Here is a little something neat to read from 360veiw on another thread.


(here's an attempt to figure out gear ratio for highway cruise in a scientific way, based on piston speed and intake manifold vacuum. comments welcome)
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Now lets discuss gearing and fuel economy.

In city driving gearing doesn't matter nearly as much as not having a
'heavy foot' or hauling a lot of weight in the bed of the truck.

A vehicle that is either overgeared or undergeared will lose MPG at highway
cruise.

An engine is numerically overgeared if it is not cruising at about
60-75% open throttle.

An engine is undergeared and "too weak for the job"
if it has to operate with its pistons going faster than an average of about
1200 feet per minute when at 75% throttle.

Note that you could reduce engine weakness by turbocharging
as well as the much more common thought to just make the engine larger in
cubic inches. This is the reason nearly all diesels have become turbocharged
in the last 20 years.

How do you calculate this average piston speed?

Multiply the stroke of the engine in inches by two (because the piston goes
both up and down on one rpm) and then divide by 12 to convert inches to
feet. Multiply this by the rpm.

So where does 1200 feet per minute end up for various engines?
Here some examples:

For the 3.58 stroke of 3.7, 5.7, 5.9 Dodge engines:
2011 rpm = 1200 ft/min /( 2 x 3.58 inches/12 inches per ft)

For the 3.405 stroke of the Dodge 4.7V8
2114 rpm = 1200/(2x3.405/12)

For the 3.00 stroke of the Ford 5.0L V8
2400 rpm = 1200/(2x3.00/12)

For the 4.72 stroke of the Cummins Inline 6 diesel
1525 rpm = 1200/(2x4.72/12)

Is it possible for an engine to be made to get its best fuel economy at a
piston speed above the typical 1200 feet per minute?
Yes.
Very thin piston rings, using less than the normal 3 rings,
slippery coatings on piston skirts, extremely hard but slick coatings
on bore walls like "NikoSil" and keeping the bore walls very hot
so that the oil there will be thin and less viscous can all allow the
'best economy' piston speed to be raised but even 'state of the art'
giant marine diesel where nearly every trick is used seldom exceed
1500 feet per minute.

Honda has announced that over the next 5 year period that the major
part of their engine research $ will be spent on ways to reduce internal
engine friction, and this is from a company that NASCAR engine builders
already admit has the best rod and crankshaft bearing material for sale.

Which is more important: having the rpms near this 1200 foot per minute
speed for the pistons, or having the throttle in the 65-75% open range?
Answer: it is more important to be in the 70% throttle range and you should
slow down the rpms to get there. There is not much change in efficiency
when piston speed drops from 1200 down to 800 ft/minute but there is a big
change in efficiency when the throttle goes from 70% open to 40% open.

Why?

Imagine that you have a disassembled engine in front of you. Put a loose
piston in a bore and pull it down against the friction of the rings. It won't
be very hard.

Now imagine that same piston in the bore has the top of the
bore sealed off and has a vacuum sucked of 12 inches of Mercury.
12 inches of vacuum is about 6 psi of negative pressure. If the piston is
4.00 inches in diameter it has an area of about 12.5 square inches
(remember pi R squared but most cherry pies are round?)
6 pounds per square inch times 12.5 square inches = 75 pounds would be
required to pull the piston down - you probably couldn't do it with the grip
of just a couple fingers! An engine running with a high vacuum in the intake
manifold has to do just this, and for eight cylinders!

Engineers refer to this as one of the two parts of "Pumping Losses". The
other part of Pumping Losses is due to pushing the exhaust out the tailpipe.
Most engine owners easily imagine that exhaust loss, accept it, and spend
a lot of time and money on mufflers, headers, Y pipes etc. These same
engine owners would do well to remember the "Pumping Loss" on the intake side
and try to keep it low during highway cruise conditions.

{Note to engineers: Yea, I know, 'negative pressure' does not really exist and
what actually happened is 14.7 psi of air pressure is pushing the underside
of the piston and there was just less pressure on the top of the piston to
create a delta P - but the general public thinks in 'vacuum' terms.
And it is not just the general public - talk to the biologists who think
-100 psi or more of 'negative' pressure pulls water up capillaries to tree
tops}

Setting Gear Ratios to suit the Customer's Expectations

Most auto manufacturers intentionally overgear their vehicles because they
know from experience that customers will bitterly complain about a vehicle
that downshifts to climb a hill.

Engineers know that to give their customers the best possible highway MPG
the transmission would downshift on EVERY hill, but the sales department
reminds them that that every employee at the automaker (including engineers)
will lose their jobs if customers {even ignorant ones} get mad
and buy someone else's vehicle that meets their expectation.

So vehicles are overgeared to 'feel strong' during the 20% of the time they
are climbing hills in Overdrive, even if it means this hurts MPG a bit during
the 80% of the time the vehicle is on level roads or going downhill.

An engine is numerically undergeared if it is trying to cruise in the
'Power Enrichment' zone above about 80% throtttle opening where the
PCM computer greatly enriches the air to fuel ratio from 14.7 to 11.
On most vehicles with automatic transmissions it is not possible to cruise
in OD on level highways in the power enrichment zone because the
transmission will downshift to a lower gear long before the accelerator
is pressed that far.

For the same reason anyone who presses the accelerator down all the way near
the floor whether they are driving in the city, highway, climbing a hill, or
pulling a trailer is going to get about 25% worse MPG than someone who
presses right up to about 70% throttle but never goes over it.

This is why the old advice to install a vacuum gauge
can certainly help MPG if the driver watches it out of the corner of his eye.

When the vacuum gauge reads about 1 to 6 inches of mercury
you are in the fuel guzzling 'Power Enrichment' zone that you want to avoid
except when you want the highest horsepower and accept the higher fuel usage.

When the vacuum gauge is showing about 7 to 9 inches of mercury vacuum
your engine is converting fuel into horsepower at its most efficient level.

Each engine goes into Power Enrichment at a slightly different MAP sensor
level, but if you listen closely to the engine sound you can hear it happen
as the engine gets a bit smoother with the very rich mixture.





I guess acording to that an OD should really help me, I cruise at 75mph with 19 inches vacume.