INTRODUCTION

Engine is a device which transforms one form of energy to other form.

One Form

Energy

Other Form

INTRODUCTION

Heat Engine is a device which transforms chemical energy of the fuel to heat energy which is then used to get work.

ENGINE

INTERNAL COMBUSTION

EXTERNAL COMBUSTION

SPARK IGNITION

COMPRESSION IGNITION

STEAM ENGINE

Internal Combustion Engine

Internal Combustion Engine

Derives power from the fuel burnt within the engine cylinder. Heat required to obtain power is generated inside the cylinder itself. The heat generated is converted to power with help of piston and crankshaft. Losses of heat is less as compared to External Combustion engine.

External Combustion Engines

External Combustion Engines

Fuel is burnt outside the cylinder Derives power from the steam expansion in the engine cylinder. The heat generated is converted to power with help of piston and crankshaft. Losses of heat are more as compared to Internal Combustion engine.

INTERNAL COMBUSTION

SPARK IGNITION

COMPRESSION IGNITION

Spark Ignition Engine

Spark Plug

Spark Ignition Engine

Fuel and air mixture is first compressed with help of piston. Hence a high temperature and pressure are achieved. Then the fuel is ignited with help of a spark at a constant volume. So, this type of engines are also known as CONSTANT VOLUME CYCLE ENGINE. E.g.. Petrol and Kerosene engines

Compression Ignition Engine

Injector

Compression Ignition Engine

Only air is first compressed with help of piston. Hence a high temperature and pressure are achieved. Then the fuel is injected with some desired pressure on charge at constant pressure. Hence the fuel gets ignited. So, this type of engines are also known as CONSTANT PRESSURE CYCLE ENGINE.

E.g.. Diesel engines

INTERNAL COMBUSTION

2-STROKE ENGINE

4-STROKE ENGINE

4-STROKE ENGINE

4-STROKE ENGINE

It completes its cycle in 4 strokes of piston and two revolutions of flywheel.

Sucks charge into cylinder. Compresses the charge to required pressure. Charge is ignited and power is generated. Burnt gases are exhausted out of cylinder

1st 2nd 3rd 4th

Suction Compression Power Exhaust

2-STROKE ENGINE

2-STROKE ENGINE

It completes its cycle in 2 strokes of piston and one revolution of flywheel.

Sucks charge into cylinder. Compresses the charge to required pressure. Charge is ignited and power is generated. Burnt gases are exhausted out of cylinder

Suction

1st
Compression Power 2nd Exhaust

Comparison b/w 4-s & 2-s Engines

4-stroke 2-stroke

Completes one cycle in 4-strokes. Completes one cycle in 2-strokes.

Turning For

moment is not uniform.

Turning

moment is uniform.

same size of engine the power For same size of engine the power obtained is lesser as compared. obtained is more as compared.
Valve

mechanism is present.. is complicated and

Ports

are present. is simple and

Construction

Construction

costly.
Consumes

cheap.
Consumes

less fuel for same power output.

more fuel for same power output.

Comparison b/w 4-s & 2-s Engines

4-stroke
Has

2-stroke

easy removal of exhaust

gases.
Flywheel

Has

is smaller due to more frequency of power strokes.

Lubrication

difficult removal of exhaust gases.. Flywheel is larger due to less frequency of power strokes.
Lubrication

: has separate oil

: oil is mixed with fuel

circuit Oil consumption is little.

Less

itself. Oil consumption is more.

More

carbon deposits.

carbon deposits.

Less

noisy.

More

noisy.

Working

temperature is comparatively low.

Working

temperature is comparatively high.

Comparison b/w 4-s & 2-s Engines

4-stroke 2-stroke

Crankcase Heavier

is not to be air tighten.

Crankcase Lighter

is to be air tighten

self weight.

in self weight. in size.

Larger

in size.

Smaller

ENGINE COMPONENTS

The main components of engine are

Cylinder & Cylinder Block Piston Connecting rod Crankshaft Crankcase Flywheel Timing Gears Camshaft Tappets and Push rods Valves / Ports
Click on the component for details.

Spark plug or Injector

Cross-section of a 4-s Engine

CLYINDER

CYLINDER

Cylinder is a hollow cylindrical part of the engine in which piston slides. Made up :- of high grade cast iron. Function : - It provides space for the movement of piston. - It serves space for the combustion of the fuel.

Parts of Cylinder

Cylinder Block : - It is the solid casting which includes

cylinder liner and water jackets

Parts of Cylinder
It is detachable part of the cylinder which cover the cylinder - It includes combustion chamber, sparkplugs or injector and valves
-

Parts of Cylinder

Cylinder Liner : - It is cylindrical lining in which piston slides.

- There are two types of liners.

1. Dry Liner 2. Wet Liner.

Parts of Cylinder

Types of Cylinder Liner : -

Water Jackets are not in direct contact with liner

Water Jackets are in direct contact with liner

PISTON

PISTON

Piston is cylindrical part of the engine closed at upper end which slides in the cylinder. Made up of cast iron, cast steel or aluminium alloys. Function : - It transmits the power generated in the cylinder due to pressure and energy by the combustion of the fuel to the crankshaft through connecting rod.

Parts of a Piston

Parts of a Piston
Piston Head Piston Rings

Piston Pin Oil Rings Piston Skirt

Parts of Piston

Piston Head : - Top portion of the piston facing the combustion chamber. Piston Pin : - Also known as Gudgeon pin or Wrist Pin. - Used to join the connecting rod with piston. Skirt :It is the lower portion of the piston below piston pin and it designed to absorb the side movements of the piston.

Parts of Piston

Piston Rings :

They are placed in the piston ring grooves and are split expansion type. They are made up of cast iron or pressed steel alloy usually. The clearance of 1mm per 200mm diameter is kept for expansion of the rings during operation in high temperatures.

Parts of Piston

Piston Rings : -

Functions : 1.

2.

3.
4.

It forms a gas tight combustion chamber. Reduces contact area between piston and cylinder and hence reduces excessive wear and tear. Controls cylinder lubrication. Transmits heat away from piston to the cylinder walls.

Parts of Piston

Piston Rings : - They are of two types

Compression Rings. Rings

Oil

Parts of Piston
Piston Rings : - Compression Rings

They are usually plain, single piece and are always placed in the grooves nearest to the piston head. They are used for sealing purpose and also for transmission of heat to the cylinder liner.

Parts of Piston
Piston Rings : - Oil Rings

They are usually provided with holes in them and are placed in the lower grooves in the piston skirt.

They are used lubrication as they distribute the oil evenly in the cylinder liner and also prevent excessive oil consumption also.
The excess oil is returned back from the holes provided in the ring.

Parts of Piston
Piston Head

Flat head in 4stroke

Raised Head for Scavenging in 2 stroke

CONNECTING ROD

Connecting rod is a special type of rod whose one end is connected with the piston and other end is connected with crankshaft. Made up of drop forged steel. Function :

It transmits the power to crankshaft from the piston.

CONNECTING ROD

CONNECTING ROD

Parts of Connecting Rod

Eye : - Top portion of the connecting rod which is connected with the piston pin. Shank : - Solid potion of the connecting rod which lies between eye and head. Head :- It is the lower portion of the connecting rod below shank which is connected with the crankshaft. Cap :It is the lower most portion of the connecting rod which bolted with head and connects the crankshaft.

Piston & Crankshaft Assembly

FLYWHEEL

Flywheel is a wheel mounted on the crankshaft and it is the exterior portion of the engine. Made up of cast iron.

FLYWHEEL

Functions : It stores the energy during the power stroke and returns the same during other idle stroke(s) and thus provides an uniform rotary motion of the flywheel. It also carries ring gear that meshes with the pinion of starting motor for cranking the engine. The rear surface of the flywheel serves as one of the pressure surfaces for the clutch plate.

FLYWHEEL

Functions :

Engine timing marks are usually stamped on the flywheel. Power is transmitted to rest of the mechanism using flywheel through pulleys, couplings, etc.

CRANKCASE

CRANKCASE

Crankcase is that part of the engine which encloses the crankshaft and camshaft. It provides a reservoir for the lubricating oil of the engine. It serves as mounting unit for oil pump, oil filter, generator, staring motor, and ignition components. The upper portion of the crankcase is integral with the cylinder block and the lower portion is called as the oil pan. It is usually made up of cast iron or cast aluminium.

CRANKSHAFT

CRANKSHAFT

Made up of drop forged steel or cast steel. Function :

It converts reciprocating motion of piston to the rotary motion of flywheel.

Parts of Crankshaft

Main Journal : - This is the space which supports the

crankshaft on crankcase.

Crank Journal : - It is the part where connecting rod

is attached.

Lubricating oil holes :- These holes are provided for

the passage of lubricating oil.

CAMSHAFT
Functions

:-

It operates : Fuel

Injection Pump Inlet and Outlet valves Ignition system Lubricating oil pump

CAMSHAFT

It is a shaft which raises and lowers the valves at proper time.

It is driven with the crankshaft by means of gears, chains or spokets. The speed of the camshaft is half of the speed of the crankshaft in four stroke engines.

TIMING GEAR

TIMING GEAR

It is combination of two gears, one mounted one camshaft and other on crankshaft
The gear on crankshaft is smaller in size than that of the gear on camshaft. The speed of the camshaft gear is half of the speed of the crankshaft gear in four stroke engines and hence it is also known as Half Timing Gear.

TIMING GEAR
Functions

: Controls the timing of

Ignition Opening and Closing of Valves Fuel injection

VALVES

Valves are small mechanical device used for the opening and closing of the passages leading to the cylinder.

VALVES
There are two valves in an IC Engine.
Inlet Valve :- Controls the flow of charge into the cylinder. Exhaust Valve :- Controls the flow of burnt gases outside the cylinder.

Parts of a Valve
Valve Spring Valve Stem Fixed with the valve head and placed in valve guide Valve Head Head is made inclined at 30-40 to prevent leakage.

Valve Face

Faces the combustion chamber and designed to withstand high temperature and hammering actions due to expanding gases

FIRING ORDER
It is the sequence in which the power stroke in each cylinder occurs. The crankshaft is accordingly designed so as to maintain that order. Generally the order is such that the firing will be not in neighboring cylinders as to maintain balance and temperatures. Eg. 1-4-2-3., 1-6-2-5-3-4. or 1-4-3-6-2-5.

FIRING INTERVAL

It is the interval between two successive power strokes.

FI =

720
No. of Cylinders

( 4 Stroke)

FI =

360
No. of Cylinders

( 2 Stroke)