For partial fulfillment of the requirements for the degree of ME/M.Sc/PhD
In ---------------- Engineering
Submitted by NAME ROLL NUMBER
Under the guidance of: PROFESSOR
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ACKNOWLEDGEMENT The project bears the imprints of the efforts extended by many people to whom we are deeply indebted. We would like to thank our mentor Mr. xxxxxxx under whose able guidance we gained the insights and ideas without which the project could not have seen the light of the day. His suggestions have been valuable and his teachings during the course of our discussions would continue to be a guiding principle in our works in the future as well. We would also like to thank Mr. xxxxx for his valuable guidance, advice and constant support throughout the project. Finally, we would like to thank the whole Mechanical Department for providing us an opportunity to apply our technical knowledge and see it materialize in the form of this project.
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ABSTRACT The two stroke engine was developed to obtain a greater output from the same size of engine. The engine mechanism eliminates the valve arrangement making it mechanically simpler. Theoretically a two stroke engine develops twice the power of a comparable four stroke engine, thus making it more compact.
Getting air into an engine is the key to making power and there are many ways to increase the air flow into the engine. There are such forced induction, nitrous system, better port and valve shapes to improve flow. But for this study the technique that has been selected were the better port size. The claims that this where the harnessing the inertia of the airs velocity to better fill the cylinders.
Modification in intake port is made. Also use of different fuel metering jets is used for different A/F mixtures. At various throttle positions and with torque and speed as input, and with porting done performance parameters of engine are calculated.
Based on the results various curves are plotted. The objective of the project is to determine how much improvement in fuel economy with the modification in intake system in compared to the original intake system. Modification to the engine without additional system attach to the engine operation were the best solution to have an optimum engine operation in term of torque and horsepower. To optimize the power and intake port flow produce by the engine modification were through a very limited value. The value is limited due to the restricted area of the engine production by the manufacturer. Hence modification must be planned carefully as over modification of the inlet port can end up with a device slower than its stock counterpart. It was found out experimentally that mechanical thermal efficiency was improved after modification. In other words Fuel economy was improved after modification in intake port.
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INTRODUCTION
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INTRODUCTION A two stroke engine is one which completes its cycle of operation in one revolution of crankshaft or in two stroke of the piston. In this engine the function of intake and exhaust processes of the 4-stroke engine are taken care of by the incoming fresh charge which is compressed either in the crankcase or by a separate blower while the piston is near the BDC. The combustible A/F mixture is obtained from simple carburetor.
The conventional, carbureted, two-stroke SI engine has a number of potential advantages over the equivalent four stroke engine; these include higher specific power output, compactness, simple construction, lower production and maintenance costs, lower brake-specific NO, emissions, lower engine friction, and reduced part-load pumping losses. As a result of these advantages, the two stroke
SI engine is widely used in mopeds, motorcycles, three wheeled auto rickshaws, chainsaws, snowmobiles, lawn mowers, and outboard marine applications. In India, the two wheeled vehicles powered by two-stroke SI engines are numbered around 17 million, compared to only 2.8 million Modification to the engine without additional system attach to the engine operation was the best solution to have an optimum engine operation in term of torque and horsepower. To optimize the power and intake port flow produce by the engine modification were through a very limited value. The value is limited due to the restricted area of the engine production by the manufacturer. Hence modification must be planned carefully as over modification of the inlet port can end up with a device slower than its stock counterpart. In our project modification in intake port is done, also with the use of two jets (0.85mm & 0.70mm) and readings are taken at a particular rpm(580).It was found that mechanical thermal efficiency was and Fuel economy was improved after modification in intake port.
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LITERATURE REVIEW
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LITERATURE REVIEW The two-stroke internal combustion engine has now been developed to a degree that was not thought possible just a few years ago. Getting air into an engine is the key to making power and there are many ways to increase the air flow into the engine. There are such forced induction, nitrous system, better port and valve shapes to improve flow. But for this study the technique that has been selected were the better port size. The claims that this where the harnessing the inertia of the airs velocity to better fill the cylinders.
In two stroke engines the cycle is completed in one revolution of the crankshaft. The main difference between the two stroke and four stroke engines is the method of filling fresh charge and removing the burnt gases from the cylinder.
The two stroke engine is of simple design which also facilitates servicing and maintenance; secondly it has a very good performance/weight ratio, and thirdly it will operate in any working position.
OPERATION: [Type the document title] Page 7
Although a two-stroke engine has less moving parts than a four-stroke engine, a two-stroke is a complex engine because it relies on gas dynamics. There are different phases taking place in the crankcase and in the cylinder bore at the same time. That is how a two-stroke engine completes a power cycle in only 360 degrees of crankshaft rotation compared to a four-stroke engine which requires 720 degrees of crankshaft rotation to complete one power cycle.
1) Starting with the piston at top dead center (TDC 0 degrees) ignition has occurred and the gasses in the combustion chamber are expanding and pushing down the piston. This pressurizes the crankcase causing the reed valve to close. At about 90 degrees after TDC the exhaust port opens ending the power stroke. A pressure wave of hot expanding gasses flows down the exhaust pipe. The blow-down phase has started and will end when the transfer ports open. The pressure in the cylinder must blow-down to below the pressure in the crankcase in order for the unburned mixture gasses to flow out the transfer ports during the scavenging phase.
2) Now the transfer ports are uncovered at about 120 degrees after TDC. The scavenging phase has begun. Meaning that the unburned air fuel mixture are flowing out of the transfer ports and merging together to form a loop. The gasses travel up the back side of the cylinder and loops around in the cylinder head to scavenge out the burnt mixture gasses from the previous power stroke. It is critical that the burnt gasses are scavenged from the combustion chamber, in order to make room for as much unburned gasses as possible. That is the key to making more power in a two-stroke engine. The more unburned gasses you can squeeze into the combustion chamber, the more the engine will produce. Now the loop of unburned mixture gasses has traveled into the exhaust pipe's header section. The gasses aren't lost because a compression pressure wave has reflected from the end of the exhaust pipe, to pack the unburned gasses back into the cylinder before the piston closes off the port. This is the unique super-charging effect of two-stroke engines. The main advantage of two-stroke engines is that they can combust more volume of fuel/air mixture than the swept volume of the engine. Example: A 125cc four-stroke engine combusts about 110cc of F/A gasses but a 125cc two-stroke engine combusts about 180cc of F/A gasses. [Type the document title] Page 8
3) Now the crankshaft has rotated past bottom dead center (BDC 180 degrees) and the piston is on the upstroke. The compression wave reflected from the exhaust pipe is packing the unburned gasses back in through the exhaust port as the piston closes off the port the start the compression phase. In the crankcase the pressure is below atmospheric producing a vacuum and a fresh charge of unburned mixture gasses is flowing through the reed valve into the crankcase.
4) The unburned mixture gasses are compresses and just before the piston reaches TDC, the ignition system discharges a spark causing the gasses to ignite and start the process all over again.
TYPES OF ENGINE Various types of engine used depending on the number of cylinders:
Flat: The cylinder lies flat. Half of the cylinders are located on one side of the crankshaft and the other half on other side. This makes a car more stable due to lower centre of gravity.
Inline: Inline have cylinders on top of the crankshaft. They stand in line at a vertical 90 degrees. Inline engines can run smooth and provide a lot of power.
V Type: The cylinders are located on opposite side of the crankshaft and are elevated up a varying amount of degrees depending on the manufacturer.
W Type: W type work well for a large number of cylinders because everything become more compact and shorter. These are found in few cars.
The engines are classified based on combustion (ignition), fuel used, cooling, application and construction.
Based on the combustion type: 1. External combustion engine. 2. Internal combustion engines.
Based on fuel used: 1. Diesel engines [Type the document title] Page 9
2. Petrol engines 3. CNG engines and LPG engines.
Based on cooling system: 1. Air cooled engines 2. Liquid cooled engines
Based on applications: 1. Stationary engine 2. Rocket engine 3. Automobile engine
Based on construction: 1. Inline engines 2. Opposed engines 3. Rotary engine 4. V-engines 5. W engines
INTAKE SYSTEM OF TWO STROKE ENGINE CARBEURETOR: It is a device which is used in SI engine for the purpose to provide a combustible homogeneous mixture of fuel and air in the required quantity and quality for efficient operation of the engine under all condition.
WORKING PRINCIPLE: [Type the document title] Page 10
The carburetor works on Bernoulli's principle: the faster air moves, the lower its static pressure and the higher its dynamic pressure. The throttle (accelerator) linkage does not directly control the flow of liquid fuel. Instead, it actuates carburetor mechanisms which meter the flow of air being pulled into the engine. The speed of this flow, and therefore its pressure, determines the amount of fuel drawn into the airstream. When carburetors are used in aircraft with piston engines, special designs and features are needed to prevent fuel starvation during inverted flight. Later engines used an early form of fuel injection known as a pressure carburetor.
The main disadvantage of basing a carburetor's operation on Bernoulli's principle is that, being a fluid dynamic device, the pressure reduction in a venturi tends to be proportional to the square of the intake air speed. The fuel jets are much smaller and limited mainly by viscosity, so that the fuel flow tends to be proportional to the pressure difference. So jets sized for full power tend to starve the engine at lower speed and part throttle. Most commonly this has been corrected by using multiple jets. In SU and other movable jet carburetors, it was corrected by varying the jet size. For cold starting, a different principle was used in multi-jet carburetors. A flow resisting valve called a choke, similar to the throttle valve, was placed upstream of the main jet to reduce the intake pressure and suck additional fuel out of the jets. OPERATION: [Type the document title] Page 11
A carburetor basically consists of an open pipe through which the air passes into the inlet manifold of the engine. The pipe is in the form of a venturi: it narrows in section and then widens again, causing the airflow to increase in speed in the narrowest part. Below the venturi is a butterfly valve called the throttle valve a rotating disc that can be turned end-on to the airflow, so as to hardly restrict the flow at all, or can be rotated so that it (almost) completely blocks the flow of air. This valve controls the flow of air through the carburetor throat and thus the quantity of air/fuel mixture the system will deliver, thereby regulating engine power and speed. The throttle is connected, usually through a cable or a mechanical linkage of rods and joints or rarely by pneumatic link, to the accelerator pedal on a car or the equivalent control on other vehicles or equipment. Fuel is introduced into the air stream through small holes at the narrowest part of the venturi and at other places where pressure will be lowered when not running on full throttle. Fuel flow is adjusted by means of precisely calibrated orifices, referred to as jets, in the fuel path
ADVANTAGES OF TWO STROKE ENGINE The power developed is nearly twice as compared to four stroke engine of the same dimensions and operating at same speed. Two stroke engines are lighter than four stroke engine for the same output and speed. It eliminates the valve arrangement which making it simpler. Work required to overcome the friction of the exhaust and suction strokes is saved. DISADVANTAGES OF TWO STROKE ENGINE [Type the document title] Page 12
The application of the two stroke petrol engine is that it is suitable only for the small engine. Such as motor cycles, scooters, lawn mowers etc. It has more fuel consumption and low thermal efficiency. It required more cooling and lubrication because of one power stroke in each revolution of crankshaft. Two stroke engines are liable to cause a heavier consumption of lubricating oil.
MODIFICATION IN TWO STROKE ENGINE: Technical modifications are basically made in order to increase the overall efficiency. Similarly modifications in a two stroke petrol engine are made to increase the power output of the engine. Getting air into an engine is the key to making power and there are many ways to increase performance of the engine. There are such forced induction, nitrous system, better port and valve shapes to improve flow. But for this project the technique that has been used was preheating of the air before the intake. PERCENTAGE INCREASE IN A/F RATIO OF 0.70MM IN THE INLET ma/ mf) = (cda/cdf) * (At/Af)* (Pa/Pf)
Where ma= mass of air flow mf =mas of fuel cda =coefficient of discharge for venturi cdf =coefficient of discharge of fuel nozzle At =area of throat Af =area of jet Pa =pressure inside the cylinder Pf)=pressure depression at throat
For 0.70 mm (ma/ mf) = 1/(*0.72*10^-6/4)* (cda/cdf) * (At)* (Pa/Pf) (ma/ mf) = 2598448.05*[(cda/cdf) * (At)* (Pa/Pf)]
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At a design and development stage an engineer would design an engine with certain aims in his mind. The aims may include the variables like indicated power, brake power, brake specific fuel consumption, exhaust emissions, cooling of engine, maintenance free operation etc. The other task of the development engineer is to reduce the cost and improve power output and reliability of an engine. In trying to achieve these goals he has to try various design concepts. After the design the parts of the engine are manufactured for the dimensions and surface finish and may be with certain tolerances. In order verify the designed and developed engine one has to go for testing and performance evaluation of the engines. Thus, in general, a development engineer will have to conduct a wide variety of engine tests starting from simple fuel and air-flow measurements to taking of complicated injector needle lift diagrams, swirl patterns and photographs of the burning process in the combustion chamber. The nature and the type of the tests to be conducted depend upon various factors, some of which are: the degree of development of the particular design, the accuracy required, the funds available, the nature of the manufacturing company, and its design strategy. In this chapter, only certain basic tests and measurements will be considered.
INTRODUCTION Conventional 2-stroke engines are commonly used for two-wheeled and marine vehicles that have small engine displacement. However problems such as unstable combustion, high fuel consumption rate, high HC emission, need to be resolved. 2-stroke engines have advantages over 4-stroke engines such as higher torque and power, being more compact and lighter. In order to solve these problems without compromising these advantages, a new 2-stroke engine was designed with pre heating unit to improve the performance of the engine and reduce the fuel consumption. In this study, performance of the 2 stoke engine was researched, and considerations concerning fuel consumption, performance and exhaust gas emissions were made. These findings were then compared via simulations done using the ANSYS software.
Objectives Understand the performance parameters in evaluation of IC engine performance, Calculate the speed of IC engine, fuel consumption, air consumption, etc., Evaluate the exhaust smoke and exhaust emission, and Differentiate between the performance of SI engine and CI engines.
PERFORMANCE PARAMETERS Engine performance is an indication of the degree of success of the engine performs its assigned task, i.e. the conversion of the chemical energy contained in the fuel into the useful mechanical work. The performance of an engine is evaluated on the basis of the following:
Specific Fuel Consumption. Brake Mean Effective Pressure. [Type the document title] Page 14
Specific Power Output. Specific Weight. Exhaust Smoke and Other Emissions
The particular application of the engine decides the relative importance of these performance parameters. For Example: For an aircraft engine specific weight is more important whereas for an industrial engine specific fuel consumption is more important. For the evaluation of an engine performance few more parameters are chosen and the effect of various operating condition, design concepts and modifications on these parameter are studied. The basic performance parameters are the following:
Power and Mechanical Efficiency. Mean Effective Pressure and Torque. Specific Output. Volumetric Efficiency. Fuel-air Ratio. Specific Fuel Consumption. Thermal Efficiency and Heat Balance. Exhaust Smoke and Other Emissions. Specific Weight.
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POWER AND MECHANICAL EFFICIENCY The main purpose of running an engine is to obtain mechanical power.
(a) Power is defined as the rate of doing work and is equal to the product of force and linear velocity or the product of torque and angular velocity.
(b) Thus, the measurement of power involves the measurement of force (or torque) as well as speed. The force or torque is measured with the help of a dynamometer and the speed by a tachometer.
The power developed by an engine and measured at the output shaft is called the brake power (bp) and is given by,
Where, T is torque in N-m and N is the rotational speed in revolutions per minute.
The total power developed by combustion of fuel in the combustion chamber is, however, more than the bp and is called indicated power (ip). Of the power developed by the engine, i.e. ip, some power is consumed in overcoming the friction between moving parts, some in the process of inducting the air and removing the products of combustion from the engine combustion chamber.
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It is the power developed in the cylinder and thus, forms the basis of evaluation of combustion efficiency or the heat release in the cylinder.
Where, pm = Mean effective pressure, N/m2, L = Length of the stroke, m, A = Area of the piston, m2, N = Rotational speed of the engine, rpm (It is N/2 for four stroke engine), and k = Number of cylinders.
Thus, we see that for a given engine the power output can be measured in terms of mean effective pressure. The difference between the ip and bp is the indication of the power lost in the mechanical components of the engine (due to friction) and forms the basis of mechanical efficiency; which is defined as follows:
The difference between ip and bp is called friction power (fp). fp ip bp
MEAN EFFECTIVE PRESSURE AND TORQUE Mean effective pressure is defined as a hypothetical/average pressure which is assumed to be acting on the piston throughout the power stroke. Therefore,
Where, Pm = Mean effective pressure, N/m2, Ip = Indicated power, Watt, L = Length of the stroke, m, A = Area of the piston, m2, N = Rotational speed of the engine, rpm (It is N/2 for four stroke engine), and k = Number of cylinders. If the mean effective pressure is based on bp it is called the brake mean effective pressure (bmep Pmb replace ip by bp in Eq. 5.5), and if based on ihp it is called indicated mean effective pressure (imep). Similarly, the friction mean effective pressure (fmep) can be defined as, fmap imep bmep
The torque is related to mean effective pressure by the relation
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Thus, the torque and the mean effective pressure are related by the engine size. A large engine produces more torque for the same mean effective pressure. For this reason, torque is not the measure of the ability of an engine to utilize its displacement for producing power from fuel. It is the mean effective pressure which gives an indication of engine displacement utilization for this conversion. Higher the mean effective pressure, higher will be the power developed by the engine for a given displacement. Again we see that the power of an engine is dependent on its size and speed. Therefore, it is not possible to compare engines on the basis of either power or torque. Mean effective pressure is the true indication of the relative performance of different engines.
SPECIFIC OUTPUT Specific output of an engine is defined as the brake power (output) per unit of piston displacement and is given by,
The specific output consists of two elements the bmep (force) available to work and the speed with which it is working. Therefore, for the same piston displacement and bmep an engine operating at higher speed will give more output. It is clear that the output of an engine can be increased by increasing either speed or bmep. Increasing speed involves increase in the mechanical stress of various engine parts whereas increasing bmep requires better heat release and more load on engine cylinder.
VOLUMETRIC EFFICIENCY
Volumetric efficiency of an engine is an indication of the measure of the degree to which the engine fills its swept volume. It is defined as the ratio of the mass of air inducted into the engine cylinder during the suction stroke to the mass of the air corresponding to the swept volume of the engine at atmospheric pressure and temperature. Alternatively, it can be defined as the ratio of the actual volume inhaled during suction stroke measured at intake conditions to the swept volume of the piston.
Volumetric efficiency =
The amount of air taken inside the cylinder is dependent on the volumetric efficiency of an engine and hence puts a limit on the amount of fuel which can be efficiently burned and the power output.
For supercharged engine the volumetric efficiency has no meaning as it comes out to be more than unity.
FUEL-AIR RATIO (F/A) Fuel-air ratio (F/A) is the ratio of the mass of fuel to the mass of air in the fuel-air mixture. Air-fuel ratio (A/F) is reciprocal of fuel-air ratio. Fuel-air ratio of the mixture affects the combustion phenomenon in that it [Type the document title] Page 18
determines the flame propagation velocity, the heat release in the combustion chamber, the maximum temperature and the completeness of combustion. Relative fuel-air ratio is defined as the ratio of the actual fuel-air ratio to that of the stoichiometric fuel-air ratio required to burn the fuel supplied. Stoichiometric fuel-air ratio is the ratio of fuel to air is one in which case fuel is completely burned due to minimum quantity of air supplied.
Relative fuel-air ratio, F r =
BRAKE SPECIFIC FUEL CONSUMPTION Specific fuel consumption is defined as the amount of fuel consumed for each unit of brake power developed per hour. It is a clear indication of the efficiency with which the engine develops power from fuel.
Brake specific fuel consumption (bsfc)=
THERMAL EFFICIENCY AND HEAT BALANCE Thermal efficiency of an engine is defined as the ratio of the output to that of the chemical energy input in the form of fuel supply. It may be based on brake or indicated output. It is the true indication of the efficiency with which the chemical energy of fuel (input) is converted into mechanical work. Thermal efficiency also accounts for combustion efficiency, i.e., for the fact that whole of the chemical energy of the fuel is not converted into heat energy during combustion.
Where, Cv = Calorific value of fuel, kJ/kg, and mf = Mass of fuel supplied, kg/sec. The energy input to the engine goes out in various forms a part is in the form of brake output, a part into exhaust, and the rest is taken by cooling water and the lubricating oil. The break-up of the total energy input into these different parts is called the heat balance. The main components in a heat balance are brake output, coolant losses, heat going to exhaust, radiation and other losses. Preparation of heat balance sheet gives us an idea about the amount of energy wasted in various parts and allows us to think of methods to reduce the losses so incurred.
EXHAUST SMOKE AND OTHER EMISSIONS Smoke and other exhaust emissions such as oxides of nitrogen, unburned hydrocarbons, etc. is nuisance for the public environment. With increasing emphasis on air pollution control all efforts are being made to keep them as minimum as it could be. Smoke is an indication of incomplete combustion. It limits the output of an engine if air pollution control is the consideration. Exhaust emissions have of late become a matter of grave concern and with the enforcement of legislation on air pollution in many countries; it has become necessary to view them as performance parameters. SPECIFIC WEIGHT Specific weight is defined as the weight of the engine in kilogram for each brake power developed and is an indication of the engine bulk. Specific weight plays an important role in applications such as power plants for aircrafts
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The following figure shows a cross section of the test engine. The main characteristic of the test engine is having intake valves which are on the cylinder head rather than the cylinder wall, on the opposite side to the exhaust port.
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Two Stroke Design Advantages The two stroke diesel engine has some advantages not found in the four stroke types which are of huge advantage to its application as an aero engine. Weight and Power With twice as many power strokes per engine revolution, a diesel two stroke engine produces more power than a four stroke diesel of the same displacement. A two stroke engine of the same power as a four stroke will not have the same weight and is usually heavier. Response and Acceleration Since every cylinder of a two stroke engine produces a power stroke for every revolution, there is a quick response to load changes. This becomes an advantage if the engine is equipped with a constant speed propeller where its RPM control will be quicker to react. Durability The two stroke "spreads the load", each piston is producing two lighter power impulses per two revolutions instead of the single heavy impulse of a four stroke. At normal loads and speeds, there is no load reversal on pistons, rods, and bearings; this continuous downward loading reduces impact load effects. Lighter loading permits two stroke diesels to use more compact structural and load bearing parts without over stressing. The lighter power impulses are produced by smaller displacement cylinders, which mean smaller pistons and shorter connecting rods for comparable performance. Shorter stroke lowers piston speed, a major factor in cylinder kit life. All of these weight and size advantages are achieved without sacrificing engine life. Smoothness Two stroke engines run smoother than four stroke engines. This is because two stroke engines have twice as many power impulses at the same RPM. The lighter, more frequent power impulses mean less damping is required from the flywheel; hence smaller, lighter flywheels can be used. This permits more rapid acceleration and unsurpassed transient load response. Lower Exhaust Temperatures More air goes through a two stroke engine than a four stroke for the same amount of fuel consumed. This results in lower exhaust temperatures for two stroke diesels and in longer valve and turbo life. Higher piston loads The piston loads in a two stroke diesel are higher than in a four stroke, mainly because there is always a downward pressure on the piston either by the combustion or by pushing out the exhaust gasses. There is no load reversal to build up the oil film on the piston pin. An innovative manufacturer uses a sort of ball bearing in the piston with pressure lubrication, this design also solves the problem with piston cooling and lubrication. Time will tell if this will work and be durable over thousands of engine hours. Indirect vs direct fuel injection [Type the document title] Page 21
A DI (direct injection) engine has the diesel fuel injected straight into cylinder almost at the top of the compression stroke. In the old days this meant that it burned and expanded very quickly, making it a noisy, rattly engine. This is why most diesel cars were IDI (indirect injection); the rough behaviour was fixed by injecting the fuel into a small precombustion chamber which is connected to the cylinder by a narrow passage. This slows down the combustion as the gasses have to escape through the narrow passage into the cylinder. This gives a softer bang and a smoother engine, but the gasses have to work harder, which spoils the efficiency a little. However, the newer breed of DI engines use other techniques to tame the behaviour: such as two stage injection, electronic control (FADEC), and acoustic shrouds and fancy engine mounts to mask the rattle. For an aircraft to have a DI engine this means extra hardware (2 stage injectors, common rail etc), dual electronics for redundancy, weight and all of this complexity for about 10% more efficiency. The IDI does not have all of these but in return is simpler and more reliable, which definitely is what we are looking for in an aircraft engine. Performance at altitude A two stroke diesel is able to run without a turbocharger just by using a roots blower to scavenge the engine from exhaust gasses. This roots blower is not a supercharger but supplies the engine with enough air to clean the cylinders for the next fuel injection and power stroke. This is seen as a naturally aspirated engine. Adding a turbocharger would give the advantage of more air thus more fuel which can be injected and the engine would able to sustain its rated power to a much higher altitude. More air means also better scavenging and cooler exhaust valves translating to a longer life and more reliable engine.