1: The internal-combustion engine: an introduction
1.1 Heat engines and internal combustion engines
1.2 The reciprocating piston engine
1.3 Engine operating cycles
1.4 Supercharging and turbocharging
1.5 Production engine examples
1.6 Basic measures
1.7 Recommendations for further reading
2: Engine maps, customers, and markets
2.1 Engine mapping
2.2 Automobile, motorcycle, and light-truck applications
2.3 Heavy-truck applications
2.4 Off-highway applications
2.5 Recommendations for further reading
3: Engine validation and durability
3.1 Developing a durable engine
3.2 Fatigue analysis
3.3 Friction, lubrication, and wear
3.4 Further wear and failure mechanisms
3.5 Recommendations for further reading
4: Engine development process
5: Determining displacement
5.1 The engine as an air pump
5.2 Estimating displacement
5.3 Engine uprating and critical dimensions
6: Engine configuration and balance
6.1 Determining the number and layout of cylinders
6.2 Vibration fundamentals reviewed
6.3 Rotating forces and dynamic couples
6.4 Reciprocating forces
6.5 Balancing the forces in multicylinder engines
6.6 Gas pressure forces
6.7 Bore-to-stroke ratio optimization
6.8 Recommendation for further reading
7: Cylinder block and head materials and manufacturing
7.1 Block and head materials
7.2 Block and head casting processes
7.3 A look at block and head casting
7.4 Block and head machining processes
7.5 Recommendations for further reading
8: Block layout and design decisions
8.1 Initial block layout
8.2 Crankcase design decisions
8.3 Cylinder design decisions
8.4 Camshaft placement decisions
9: Cylinder head layout design
9.1 Initial head layout
9.2 Combustion chamber design decisions
9.3 Valve, port, and manifold design
9.4 Head casting layout
9.5 Cylinder head cooling
9.6 Oil deck design
10: Block and head development
10.1 Durability validation
10.2 High-cycle loading and the cylinder block
10.3 Modal analysis and noise
10.4 Low-cycle mechanical loads
10.5 Block and head mating and the head gasket
10.6 Cylinder head loading
10.7 Thermal loads and analysis
10.8 Recommendations for further reading
11: Engine bearing design
11.1 Hydrodynamic bearing operation
11.2 Split-bearing design and lubrication
11.3 Bearing loads
11.4 Classical bearing sizing
11.5 Dynamic bearing sizing
11.6 Bearing material selection
11.7 Bearing system validation
11.8 Recommendations for further reading
12: Engine lubrication
12.1 Engine lubricants
12.2 Lubrication circuits and systems
12.3 Oil pumps
12.4 Oil pans, sumps, and windage
12.5 Filtration and cooling
12.6 Lubrication system performance analysis
12.7 Recommendations for further reading
13: Engine cooling
13.1 Engine cooling circuits
13.2 Cooling-jacket optimization
13.3 Water pump design
13.4 The cooling system
13.5 Venting and deaeration
13.6 Recommendations for further reading
14: Gaskets and seals
14.1 Gasketed-joint fundamentals
14.2 Engine cover design
14.3 Clamping load parameters
14.4 Bolt torque and sealing load control
14.5 Shaft seal design
14.6 Recommendations for further reading
15: Pistons and rings
15.1 Piston construction
15.2 Piston crown and ring land development
15.3 Piston pin boss development
15.4 Piston skirt development
15.5 Piston ring construction
15.6 Dynamic operation of the piston rings
15.7 Cylinder wall machining
15.8 Recommendations for further reading
16: Crankshafts and connecting rods
16.1 Crankshaft construction and manufacturing
16.2 Crankshaft fillet development
16.3 Torsional vibration and dampeners
16.4 Crankshaft nose development
16.5 Crankshaft flange and flywheel dev

The mechanical engineering curriculum in most universities includes at least one elective course on the subject of reciprocating piston engines. The majority of these courses today emphasize the application of thermodynamics to engine ef?ciency, performance, combustion, and emissions. There are several very good textbooks that support education in these aspects of engine development. However, in most companies engaged in engine development there are far more engineers working in the areas of design and mechanical development. University studies should include opportunities that prepare engineers desiring to work in these aspects of engine development as well. My colleagues and I have undertaken the development of a series of graduate courses in engine design and mechanical development. In doing so it becomes quickly apparent that no suitable te- book exists in support of such courses. This book was written in the hopes of beginning to address the need for an engineering-based introductory text in engine design and mechanical development. It is of necessity an overview. Its focus is limited to reciprocating-piston internal-combustion engines - both diesel and spa- ignition engines. Emphasis is speci?cally on automobile engines, although much of the discussion applies to larger and smaller engines as well. A further intent of this book is to provide a concise reference volume on engine design and mechanical development processes for engineers serving the engine industry. It is intended to provide basic information and most of the chapters include recent references to guide more in-depth study.