Six-cylinder aircraft boxer engine.
Completed engineering project covering concept development, CAD modelling, performance characteristics, structural calculations, strength analyses, technical documentation and manufacturing methodology for selected components.
From the thermodynamic cycle to production-ready documentation.
The project concerned an air-cooled, six-cylinder aircraft piston engine in a boxer configuration, supplied with Avgas 100LL through an RSA5 continuous fuel-injection system. The design assumptions targeted approximately 250 hp and around 700 Nm of torque.
The work began with an energy balance, theoretical-cycle analysis and P‑V diagrams. This was followed by crank-train calculations covering kinematics, acceleration, gas and inertia forces, and loads transferred through the piston, pin, connecting rod and crankshaft.
The later stages included strength calculations and numerical verification of selected components, cooling-system and heat-balance work, cylinder-head geometry, analytical intake/exhaust flow calculations, CAD integration, technical documentation and manufacturing methodology for key components.
CAD model of the project created in Autodesk.Performance & thermodynamics
Definition of core operating parameters, mixed-cycle analysis, P‑V diagram and calculations of engine performance at the rated operating point.
Mechanics & strength
Crank-train kinematics, gas and inertia loads, calculations for the connecting rod, piston, pin, crankshaft and selected joints.
Flow & cooling
Engine heat balance, cooling-air requirements and analytical calculations of flow areas and velocities in intake and exhaust channels.
CAD & integration
Solid modelling of the crankcase, cylinders, heads, accessories and overall assembly, including evaluation of subsystem packaging.
Technical documentation
Technical drawings of selected components, including the crankshaft, with views, sections, dimensions and production information.
Manufacturing methodology
Selection of materials and processes including Al 2618, AISI 4340, 38H steel, SAE 4140 and A356‑T6, together with forging, machining, heat treatment, nitriding, grinding and honing.
One continuous visual story of the project.
Swipe the gallery or use the arrows to move through all six project views.
