GOVERNMENT OF DELHI

PUSA INSTITUTE OF TECHNOLOGY

NEW DELHI-110012

DEPARTEMENT OF
PRINTING TECHNOLOGY

BASIC MECHANICAL ENGINEERING

LABORATORY LAB MANUAL (2019)

STUDENT NAME: ABHISHEK

BTE ROLL NO.: 1808201003
DEPARTEMENT: PRINTING TECHNOLOGY
YEAR: 2nd
SEMESTER: 3rd
 BME PRACTICAL FILE

PRINTING DEPARTMENT (PIT)

ROLL NO. - 1808201003

S. NAME OF PRACTICAL SIGNATURE

NO.
1 Study of main part of 4 stroke petrol and diesel engine

2 study of main part of 2 stroke petrol engine

3 study of ignition system of petrol engine

4 study fuel and air circuit of petrol engine

5 study of hydraulic brake

6 study of friction clutch

study of fuel injection system and air circuit of diesel
7 engine

8 study of cooling and lubricating system of IC engine

study of transmission of power through belt, pulley,
9 gears, chains and clutch

10 study of air conditioning system in building

 EXPERIMENT NO.1
AIM:
To study the main parts of a four stroke petrol and diesel engine by actually dismantling it.

PETROLL ENGINE
A four-stroke (also four-cycle) engine is an internal combustion IC engine in which the piston completes four
separate strokes while turning the crankshaft. A stroke refers to the full travel of the piston along the cylinder,
in either direction.

The four separate strokes are termed:

1. Intake: Also known as induction or suction. This stroke of the piston begins at top dead center (T.D.C.)
and ends at bottom dead center (B.D.C.). In this stroke the intake valve must be in the open position while the
piston pulls an air-fuel mixture into the cylinder by producing vacuum pressure into the cylinder through its
downward motion. The piston is moving down as air is being sucked in by the downward motion against the
piston.
2. Compression: This stroke begins at B.D.C, or just at the end of the suction stroke, and ends at T.D.C. In
this stroke the piston compresses the air-fuel mixture in preparation for ignition during the power stroke
(below). Both the intake and exhaust valves are closed during this stage.
3. Combustion: Also known as power or ignition. This is the start of the second revolution of the four
stroke cycle. At this point the crankshaft has completed a full 360 degree revolution. While the piston is at
T.D.C. the compressed air-fuel mixture is ignited by a spark plug (in a petrol engine) by heat generated by high
compression forcefully returning the piston to B.D.C. This stroke produces mechanical work from the engine to
turn the crankshaft.

4. Exhaust: Also known as outlet. During the exhaust stroke, the piston, once again, returns from B.D.C.
to T.D.C. while the exhaust valve is open. This action expels the spent air-fuel mixture through the exhaust
valve.
COMMAN PARTS FOR FOUR STROKE PETROL AND DIESEL ENGINE
 Cylinder:
 Cylinder or cylinder block is also known as Engine Cylinder Block. This is the part where combustion
of fuel is carried out. The main function of a cylinder is to allow the piston to reciprocate inside.

 In-cylinder bore, a fresh charge of the air-fuel mixture is ignited. This charge is compressed and
expanded hence piston can work further.

 Due to fuel combustion, extreme heat is generated. So, to carry out generated heat water jacket is
provided in a water cooled engine. In air-cooled engines, fins are provided to cool the cylinder block.

 To withstand high temperature and pressure, engine cylinder block is made from high grade cast iron.
The engine block is manufactured in one piece by casting process.

Crank Case:

 The crankcase is a body that holds all the other engine parts together. This is the largest parts of the
engine, but must be designed to be strong and light in weight.

 This part is also known as Oil Sump. The lube oil is filled in the crankcase for lubrication of engine. A
dipstick is also provided to check the level of lubrication oil.

 The main purpose of the crankcase is to contain the lube oil and serve as housing for the Crankshaft.

 The crankcase is typically made of cast iron in one piece via sand casting. Aluminum sand casting
process is used to manufacture crankcase from Aluminum.

Crank shaft:

 The main function of a crankshaft is to convert, linear to rotational motion. It means piston’s linear
motion is converted into rotary motion.
  To complete the conversion of these two motions, a crankpin is provided on a crankshaft. Crankpin is
also known as “crank throws”.

 Connecting Rod’s big end is bolted on crankpin while small end is fixed with piston using Gudgeon pin.

 The counterweight is provided on the crankshaft to partially balance the forces of the reciprocating
piston and reduces the load on crankshaft bearing journals.

 It is a one-piece part which cast in ductile steel. Nowadays, forged crankshafts are used due to lighter
weight, more compact design, and better inherent damping.

Connecting rod:

 As the name indicates, it connects the piston to the crankshaft so the power transmission is carried out. It
converts the reciprocating motion of the piston into rotary motion of the crankshaft.

 Connecting rod’s big end is connected to crankshaft while small end connects to the piston.

 In most cases, the connecting rod is hollow or provided with an internal cast oil duct to supply the
gudgeon pin with lubricant.

 Depending upon the requirement, connecting rod is made of High-grade aluminum, Micro-alloyed
steels. For the high-performance engine, it is made of titanium.

PISTON:

 This is a cylindrical part that slides to and fro in a hollow cylinder. The main function of the piston is to
transfer force from expanding gas in the cylinder to the crankshaft via a connecting rod.

 During suction stroke, it sucks the fresh charge of air-fuel mixture through the inlet valve. Compresses
during the compression stroke and also forces the burnt exhaust gases out of the cylinder through
the exhaust valve.
  The piston should be light in weight but sufficiently strong to withstand the gas pressure generated
because of combustion.

 So, Pistons are cast from aluminum alloys. Sometimes pistons are made from Cast Iron also.

PISTON RING:

 The piston ring is provided on the piston for good sealing and less friction in between cylinder wall and
piston.

 It prevents the compressed charge of fuel-air mixture from leaking to the other side of the piston.

 Piston Rings are split at one end so they can expand or slipped over the end of the piston.

 Quantity and size of rings are decided by the capacity of the engine. Three piston rings suggest for
a four-stroke engine while two piston rings suggested for a two-stroke engine.
 Oil ring is used for removing lubricating oil from the cylinder after lubrication. This ring prevents the
excess oil to mix with charge.

CAMSHAFT:

 The main function of a camshaft is to open and close the intake and exhaust valve at proper timing.
 So, to regulate the valve timing, lobs usually called cams are used. Cams are oval in shape and it exerts a
pressure on the valve to open and release to close.

 It takes driving force from crankshaft through gear train or chain and operates the inlet valve as well as
exhaust valve with the help of some other parts as like cam followers, push rod and rocker arms.

 An Engine performance mostly depends on camshaft design and proper functioning also.
  Camshafts can be made from several types of material. Out of that chilled iron camshafts have good
wear resistance since the chilling process hardens them. For high-quality camshaft billet steel is used.

VALVE:

 In every internal combustion engine, two types of valves are used.

 An intake valve is mounted on the cylinder head to supply the fresh charge of the mixture inside the
combustion chamber.

 An exhaust valve is also mounted on the cylinder head to permits the burnt gases to escape from the
cylinder bore at proper timing.

 The quantity of intake valve and the exhaust valve is depending upon the number of cylinders of an
engine.

 Inlet valve and the exhaust valve are operated by a camshaft. The camshaft uses lifters, pushrods and
rocker arms to activate the valves.

 Proper timing of the opening and closing of the valves is required for the engine to run smoothly. The
camshaft controls valve sequence and timing.

FLYWEEL:

 The flywheel is a disk that is mounted at one end of the crankshaft to provide inertia for the engine.

 Flywheel smoothes out some of the rpm and force deviation by its resistance to acceleration.

 The flywheel supplies the inertia required to prevent loss of engine speed and possible stoppage of
crankshaft rotation between combustion intervals.

 Flywheels are typically made of steel or cast iron.

PARTS FOR PETROL ENGINE ONLY:

SPARK PLUG:

 This part is used in Spark Ignition Engine (SI Engine) only. The main function of a spark plug is to
deliver electric current from an ignition system to the combustion chamber. So, compressed fuel/air
mixture is ignited by an electric spark.
 A spark plug consists of a metal threaded shell which is electrically isolated from a central electrode by a
porcelain insulator.

 The spark plugs metal shell is screwed into the engine’s cylinder head hence it is electrically grounded.

 Spark plugs usually require a voltage of 12,000–25,000V or more to produce spark properly.

 Spark plug replacement is rarely required due to its robust construction.

CARBURETOR:

 The main function of the carburetor is to blends air and fuel in the proper ratio for combustion in an
internal combustion engine.

 It converts petrol in a fine spray and mixes with air in the proper ratio as per requirement of the engine.

 Older engines used updraft carburetors, where the air enters from below the carburetor and exits through
the top. This has been replaced by downdraft carburetors.

 Nowadays carburetor is replaced by an electronically controlled system called fuel injection to regulate
the fuel-air mixture.

FUEL INJECTOR:

 Basically, an injector is one of the parts of total fuel delivery system.

 Fuel injectors are electronically controlled mechanical devices that are responsible for spraying
(injecting) the right amount of fuel into the combustion chamber of an engine.
  Injectors must also disperse the fuel at the right angle, pressure and spray pattern.

 The injectors are controlled by the Engine Control Unit (ECU). Engines have several fuel injectors and
they are often connected to a fuel rail.

 Fuel injectors are located in the head of the engine and are threaded into the combustion chamber with
the nozzle inside.

DIESEL ENGINE:
1. Suction stroke:
In the suction stroke of diesel engine the piston start moves from Top Dead Centre (TDC) of the cylinder
to Bottom Dead Centre (BDC) of the cylinder and simultaneously inlet valve opens. At this time air at
atmospheric pressure drawn inside the cylinder through the inlet valve due to the suction created. The
inlet valve remains open until the piston reaches the BDC of cylinder (not practically but theoretically).

2. Compression stroke:
After the piston passes BDC of the cylinder, it starts moving up. Both valves are closed and hence the
cylinder is sealed. The piston moves upward. This movement of piston compresses the air into a small
space between the piston and TDC of cylinder. The air is compressed into 1/22 (compression ratio: 22,
varies from engine to engine) or less of its original volume. Due to this compression a high pressure and
temperature is generated inside the cylinder. Both the inlet and exhaust valves do not open during any
part of this stroke. At the end of compression stroke the piston is at TDC the cylinder.

3. Power stroke:
At the end of the compression stroke when the piston is at TDC a pre metered quantity of diesel is
injected into the cylinder by the injector. The temperature inside the cylinder is very high which is
sufficient to ignite the fuel injected and this generates tremendous energy which is in the form of high
pressure which pushes down the piston. The connection rod carries this force to the crankshaft which
turns to move the vehicle. At the end of power stroke the piston reaches the BDC.

4. Exhaust stroke:
When the piston reaches the BDC after the power stroke, the exhaust valve opens. The pressure of the
burnt gases is higher than atmospheric pressure. This pressure difference allows burnt gases to escape
 through the exhaust port and the piston move through the TDC. At the end of exhaust all burn gases
escape (theoretically) and exhaust valve is closed.

PARTS FOR DIESEL ENGINE ONLY:

Injector:

 The performance of diesel engines is heavily influenced by their injection system design. In fact, the
most notable advances achieved in diesel engines resulted directly from superior fuel injection system
designs.

 While the main purpose of the system is to deliver fuel to the cylinders of a diesel engine, it is how that
fuel is delivered that makes the difference in engine performance, emissions, and noise characteristics.

 Unlike its spark-ignited engine counterpart, the diesel fuel injection system delivers fuel under
extremely high injection pressures.
Fuel injection pump:
 Can be a multi element type driven by a chain or gears from the crankshaft or camshaft.

 Each element is connected to a fuel injector. In some engines there is a pump for each cylinder and it is
driven off the camshaft.

Fuel left pump:

 Unless a day tank is fitted where the fuel is fed by gravity to the engine, it will be necessary to have a
fuel lift pump to get the fuel from the tanks to the fuel pump.

 A fuel lift pump can be a gear, diaphragm or plunger type.