EXPERIMENT NO.

:- 6

AIM:- LOCATE AND DRAW THE COOLING CIRCUIT OF MULTI-CYLINDER

ENGINE AND STUDY THE CONSTRUCTION OF RADIATER AND ALSO LOCATE AND
DRAW THE LUBRICATING CIRCUIT OF A SINGLE CYLINDER DIESEL ENGINE.

APPARATUS REQUIRED:-
Model of cooling circuit and lubricating circuit .
THEORY:-
COOLING CIRCUIT OF MULTI-CYLINDER ENGINE
A car engine produces a lot of heat when it is running, and must be cooled continuously to avoid
engine damage. Generally this is done by circulating coolant liquid usually water mixed with an
antifreeze solution through special cooling passages. Some engines are cooled by air flowing over
finned cylinder casings.

A water-cooled engine block and cylinder head have interconnected coolant channels running
through them. At the top of the cylinder head all the channels converge to a single outlet. A pump,
driven by a pulley and belt from the crankshaft, drives hot coolant out of the engine to the radiator,
which is a form of heat exchanger. Unwanted heat is passed from the radiator into the air stream,
and the cooled liquid then returns to an inlet at the bottom of the block and flows back into the
channels again. Usually the pump sends coolant up through the engine and down through the
radiator, taking advantage of the fact that hot water expands, becomes lighter and rises above cool
water when heated. Its natural tendency is to flow upwards, and the pump assists circulation. The
radiator is linked to the engine by rubber hoses, and has a top and bottom tank connected by a
core a bank of many fine tubes. The tubes pass through holes in a stack of thin sheet-metal fins,
so that the core has a very large surface area and can lose heat rapidly to the cooler air passing
through it. On older cars the tubes run vertically, but modern, low-fronted cars have crossflow
radiators with tubes that run from side to side.

In an engine at its ordinary working temperature, the coolant is only just below normal boiling
point. The risk of boiling is avoided by increasing the pressure in the system, which raises the
boiling point. The extra pressure is limited by the radiator cap, which has a pressure valve in it.
Excessive pressure opens the valve, and coolant flows out through an overflow pipe. In a cooling
system of this type there is a continual slight loss of coolant if the engine runs very hot. The
system needs topping up from time to time. Later cars have a sealed system in which any overflow
goes into an expansion tank, from which it is sucked back into the engine when the remaining
liquid cools.

CONSTRUCTION OF RADIATER
A radiator is a heat exchanger that assists in the transfer of heat from an internal combustion
engine to the air in the surrounding environment. This is actually accomplished through the
mechanism of convection rather than thermal radiation. In modern water cooling systems,
coolant is circulated through the engine and radiator with the help of a water pump. The coolant
is heated up by the engine, and then cooled down by the radiator, and then the cycle is repeated.

The purpose of the radiator is to cool down the water received from the engine. The radiator
consists of three main parts:
(i) upper tank
(ii) lower tank
(iii) tubes.

Hot water from the upper tank, which comes from the engine, flows downwards through
the tubes. The heat contained in the hot water is conducted to the copper fins provided
around the tubes.
An overflow pipe, connected to the upper tank, permits excess water or steam to escape.
There are three types of radiators:
 (a) gilled tube radiator
(b) tubular radiator
(c) honey comb or cellular radiator

Gilled tube radiator:- This is perhaps the oldest type of radiator, although it is still in use.
In this, water flows inside the tubes. Each tube has a large number of annular rings or fins pressed
firmly over its outside surface.
Tubular radiator:-The only difference between a gilled tubes radiator and a tubular one
is that in this case there are no separate fins for individual tubes. The radiator vertical tubes
pass through thin fine copper sheets which run horizontally.
Honey comb or cellular radiator:- The cellular radiator consists of a large number
of individual air cells which are surrounded by water. In this, the clogging of any passage
affects only a small parts of the cooling surface. However, in the tubular radiator, if one tube
becomes clogged, the cooling effect of the entire tube is lost.

LUBRICATING CIRCUIT OF ENGINE

I. C. engine is made of many moving parts. Due to continuous movement of two metallic
surfaces over each other, there is wearing moving parts, generation of heat and loss of power
in the engine lubrication of moving parts is essential to prevent all these harmful effects.
PURPOSE OF LUBRICATION:-
Lubrication produces the following effects: (a) Reducing friction effect (b) Cooling effect (c)
Sealing effect and (d) Cleaning effect.
a) Reducing frictional:- effect: The primary purpose of the lubrication is to reduce friction
and wear between two rubbing surfaces. Two rubbing surfaces always produce friction.
 The continuous friction produce heat which causes wearing of parts and loss of power.
In order to avoid friction, the contact of two sliding surfaces must be reduced as far a
possible. This can be done by proper lubrication only. Lubrication forms an oil film
between two moving surfaces. Lubrication also reduces noise produced by the
movement of two metal surfaces over each other.
b) Cooling effect:- The heat, generated by piston, cylinder, and bearings is removed by
lubrication to a great extent. Lubrication creates cooling effect on the engine parts.
c) Sealing effect:- The lubricant enters into the gap between the cylinder liner, piston and
piston rings. Thus, it prevents leakage of gases from the engine cylinder.
d) Cleaning effect:- Lubrication keeps the engine clean by removing dirt or carbon from
inside of the engine along with the oil.

VARIOUS LUBRICATION SYSTEMS

The various lubrication systems used for lubricating the various parts of engine are classified
as:-

1. Mist lubrication system

2. Wet sump lubrication system
3. Dry sump lubrication system
4. Splash lubrication system.

1. Mist Lubrication System:-

Mist lubrication system is a very simple type of
lubrication. In this system, the small quantity of
lubricating oil (usually 2 to 3%) is mixed with the fuel (preferably gasoline). The oil and fuel
mixture is introduced through the carburetor. The gasoline vaporized and oil in the form of mist
enters the cylinder via the crank base. The droplets of oil strike the crank base. The droplets of
oil strike the crank base, lubricate the main and connecting rod bearings and the rest of the oil
lubricates the piston, piston rings and cylinder.

The system is preferred in two stroke engines where crank base lubrication is not required. In a
two-stroke engine, the charge is partially compressed in a crank base, so it is not possible to have
the oil in the crank base.

This system is simple, low cost and maintenance free because it does not require any oil pump,
filter, etc. However, it has certain serious disadvantages. Therefore, it is not popular among the
lubrication system. Its disadvantages are the following:

1. During combustion in the engine, some lubricating oil also burnt and it causes heavy
exhaust and forms deposits on the piston crown, exhaust port and exhaust system.
2. Since the lubricating oil comes in contact with acidic vapours produced during the
combustion, it gets contaminated and may result in the corrosion of the bearings surface.
 3. When the vehicle is moving downhill, the throttle is almost closed, and the engine suffers
lack of lubrication as supply of fuel is less. It is a very serious drawback of this system.
4. There is no control over the supply of lubricating oil to the engine. In normal operating
conditions, the two-stroke engines are always over-oiled. Thus consumption of oil is also
more.
5. This system requires thorough mixing of oil and fuel prior to admission into the engine. It
requires either separate mixing or use of some additives.

2. Wet-Sump Lubrication System:-

In the wet-sump lubrication system, the bottom of the crank case contains an oil pan or sump that
serves as oil supply, oil storage tank and oil cooler. The oil dripping from the cylinders, bearings
and other parts, fall under gravity back into the sump, from where it is picked up by pump and
recirculated through the engine lubrication system.

3. Dry-Sump Lubrication System:-

The dry sump pump is designed with multiple stages, to insure that all the oil is scavenged from
the pan. This also results in removing excess air from the crankcase, and is the reason they are
called “dry sump” meaning the oil pan is essentially dry. The oil supply is carried from an
external tank. The oil from the sump is pumped by means of a scavenging pump through filters
to the external storage tank. The oil from the storage tank is pumped to engine cylinder through
and oil cooler. The oil pressure may vary from 3 to 8 bar.
The dry-sump lubrication system is generally used for heavy-duty engines.

4. Splash Lubrication System:-

Splash lubrication system is used on small, stationary four-stroke engines. In this system, the cap
of the big end bearing on the connecting rod is provided with a scoop which strikes and dips into
the oil-filled through at every revolution of the crank shaft and oil is splashed all over the interior
of crank case into the piston and over the exposed portion of the cylinder

A hole is drilled through the connecting rod cap through which the oil passes to the bearing
surface. Oil pockets are provided to catch the splashed oil over all the main bearings and also the
cam shaft bearings. From these pockets oil passes to the bearings through drilled hole. The surplus
oil dripping from the cylinder flows back to the oil sump in the crank case.