1 Edited 2005

1.
Introduction
Topics to be discussed
 Heat Engine
 Brief Historical Development of IC Engines
 Engine Components and Basic Engine
Nomenclature
 IC Engine Classification
 Four stroke Cycle SI engines
 Four stroke CI engines
 Two stroke Engines
Heat Engine
 An engine is a device which transforms one form of

energy into another form
 A heat engine is a device which transforms the

chemical energy of a fuel into thermal energy and
uses this energy to produce mechanical work
Mechanical
Fuel Energy Thermal Energy Energy
Combustion Heat Engine

Work can be completely converted into heat, but the inverse
is not true
The transfer of energy by heating is accompanied with the
entropy transfer
 classified into two broad types:
 External combustion engines, and
 Internal combustion engines
 External combustion engine: the products of

combustion of air and the fuel transfer to a
second fluid which is the working fluid of the
cycle
 Internal combustion engine: the products of
combustion are directly the motive fluid
 Advantage of IC engines:
Greater mechanical simplicity
Lower ratio of weight and bulk to output due to the
absence of auxiliary apparatus like boiler and
condenser
Lower first cost
Higher overall efficiency
Lesser requirement of water for dissipation of energy
through cooling system
 Advantage of external combustion engine:
use of cheaper fuels including solid fuels
high starting torque (self starts)
Gas & Steam Turbine
Turbo-Jet
Turbo-Prop
Rocket Turbo-Fan
Evolution of Engines
 Stirling Engine (Hot air engine)
 Stirling engine was invented in 1816 by Robert Stirling
 External combustion for heat addition
 Carnot cycle engine
Beta type
Alpha type
Stirling Engine
 Lenoir Engine (Internal Combustion) 1860
 Jean Joseph Étienne Lenoir developed the first internal
combustion engine,
 resembled a single-cylinder, double-acting horizontal
steam engine, with two power strokes per revolution
 a single-cylinder two-stroke engine
 Induction of a mixture of coal gas and air (air/gas)
 exhaust of the burnt mixture were controlled by slide
valves
 ignited by a "jumping spark" ignition system
• the burnt mixture were controlled by slide valves
• combustion occurred on both sides of the piston,
but considering just one combustion chamber
Efficiency ~ 3-5%
~6 hp
 Atmospheric or Free-piston engine (Otto -Langen
1866 )
 At the world exhibition of 1867 in Paris, Nikolaus
August Otto's (1832-1891) and Eugen Langen's
(1833-1895) success with the atmospheric engine
 The engine was working with illuminating gas, too, and
achieved a better efficiency of about 30 percent than the
Lenoir engines because of a better technology
 the fuel consumption was about half that of the Lenoir
Engine.
 The main features of the engine were a
 long vertical cylinder,
 Heavy piston and
 Racked piston rod
 The Otto engine (in1876 he built his first four-stroke engine )
 Otto had great success with his atmospheric engines
 solution of the problems which prevented the explosion engines from
delivering a regular work: The burn was jerky.
 Otto finally found the right way. His improvements were fantastic:
 He learned how to let a mixture burn slowly and safely. At the same time,
he could hold the performance of the engine on a high level by a
compression of the gas
 the otto engine was developed very quickly therefore, better accessories
(carburetor, ignition mechanism, valves, pistons) were produced, the
cylinder capacity, engine speed and the horsepower performances were
increased dramatically
 Otto experienced a 100 HP Otto engine before he died (His first four-
stroke engine had a power of approx. 3 HP)
 Four-stroke I.C engine ( Nicolaus Otto in 1877)
 Four up-down strokes are involved:
 Downward intake stroke coal-gas and air enter the piston
chamber,
 Upward compression stroke the piston compresses the
mixture,
 Downward power stroke ignites the fuel mixture by electric
spark, and
 Upward exhaust stroke releases exhaust gas from the
piston chamber
 Fuel question
 The exploration of oil wells in the USA occurring as
a result of the pioneer drilling by Drake in 1859.
 In1883, Karl Benz and Gottlieb Daimler, who are
still very famous because of their cars, built an
engine, where gasoline is induced into the induction
air through a surface carburetor
 For the first time people succeeded in using liquid
fuels.
 A large step was done toward the automobile with
this, because liquid fuel needs less space than
gaseous and can be transported more easily
 Diesel Engine (Rudolph
Diesel 1893)
 The first Diesel Engine
 Four Stroke Compression
Ignition Engine
 Wankel (Rotary Engine) (1929)
 Operate in four stroke principle
 Advantages:
 High power output

 More reliable
 Simple structure and less moving parts
 Lower production cost
 Lighter and higher speed
 Disadvantages :
 Air-fuel mixing problem
 High hydrocarbon emissions
 Less fuel efficiency
 Sealing difficulty
 Current Engine Challenges
 Limited energy supply (Higher fuel efficiency)
 Global warming effect
 Environmental protection (Less pollutant emissions)
Evolution of Heat Engines
 Possible options to power future vehicles
 IC engines are still competitive for the near future
 Technology advancement
 Infrastructure
 Manufacture cost
I.C Engine Fundamentals
 Major Engine Parts
 Cylinder Block  Valves
 Cylinder Head  Valve Springs
 Crankshaft  Pistons
 Camshaft  Connecting Rod
 Timing Chain  Piston Ring
 Bearing shell  Cylinder sleeve
 Oil pump
 Inlet manifold
 Water pump
 Exhaust manifold
 Fly wheel
 Rocker Arm
 Engine Systems
 An engine must at least include the following
systems to operate
 Air supply and Exhaust system
 Fuel supply system
 Combustion system
 Ignition system (SI)
 Cooling system
 Lubricating system
 Starting system
 Electrical power supply (battery or generator)
pressure = force
area
force = pressure x area
pressure = force
area
force = pressure x area
Ignition system
ignition system
crank mechanism
intake system
ignition system
crank mechanism
intake system
exhaust system
ignition system
crank mechanism
intake system
thermostat exhaust system
cooling system
ignition system
crank mechanism
intake system
thermostat exhaust system
cooling system
ignition system
lubrication system
crankcase vent
 Working Principle of Engines
 Four- Stroke Ignition Engine
 The cycle of operation completed in 4 strokes of piston
operation ( 2 revolutions of Crankshaft)
 Each stroke consists of 1800 of crankshaft rotation.
 During 4 strokes, there are 5 events
 Suction
 Compression
 Combustion
 Expansion
 Exhaust
 Nomenclature
 Cylinder Bore (d) or B
 The nominal inner diameter of the working cylinder
 Piston Area (A)
 The area of circle diameter equal to the cylinder bore
 Stroke (L) or (s)
 The nominal distance through which a working piston moves between two successive
reversal of its distance of motion
 Dead Centers
 The potion of the working piston at the moment when the dirction of piston motion
reversed at either end of the stock
 Top Dead Center (TDC) or Inner Dead Center IDC) – when the piston is a farthest from the
crankshaft
 Bottom Dead Center (BDC) or outer Dead Center (ODC) – when the piston is nearest to the
crankshaft
 Displacement Volume (Vs)
 The nominal volume swept by the working piston
when traveling from one dead center to the other
 Vs = A Х L= π/4(d2L)
 Clearance Volume (Vc)
 The nominal volume of the combustion chamber above the piston
when it is at TDC is the clearance volume.
 Compression Ratio (r)
 It is the ratio of the total cylinder volume when the piston is at the
BDC, VT, to the clearance volume vc
VT  VC + VS  V 
r= =  =1 +  s 
VC  VC   VC 
I.C Engine Funda (SI Engine)
 Otto Cycle
 Intake
 Compression,
 Combustion
 Power
 Exhaust
fuel
air air + fuel
pressure

volume
TDC BDC
I.C Engine Fanda (SI Engine)
pressure
stoichiometric mixture
 
volume
TDC BDC
pressure

 
volume
TDC BDC
pressure

 
volume
TDC BDC


pressure

 
volume
TDC BDC


pressure


 
volume
TDC BDC


pressure


 

volume
TDC BDC


pressure


 
volume
TDC BDC
Work =  (pressure x volume)
positive work


pressure


 
exhaust gas residual
volume
TDC BDC
negative work
I.C Engine Funda-Some Problem
intake tuning exhaust tuning emissions
mixture preparation combustion, autoignition CxHx

CO
wear
NOx
inertia
lubrication
I.C Engine Funda (Diesel Engine)
pressure
volume
TDC BDC
negligible negative work
The Diesel Engine

I.C Engine Funda (Diesel Engine)
10000 - 20000 psi
The Diesel Engine

I.C Engine Funda (2- S Engine)
 The two stroke engine
employs the crankcase as
well as the cylinder to
achieve all the elements of
the Otto cycle in only two
strokes of the piston.
upward stroke of the piston During the downward stroke
Intake Valve open Crank Case compression Transfer port Opening

Scavenging
upward stroke of the piston Down ward stroke of the piston
Cylinder compression
Power Stroke Exhaust Stroke
another intake stroke is
Crankcase compression Scavenging
happening beneath the piston
The Two Stroke Engine



 two engine/fuel types
 gasoline (premixed)
Four Stroke Gasoline Engine  diesel (diffusion)
 four stroke, two stroke
Four Stroke Diesel Engine  intake
 compression
 power
Two Stroke Gasoline Engine  exhaust
 problem areas
 performance
 Emissions
 Fuel economy
I.C. Engine Fundamentals
 Comparison of SI & CI Engines
Description SI Engine CI Engine
Basic Cycle Otto Cycle Heat addition @ V=C Diesel cycle, Heat addition @P=C
Gasoline, Highly volatile fuel, Diesel oil, non volatile fuel, self-
Fuel
self ignition temp is high ignition temp is comparatively low
Fuel-air mixture introduced Fuel directly injected to the com.
Introduction of
during suction stroke Chamber at high pressure (fuel
Fuel
(Carburettor is necessary) pump and injector is necessary
The quantity of fuel is regulated in
Throttle controls the quantity of
Load control the pump. Air quantity is not
mixture introduce
control
Required an ignition system with Ignition system & sparkplug are

Ignition
spark plug not necessary
Description SI Engine CI Engine
Compression 6-10, upper limit is fixed by anti 16-20 upper limit is limited by
ratio knock quantity of fuel weight increase of the engine
They are high speed engines They are low speed engines (
Speed (light weight & homogeneous heavy weight & heterogeneous
combustion) combustion)
Thermal Lower thermal Efficiency (lower Higher thermal efficiency (higher

Efficiency compression ratio compression ratio)
Lighter due to lower peak Heavier due to higher peak

weight
pressure pressure
 Comparison of 2-S & 4-S Engines
4-S Engines 2-S Engine
The cycle is completed in two strokes
The cycle completed in 4 strokes of
of the piston or one power strokes
piston or 2-revo. of crankshaft
obtained in every revo. of crakshaft
Turning moment is not uniform & Turning moment is more uniform &
hence a heavier flywheel is needed hence a lighter flywheel can be used
Power produced for the same size of

The power produced for the same size engine is more (Theoretically twice,
engine is less (2 revo gives 1 power) actually 1.3 times) due to 1 Power
stroke in 1 revo. Of Cra Sh)
Lesser cooling & lubrication Greater cooling & lubrication
requirement requirements
Lower rate of wear & tear Higher rate of wear & tear
4-S Engines 2-S Engine
Contains valve & Valve mechanisms to No valves but ports (some 2-s engines are
open & close valves fitted with exhaust valves or reed valve)
The initial cost is very high (Coz of heavy Initial cost of the engine is less (Coz od
wt. & complicated valve mechanism) light wt. & simplicity)
Volumetric Efficiency is more (Coz of more Volumetric Efficiency is low (Coz of lesser
time for induction) time for induction)
Thermal Efficiency is higher, part load Thermal Efficiency is less, part load
efficiency is better efficiency is poor compared 4-s engine
Used where Efficiency is important Used where low cost, compactness & Light
( in Cars, Buses, aero planes, etc… Wt. are important (in Scooters, Motercycles
Classification of I.C. Engines
 Engines can be classified according to the following Points
 Application
 Basic Engine Design
 Operating Cycle
 Working Cycle
 Valve/Port Design and Location
 Fuel
 Mixture Preparation
 Ignition
 Stratification of Charge
 Combustion Chamber Design
 Method of Load Control
 Cooling
 Application
 Automotive: (i) Car , (ii) Truck/Bus (iii) Off-highway
 Locomotive
 Light Aircraft
 Marine: (i) Outboard (ii) Inboard (iii) Ship
 Power Generation: (i) Portable (Domestic) (ii) Fixed (Peak Power)
 Agricultural: (i) Tractors (ii) Pump sets
 Earthmoving: (i) Dumpers (ii) Tippers (iii) Mining Equipment
 Home Use: (i) Lawnmowers (ii) Snow blower (iii) Tools
 Others
Basic Engine Design:
1. Reciprocating
(a) Single Cylinder
(b) Multi-cylinder
(I) In-line
(ii) H, U,V,W & X
(iii) Radial
(iv) Opposed Cylinder
(v) Opposed Piston
2. Rotary:
(a) Single Rotor
(b) Multi-rotor
Position & Number
of Cylinders
 Radial Engine
Wankel (Rotary Piston Engine)

Operating Cycle
 Otto (For the Conventional SI Engine)

 Atkinson (For Complete Expansion SI Engine)
 Miller (For Early or Late Inlet Valve Closing type
SI Engine)
 Diesel (For the Ideal Diesel Engine)
 Dual (For the Actual Diesel Engine)
4. Working Cycle (Strokes)
1. Four Stroke Cycle:

(a) Naturally Aspirated
(b) Supercharged/Turbocharged
2. Two Stroke Cycle:
(a) Crankcase Scavenged
(b) Loop Scavenged
(i) Inlet valve/Exhaust Port
(ii) Inlet Port/Exhaust Valve
(iii) Inlet and Exhaust Valve
7. Method of increasing inlet
pressure (power boosting)
1. Supercharger
2. Turbocharger
(a) Valve/Port Design
1. Poppet Valve
2. Rotary Valve
3. Reed Valve
4. Piston Controlled Porting
(b) Valve Location
1. The T-head
2. The L-head
3. The F-head
4. The I-head:
(i) Over head Valve (OHV)
(ii) Over head Cam (OHC)
Valve Location
6. Fuel
1.Conventional:
(a) Crude oil derived (i) Petrol (ii) Diesel
(b) Other sources: (i) Coal
(ii) Wood (includes bio-mass)
(iii) Tar Sands
(iv) Shale
2. Alternate:
(a) Petroleum derived (i) CNG (ii) LPG
(b) Bio-mass Derived (i) Alcohols (methyl and ethyl)
(ii) Vegetable oils
(iii) Producer gas and biogas
(iv) Hydrogen
3. Blending
4. Dual fueling
7. Mixture Preparation
1. Carburetion
2. Fuel Injection
(i) Diesel
(ii) Gasoline
(a) Manifold
(b) Port
(c) Cylinder
8. Ignition
1. Spark Ignition
(a) Conventional
(i) Battery
(ii) Magneto
(b) Other methods
2. Compression Ignition
10. Combustion Chamber Design
1. Open Chamber:
(i) Disc type
(ii) Wedge
(iii) Hemispherical
(iv) Bowl-in-piston
(v) Other design
2. Divided Chamber: (For CI):
(i) Swirl chamber
(ii) Pre-chamber (For SI)
(i) CVCC
(ii) Other designs
9. Charge Stratification
1. Homogeneous Charge (Also Pre-mixed charge)
2. Stratified Charge
(i) With carburetion
(ii) With fuel injection
11. Method of Load Control
1. Throttling: (To keep mixture strength constant) Also called Charge

Control Used in the Carbureted S.I. Engine
2. Fuel Control (To vary the mixture strength according to load)
Used in the C.I. Engine
3. Combination
Used in the Fuel-injected S.I. Engine.
12. Cooling
1. Direct Air-cooling
2. Indirect Air-cooling (Liquid Cooling)
3. Low Heat Rejection (Semi-adiabatic) engine.

 13- Various Operational Modes
 Electric Drive Motors

 Hybrid Electric Engine
Applications of Engines
IC Engine CI Engine
Types Application Types Application

Automotive
Locomotive
Gasoline Engines Marine Steam Engine
Marine
Aircraft
Experimental
Industrial
Gas Engines Sterling Engine SpaceVehicles
Power
submarines
Automotive
Locomotive Power
Diesel Steam Turbine
Power Large Marine
Marin
Power
Aircraft Closed cycle Gas Power

Gas turbine
Industrial Turbine Marine
Marine
S. Name of the Part Material Used Method of
No Manufacture
1 Cylinder Cast iron, alloy steel casting
2 Cylinder head Cast iron, aluminum alloy Casting, forming
3 Piston Cast iron, aluminum alloy Casting, forging
4 Piston rings Silicon cast iron casting
5 Wrist or piston Steel Forging
(gudgeon)pins
6 Valves Specially alloyed steels Forging
7 Connecting rod Steel Forging
8 Crankshaft Alloy steel, SG iron Forging
9 Crankcase Aluminum alloy, steel, cast iron casting
10 Cylinder liner Cast iron, nickel alloy steel casting
11 Bearing White metal, leaded bronze casting

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1.

 An engine is a device which transforms one form of

 A heat engine is a device which transforms the

Combustion Heat Engine

 Internal combustion engines

 External combustion engine: the products of

 High power output

air air + fuel

Work =  (pressure x volume)

mixture preparation combustion, autoignition CxHx

negligible negative work

The Diesel Engine

10000 - 20000 psi

The Diesel Engine

Intake Valve open Crank Case compression Transfer port Opening

The Two Stroke Engine

The Two Stroke Engine

The Two Stroke Engine

Required an ignition system with Ignition system & sparkplug are

Thermal Lower thermal Efficiency (lower Higher thermal efficiency (higher

Lighter due to lower peak Heavier due to higher peak

Power produced for the same size of

Wankel (Rotary Piston Engine)

 Otto (For the Conventional SI Engine)

1. Four Stroke Cycle:

1. Homogeneous Charge (Also Pre-mixed charge)

1. Throttling: (To keep mixture strength constant) Also called Charge

2. Indirect Air-cooling (Liquid Cooling)

3. Low Heat Rejection (Semi-adiabatic) engine.

 Electric Drive Motors

Types Application Types Application

Aircraft Closed cycle Gas Power

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