LECTURE 4

MEC 2621- INTRODUCTION TO

AUTOMOTIVE ENGINEERING
By: Dr. SANISAH SAHARIN

MID TERM EXAM

21 OCTOBER 2015
WEDNESDAY
3.30 pm 5.00 pm

Engine ConstrucDon

CYLINDER BLOCK
The cylinder block is the foundation of the engine.
The parts are attached to the cylinder blocks are mainly:

Crankshaft with main bearings,

Piston with piston rings and connecting rods,
Valves with camshaft,
Intake and exhaust manifold
Cylinder head
Flywheel

 Most blocks are cast from gray iron (cast iron) or iron mixed
with other metals such as nickel and chromium.
Some blocks are cast from aluminum alloy.
As the aluminum alloy is too soft and wear rapidly.
Either cast iron or cast from aluminum alloy
containing silicon particles cylinder liners are used.
Aluminum weight much less and conducts heat more
rapidly than cast iron.
Aluminum alloy reduces vehicle weight and improves
fuel economy.

CYLINDER HEAD
It sits above the cylinders on
top of the cylinder block.
It closes in the top of the
c y l i n d e r, f o r m i n g t h e
combustion chamber.
This joint is sealed by a
head gasket. In most engines,
the head also provides space
for the passages that feed air
and fuel to the cylinder, and
that allow the exhaust to
escape.
The head can also be a place
to mount the valves,
s p a r k p l u g s, a n d
fuel injectors.

PISTON AND PISTON RINGS


Piston and piston ring
Piston: are made of aluminum alloy. Its diameter is
slightly smaller than the cylinder which allows the
piston to slide up and down
It is called sliding fit
Piston rings are installed on the pistons ring grooves for
preventing excessive blow-by. There are two types of
piston ring:
Compression ring: these form a sliding seal between
the piston and the cylinder wall.
So that the gases which is developed due to the
burning of A/F mixture will not able to go down to
the crankage.

 Oil control ring (oil rings) :These scrape off most of the
lubricating oil splashed on the cylinder wall and return the oil
to the crankcase.

 Pistons clearance

Pistons clearance is the distance between the cylinder wall
and the skirt.
The skirt is the lower part of the piston
Piston clearance is usually in the range of
0.025-0.12 mm.
In the running engine, the piston and rings move
on films of oil that fill the piston clearance.
If the clearance is too small, there is a loss of
power from high friction and sever wear.
If the clearance is too large, there is a chance of
piston slap.
Piston slap may collapse pistons skirt.

 A device that can be opened or closed to allow or to stop the

flow of liquid or gas.
Allows the IC engine cylinder to breath-in and breathout.
Each engine has at least two valves
An intake valve opens just before the intake stroke
begins.
Allows the air-fuel mixture to enter the cylinder
A exhaust valve opens just before the exhaust stroke
begins
Allows the burn gases to leave the cylinder

 The valve for the IC engine is usually a flat disk of metal with a
long rod known as the valve stem.
The stem is used to push down on the valve and open it,
with a spring generally used to close it when the stem is
not being pushed on.
The valves are operated by a valve train which is comprised of
valves, the valve stem, cam and cam followers.
The engine normally operates the valves by pushing on the
stems with cams (rotating or sliding piece in a
mechanical linkage used especially in transforming rotary
motion into linear motion or vice-versa) and cam followers .

ENGINE VALVES

 The shape and position of the cam determines the valve

lift and when and how quickly (or slowly) the valve is
opened.
The cams are normally placed on a fixed camshaft which
is then geared to the crankshaft, running at half
crankshaft speed in a four-stroke engine.

What are the advantage and disadvantage of using

bigger shape exhaust valve.
What are the merit and demerit of using bigger size of
intake valve ?

Advantage: Increased volumetric efficiency due to
very large port openings . This is important when
an engine operates over a wide RPM range.

Disadvantage: perfect sealing is difficult to achieve

 Arrangement of valves and valve trains

Engine valve allows the engine to breath.
The intake valve open to admit the A/F mixture to the
engine cylinders.
The exhaust valves open to allow burned gases to exit or
exhaust from the engine cylinders.
Cam on rotating camshaft operate the valve train, which
open the valves.
Location of the camshaft
Either on the cylinder head or in the cylinder block.
Types of camshaft drive
Camshaft are driven by timing gears, sprockets and
timing chain or sprockets and toothed timing belt

 Types of valve train

Two basic types of valve train
Overhead camshaft- SOHC and DOHC
Camshaft in block with pushrod


Number of valves per cylinder
Normally each cylinder of the engine has two valves
Some have multi-valve cylinder engine
PURPOSE of these added valves is to allow the engine
to breathe more freely.

Camshaft timing
Camshaft timing is the relationship between the
operation of camshaft and crankshaft
Camshaft is driven by crankshaft
Crankshaft makes two complete revolutions (720
degree) to complete the four piston strokes
This makes the engine a four cycle engine
Word cycle means a series of events that repeat
themselves

 Two crankshaft revolutions make one revolution of the

camshaft
One revolution of camshaft opens each valve once.
1:2 gear ratio is needed to complete the rotation of the
camshaft by the crankshaft
Therefore, the camshaft diameter must be twice time
larger than the crankshaft sprocket diameter (i.e.
2dcrankshaft= Dcamshaft )

 M e t h o d s o f c a m s h a f t
driving
T i m i n g g e a r : d r i v e
camshaft in cylinder block
T i m i n g c h a i n : d r i v e
camshaft in cylinder block
T i m i n g c h a i n : d r i v e
camshaft on cylinder head
T i m i n g b e l t : d r i v e
camshaft on cylinder head

CRANKSHAFT
The crankshaft is a one piece casting or forging of heattreated alloy steel.
Counter-weights placed opposite the crankpins balance
the crankshaft.
The output end of the crankshaft has the flywheel or
drive plate attached to it.
The front end has a sprocket drives the camshaft, the
vibration damper and the pulleys.
Electromagnetic pick-up sensor is placed on the
crankshaft in order to calculate the engine speed (rpm)
and to maintain the piston position and firing order.

HARMONIC BALANCER/
VIBRATION DAMPER
Vibration damper is a component that prevents the
unwanted vibration or bunching or twisting affect.
The power strokes tend to twist the crankshaft;
Each power stroke applies a very high force (18,000 N)
on the crankpin and it;
might pushes the rest of the crankpins of the
crankshaft and crankshaft untwists.
this twist-untwist action repeats in every power stroke
this action tends to create an oscillating (back and
forth) motion in the crankshaft
TORSIONAL VIBR ATION which prevents the
crankshaft from breaking.

 VibraDon damper helps the crankshaM to control the tensional

vibraDon and allow the crankshaM to rotate according to the applying
force of the power stroke.
It mounted on the front end of the crankshaft.
This forms the hub to which the crankshaM pulley aQaches.
The inerDa ring is bonded through the rubber ring to the pulley.
The inerDa ring has a damping eect which tends to hold the
crankshaM to a constant speed.

INTAKE MANIFOLD
The intake manifold is a set
of tubes.
These tubes carry A/F
mixture from throttle
valve to the intake
ports in the cylinder
head.

EXHAUST MANIFOLD
The exhaust manifold is a
set of tubes.
It carries exhaust gas
from the cylinder head
to the exhaust system
The exhaust gas passes
through the catalytic
converter, the muffler
and the resonator.
T h e c a t a l y t i c
converter converts
m o s t o f t h e
pollutants in the
exhaust gas to
h a r m l e s s
substances.
The muffler and the
resonator reduce
exhaust noise.

FIRING ORDER
The firing order is the sequence of power delivery of each
cylinder in a multi-cylinder reciprocating engine.
This is achieved by sparking of the spark plugs in a
gasoline engine in the correct order, or by the sequence
of fuel injection in a Diesel engine.
When designing an engine, choosing an appropriate firing
order is critical
To minimizing vibration and for achieving smooth
running,
Correct firing order also provide long engine fatigue life
and user comfort.

 In a gasoline engine, the correct firing order is obtained by

the correct placement of the spark plug wires on the
distributor.
In a modern engine with an engine management system
and direct ignition, the Engine Control Unit (ECU) takes
care of the correct firing sequence.

 The crankpin and crankshaft arrangement determine the

firing order.
Firing orders for the same type of engine may differ.
Two firing orders for in-line
4-cylinders engines are 1-3-4-2 and 1-2-4-3

 6-Cylinders engines 1-5-3-6-2-4

The complete firing order of a four-cycle engine represents
two complete revolutions of the crankshaft.
This is 720 degrees of crankshaft rotation
Firing impulse occurs every 120 degrees of
crankshaft rotation (720/6=120).
When piston number 1 is at TDC on the end of
compression stroke, piston number 6 is at TDC on
the end of the exhaust stroke.

Il faut tre matelot avant dtre

capitaine