturing technique, design intent and analysis. Caterpillar Inc. Engineering standards have been taken as a reference for defining all form fit functions. Pro engineering, Abaqus, Gambit and Fluent are the computer aided design tools used in this project for the execution of design intent. Identification of a proper manufacturing technique, processed execution of design requirements and analysis of concepts of design are validated across the requirements in this project with a justification of value added solutions are notified in the project. Conclusion on complete product design of integrated breather valve cover with optimal solution of all the available techniques in every aspect of design, development and real time production of valve cover have been discussed in this project,