University of Wisconsin-Madison Physical Sciences Lab

Building Cleaner and More Efficient Engines

Friday, August 3rd, 2012

The UW-Madison Engine Research Center (ERC) is developing cleaner and more fuel efficient diesel engines. The ERC designed a cylinder head which allows optical instruments to monitor the combustion process. This research will lead to diesel engines that produce less soot while maximizing fuel economy.

The optical head, was designed by the ERC, and machined at PSL. The project was primarily performed on PSL’s Hermle CNC Mill. The material was a thick piece of 2205 stainless steel. A few challenges the shop faced were the deep bores that were required for the water cooling passages for the final product. The passages were under a tight tolerance because of other features that could be interfered with if the holes were misaligned. There was also a fragile post machining needed to the top of the welded ports to ensure a proper sealing surface when put into its final assembly.

This research is sponsored by the U.S. Department of Energy.