Manufacturing and cost analysis of cylinder head, turbocharger, basement and crankshaft for a high-power density internal combustion engine used as range extender

The thesis work has been developed in collaboration with the company “Leonardo Engineers for integration S.R.L.”, it is part of an innovative and totally brand-new hybrid electric powertrain design. The project is included in a series of works previously carried out by other students, in collaboration with the company, aimed to design and optimize the internal combustion engine that will be exploited as a range extender unit for the series hybrid electric vehicle. General design goal is the minimization of fuel consumption without penalizing the engine power output; other two important aspects that lead the project are the cost involved in the internal combustion engine manufacturing and the noise and vibration produced. In this work the cost analysis and the feasibility of the project will be started and some components such as the engine basement, the cylinder head, the crankshaft and the turbocharger assembly will be further investigated. Moreover, working cycle for the prudction cycle, chosen of industrial machinery and production times will be pointed out. Some tools and applications have been used to pursue the targets: the CAD drawings of the engine, part of previously projects, made with PTC Creo Parametric, have been analysed and studied with Solidworks; instead, for the calculation and for the Engineering bill of material, Microsoft Excel sheets have been widely exploited.