A SEMINAR RERPORT On

W ENGINES – THE SUPER ENGINES

Submitted in partial fulfillment of award of
BACHELOR OF TECHNOLOGY
By
Shubham Gupta
IIIrd year, ME, Section L
Roll No- 1108240101
Session- 2012-2013

Seminar Incharge: - Seminar Guide:-

Mr. Mr. Akhilesh Kumar
(Assistant Professor) (Assistant Professor)
Mr. Rakesh Kr. Gangwar
(Assistant Professor)
Mr. Himanshu Agrawal
(Assistant Professor)

DEPARTMENT OF MECHANICAL ENGINEERING

 CERTIFICATE

This is to certify that the seminar entitled “W ENGINES – THE SUPER ENGINES”
Submitted by ANKIT CHAHAL Roll No. 0908240019 in partial fulfillment of the degree of
Bachelor of Technology in Mechanical Engineering embodies the work done by him under my
guidance.

Seminar Guide:-

Mr. HIMANSHU AGRAWAL

Assistant Professor
Deptt. Of Mechanical Engg.

(i)
 ABSTRACT
With the rising demands of power , better performance & fuel economy in automobile vehicles,
engineers do many research & finally they got success in the form of a new breed of engines the
‘W Engines’. One of the first W engines was a three-cylinder (W3), built by Anzani in 1906 to
be used in motorcycle. The 1917 Napier Lion aircraft engine was an early W12 engine.
After many years of research Volkswagen Group created the first successful automotive W
engine, with the introduction of itsW8 engine (as a testbed for W12). The W12 combines two
narrow-angle VR6 engines around a single crankshaft for a total of four banks of cylinders. For
this reason, the four-bank configuration is sometimes, and more accurately, referred to as a "VV"
or "VR", to distinguish it from the traditional three-bank "W" design. Volkswagen Group went
on to produce a W16 engine prototype which produced 465 kilowatts (624 bhp). A quad-
turbocharged version of this engine went into production in 2005 powering the 736 kilowatts
(987 bhp). The major advantage of these engines is packaging; that is, they contain high numbers
of cylinders but are relatively compact in their external dimensions.
In 2006, the Volkswagen Group-owned Bugatti produced an impossible missile, the Bugatti
Veyron EB16.4, a supercar; with an 8.0 litre W16 engine. This had four turbochargers, and it
produces motive power output of 736 kilowatts (987 bhp) at 6,000rpm. It utilises four valves per
cylinder, 64 valves total, with four overhead camshafts. This car is now the fastest production car
of world with unbelievable speed of 432kph and may be it goes on in coming years.

(ii)
 ACKNOWLEDGEMENT
It is the great pleasure and pride that I present that seminar report before you. At this
moment of triumph, it is unfair to neglect those who helped me in the successful completion of
that seminar report. First of all I would like to keep myself at the feet of GOD ALMIGHTY for
his everlasting love and for the blessings that he gave to me, which made it possible to see in
between turbulence and set up the right path.
I would also like to thanks the H.O.D. of “Mechanical Engineering” Mr. PARUL GUPTA to
providing the various types of facilities and equipments. I am grateful to my seminar guide:
Mr.HIMANSHU AGRAWAL for his guidance and whole hearted support and unforgettable
constructive special tips gave by him to me, which had driven the whole seminar successfully.

ANKIT CHAHAL

ROLL NO:-0908240019

(iii)
 TABLE OF CONTENT Page No

Chapter 1: -
Introduction.................................................................1
Chapter 2: -
W Principle………………………………………….2 - 3
Chapter 3: -
Comparison- W & V……………………………....4 - 5
Chapter 4: -
Specifications………………………………………...6
Chapter 5: -
Construction……………………………………….7 - 8
Chapter 6: -
Latest W Engine........................................................9
Chapter 7: -
Why Called Super Engine……………………….10 - 11
Chapter 8: -
Application…………………………………………12
Conclusion

Reference
Tables

 Table 1- Specifications of W8 Engine

 Table 2- Specifications of Bugatti Veyron SS

Diagrams

 Figure 1- Showing W concept

 Figure 2- Modular design principle of W engine
 Figure 3- W8 & V8 design comparison
 Figure 4- W12 & V12 crankshaft comparison
 Figure 5- W engine crankcase
 Figure 6- W engine cylinder heads
 Figure 7- Cylinder head with valves and ports

Pictures

 Picture 1- W16 engine at Volkswagen Research Centre

 Picture 2- Bugatti Veyron SS front
 Picture 3- Bugatti Veyron SS back & top
 Chapter 1 - Introduction

 The constantly rising demands regarding performance, running comfort and fuel
economy have led to the advancement of existing drive units and the development of new
drive units.
 The new W8 as well as the W12 engines are representatives of a new engine generation -
the W engines.
 Large numbers of cylinders were adapted to the extremely compact dimensions of the
engine. In the process, more attention was paid to lightweight design.
 With the aim of building even more compact units with a large number of cylinders, the
design features of the V and VR engines were combined to produce the W engines.
 As with the V engines, the cylinders are distributed to two banks. In the W engines, these
banks of cylinders are aligned at a V-angle of 72° in relation to one another.
 When the W engine is viewed from the front, the cylinder arrangement looks like a
double-V. Put the two Vs of the right and left cylinder banks together, and you get a W.
This is how the name "W engine" came about.

Figure 1- Showing W Concept

1
 Chapter 2 - The W principle
To illustrate the principle of the W engine cylinder arrangement, let first look at conventional
engine types.

(a)The Inline Engine

 Represents the earliest development level in engine development. The cylinders are
arranged in-line vertically above the crankshaft.
 Advantage: Simple design
 Drawback: Large numbers of cylinders result in very long units unsuitable for transverse
mounting.

(b)The V Engine
 To make engines shorter, the cylinders in the V engines are arranged at an angle of
between 60° and 120°, with the centre lines of the cylinders intersecting with the centre
line of the crankshaft.
 Advantage: Relatively short engines
 Drawback: The units are relatively wide, have two separate cylinder heads, and therefore
require a more complex design and a larger engine compartment volume.

(c)VR Engines
 The need for a powerful alternative suitable for transverse mounting for use in lower
mid-range vehicles saw the development of the VR engine. Six cylinders, offset at a V-
angle of 15°, are accommodated in a fairly slender and very short engine block. Unlike
previous designs, the engine only has one cylinder head.

(d)W Engines
 The engines of the W family are a combination of two "VR banks" based on a modular
design principle. The cylinders of one bank have an angle of 15° relative to each other
while the two VR banks are arranged at a V-angle of 72°.

2
(e)The Modular Design Principle of the W Engines
 Two compact VR engines from the VR series are combined to produce a W engine. The
result is a series of compact petrol engines ranging from the W8 to the W16.
 Numerous components of the VR and W series are identical, e.g.:
- Valves, valve springs and valve seat inserts
- Roller rocker fingers
- Valve clearance compensating elements

Figure 2- Modular design principle of W engine

 With regard to the evolution of the 6-cylinder engine, the VR6 engine stands out due to
its compactness. It is much shorter than the comparable inline engine, and narrower than
the V engine. Combining two VR6 engines with a cylinder angle of 72° produces a W12
engine.
 A W16 engine is obtained by joining two cylinders to each cylinder bank of a W12
engine. Splitting the W16 in the middle leaves two W8 engines.

3
 Chapter 3 - Comparison
(a)W8 & V8
 When a conventional 8-cylinder V engine is compared to an 8- cylinder W engine, the
latter particularly stands out due to its compact design and very small external
dimensions.
 This is also reflected in a comparison of the crankshafts. The compact design of the 12-
cylinder W engine is highlighted by the fact that it has even smaller external dimensions
than a conventional V8 engine.
The W8 Engine The V8 Engine

W8 crankshaft V8 crankshaft
Figure3- W8 and V8 crankshaft
4
(b)W12 & V12
 Comparing the 12-cylinder crankshaft of a conventional V12 engine with that of a 12-
cylinder W engine emphasizes the constructional advantage.
 Depending on the number of cylinders, the W principle therefore saves material, and
hence also weight.

W12 crankshaft V12 crankshaft

Figure 4- W12 and V12 crankshaft

 Hence it is clear from the figure that W engines are always smaller in dimension than
V engines.

5
 Chapter 4 - Specifications
(a) The W8 Engine
TABLE 1- Specifications of W8 engine
Displacement [cc] 3999
Bore [mm] 84
Stroke [mm] 90.168
Number of cylinders 8
Number of cylinder heads 2
V-angle of cylinder heads [°] of both banks 72
V-angle of cylinders [°] in a bank 15
Number of valves 4 / cylinder
Firing order 1-5-4-8-6-3-7-2
Dimensions (l x w x h) [mm] 420 x 710 x 683
Weight [kg] approx. 193
Max. output [kW] ([bhp]) 202 (275)
Max. torque [Nm] 370
Fuel 98 RON to DIN EN 228
Engine management system Bosch Motronic ME7.1

6
 Chapter 5 - Construction
(a)The Crankcase
 The crankcase comprises two components: the crankcase upper section and the crankcase
lower section. The upper section contains, among other things, the cylinders and the
upper bearing cover halves of the crankshaft. The crankcase lower section is designed as
a bearing support and carries the lower bearing cover halves.
The crankcase upper section
 The "aluminium" crankcase upper section is made of a hypereutectic aluminium-silicon
alloy (AlSi17CuMg).
 Use of this alloy eliminates the need for additional cylinder liners or a plasma coating for
the purposes of cooling and lubricating the cylinder surfaces as the material already has
sufficient natural strength and thermal stability.
The crankcase lower section
 The crankcase lower section is a bearing support with integral bearing seats.
 The bearing support is also made of aluminium. It serves as a frame structure for the
lower crankshaft bearing covers. These bearing covers are made of grey cast iron and are
also embedded when the bearing support is cast.
 They are located on the pressure side of the crankshaft and give the crankshaft bearing
the strength it requires.
 The bearing support is attached to the crankcase upper section by 4 bolts per bearing
cover.

Crankcase upper section Crankcase lower section

Figure 5- W engine crankcase
7
(b) The Cylinder Heads
 The W engines have two aluminium cylinder heads with two overhead camshafts apiece.
The injectors are inserted into the cylinder heads.

Figure 6- W engine cylinder heads

 Each of the cylinder heads in the two W engines has an intake camshaft and an exhaust
camshaft with camshaft adjusters attached to their end faces.
 Due to the cylinder arrangement, short and long valves as well as short and long inlet
and exhaust ports alternate with one another.

Figure 7- Cylinder head with valves and ports

8
 Chapter 6 - Latest W Engine
(a)The W 16 Engine-
 A W16 engine is a sixteen cylinder piston internal combustion engine in a four-bank W
configuration.
 All W16 engines consist of two ‘double-row' banks of eight cylinders, coupled to a single
crankshaft.
 Volkswagen Group is the only automotive manufacturer currently producing W16
engines. Volkswagen Group's design is a stretched form of its W12 engine, which is itself
based on technology from its VR6 engine.
 In the W16, each side is made up of eight cylinders, but the 'bank' angle is increased to 90
degrees.
 The narrow angle of each set of cylinders allows just two overhead camshafts to drive
each pair of banks, so just four are needed in total. For this reason, the engine is
sometimes described as a WR16.

Picture 1- W16 engine at Volkswagen research centre

9
 Chapter 7 - Why Called SUPER ENGINE?

 The Bugatti Veyron 16.4 is the fastest and most expensive street-legal production
supercar in the world, with a proven top speed of over 400 km/h (407 km/h or 253 mph).
 The Bugatti Veyron features a super W16 engine—16 cylinders in 4 banks of 4
cylinders.
 It reached full production in September 2005.
 It is named after racing driver Pierre Veyron, who won the 24 hours of Le Mans in 1939
while racing for the original Bugatti firm.
 Bugatti once again claimed the land speed record for production cars on July 4, 2010 with
the Veyron Super Sport prototype.
 At the hands of Bugatti test driver Pierre Henri Raphanel, the Super Sport managed
runs of 265.9 and 269.8 mph (approx 432kph).

Picture 2- Bugatti Veyron SS (front)

10
 (a) Specifications- Bugatti Veyron SS
Table 2- Specifications of Bugatti Veyron SS

Price Rs 10.22 crore/ $ 144800

0-100 kph 2.5 sec
Top speed 432 kph
Economy 5.19 kpl
Kerb weight 1838kg
Engine layout W16, 7993cc, quad-turbo, petrol
Installation Mid, longitudinal, 4WD
Power 1184 bhp at 6400 rpm
Torque 152.77 kgm at 3000-5000 rpm
Compression ratio 8.3:1
Gearbox 7-speed dual-clutch automatic
Length 4462 mm
Width 1998 mm
Height 1190 mm
Wheelbase 2710mm
Fuel tank 100 litres
Front & Rear suspension Double wishbones, coil springs, anti-roll bar
Brakes 400mm carbon-ceramic discs (f)
380mm carbon-ceramic discs (r)
Wheels 20 in, magnesium alloy
Tyres 265/35 R20 (f)
365/30 R20 (r)

Picture 3- Bugatti Veyron SS (back & top)

11
 Chapter 8 - APPLICATION

 A 4.0 litre W8 engine producing 275 PS (202 kW) was introduced in 2001 in a
luxury version of the car Passat 5.5. This engine was intended to be a test bed for
Volkswagen Group's new W engine technology. The engine was discontinued in 2004.
 This engine would later make an appearance on the W12 in the Phaeton and Audi A8,
and the W16 engine in the Bugatti Veyron.

 The Volkswagen Group W12 engine is used in some high-end luxury models:
Audi A8L W12
Bentley Continental GT
Bentley Continental Flying Spur
Spyker C12 LaTurbie
Spyker C12 Zagato
Volkswagen Phaeton W12
Volkswagen Touareg W12
 The W16 engine was introduced with the Bentley Hunaudieres concept car, a mid-
engined sports car, which was never intended for production. This W16 was later used in
the Audi Rosemeyer (never produced) concept car. W16 engines are now currently
employed in Bugatti Veyron, a mid engine sports car.
 W24 engine was used by General Motors in Allison V-3420 (aviation engine), from
1937-1944.

12
 Conclusion
W Engine with their successful story created a new era of powerful & efficient
engines with better fuel economy. From 1906 to present there is a constant increase in power and
performance of W engines. Volkswagen is the only car manufacturer in the world, currently
producing W engines. Volkswagen working in this field since 1998 produced many W engines
e.g. W8, W12 and then W16. W16 engine is currently the most powerful Engine in the world
which when installed in Bugatti Veyron gives running speed of 432kph.
So as centuries goes on people’s demand for supercars also increases which led many automobile
companies to do research and produce more powerful engine. Hope the successful story of
Volkswagen, in producing powerful engines continues in the coming years.
 Reference

1. http://www.volkspage.net/technik/ssp/ssp/SSP_248.pdf
2. http://en.wikipedia.org/wiki/W_engine
3. http://www.eskimo.com/~riffraff/files/W_engines.pdf
4. Autocar India magazine
5. http://www.autozine.org/technical_school/engine/tech_engine_packaging.htm