Reciprocating Engine parts Design

G.T.U. B.E. (MECH) SEM-VIII

2011-12

Proverb

Nothing in the world is difficult for one who sets his mind to it.

Reciprocating Engine parts Designs

Main topic: Classification of engines Engine construction-Function of each components Design of different components

1.1 Classification of engines

1. By Cycles: 2- or 4-cycle engines 2. By Cooling systems: Liquid-cooled engines and air-cooled engines

1.1 Classification of engines

3.By Fuel: gasoline, diesel, propane, LPG (Liquefied Petroleum Gas ), natural gas and so on 4. By ignition method: compression ignition (CI) engines and spark ignition (SI) engines 5.By cylinder arrangement: in-1ine engine , Vee-engine , opposedcylinder engine

1.1 Classification of engines

In-line engine---the cylinders are arranged in a single line. Vee-engine---it has the cylinder placed in two banks and at an angle to each other. the connecting rod operates on a single crankpin.

1.1 Classification of engines

Opposed engine---the cylinders are placed on each side of the crankshaft.

1.1 Classification of engines

6. according to the position and arrangement of the intake and exhaust valves. This classification depends on whether the valves are in the cylinder block or in the cylinder head. L-head, I-head, and F-head

L-, I-, and F-valve arrangement

the shape of the combustion chamber resembles the form of the letter.

1.2 Engine construction

1. External appearance of 4100 engines 2. External appearance of 6100 engines 3. Cutaway of four in-line diesel engine(4100) 4. Cross-sectional view of four in-line diesel engine(4100)

Crosssectional view of four inline diesel engine (4100)

2.2 Engine construction

1. Stationary parts 2. Moving parts 3. Auxiliary assemblies

1.2.1 Stationary parts

These parts furnish the framework of the engine. All movable parts are attached to or fitted into this framework. Cylinder block Cylinders Cylinder head Crankcase Oil pan Exhaust and intake manifold Gasket

Stationary parts

Engine Cylinder Block

The engine cylinder block is the basic frame of a engine . The cylinder block and crankcase are often cast in one piece that is the heaviest single piece of metal in the engine.

Engine Cylinder Block

The cylinders of a liquid-cooled engine are surrounded by jackets through which the cooling liquid circulates. The cylinders of air-cooled engines have closely spaced fins surrounding the barrel .

Engine Cylinder Block

The cylinder block is cast from gray iron or iron alloyed with other metals such as nickel, chromium, or molybdenum. Some lightweight engine blocks are made from aluminum. Liners (sleeves) made of metal alloys resistant to wear of cylinder. the liners can be replaced individually. It can avoid replacing the entire cylinder block.

Cylinder Head
The cylinder head provides the combustion chambers for the engine cylinders. It is built to conform to the arrangement of the valves: L-head, I-head, or other. the cylinder head is bolted to the top of the cylinder block to close the upper end of the cylinders. It contains passages,

Crankcase and oil pan

The crankcase is that part of the engine block below the cylinders. It supports and encloses the crankshaft and provides a reservoir for the lubricating oil. The lower part of the crankcase is the OIL PAN, which is bolted at the bottom. The oil pan is made of pressed or cast steel

Exhaust and intake Manifold

The exhaust manifold is a tube that carries waste products of combustion from the cylinders. The intake manifold on a gasoline engine carries the fuel-air mixture from the carburetor and distributes it as evenly as possible to the cylinders. On a diesel engine, the manifold carries only air to the cylinders.

Gaskets
The gaskets that serve as seals between stationary parts. when properly installed, they prevent loss of compression, coolant, or lubricant.

1.2.1 Moving parts

The moving parts of an engine serve an important function in turning heat energy into mechanical energy. piston assembly connecting rods crankshaft assembly (includes flywheel and vibration dampener) camshaft Valves gear train

Piston and connecting rod Assembly

Piston and connecting rod Assembly

Functions
They transmit the force of combustion to the crankshaft through the connecting rod. They act as a guide for the upper end of the connecting rod. They also serve as a carrier for the piston rings used to seal the compression in the cylinder.

Piston and piston pin

PISTON :The structural components of the piston are the head, skirt, ring grooves, and land . PISTON PINS. The piston is attached to the connecting rod by the piston pin.

Piston rings
compression rings and oil control rings. a compression ring is to prevent gases from leaking by the piston during the compression and power strokes. oil control rings is used to lubricate the piston.

Connecting Rods
Connecting rods must be light and yet strong enough to transmit the thrust of the pistons to the crankshaft. The upper end of the connecting rod is connected to the piston by the piston pin. The lower hole in the connecting rod is split to permit it to be clamped around the crankshaft.

Engine Flywheel
The flywheel mounts at the rear of the crankshaft near the rear main bearing. The flywheel stores up rotation energy during the power impulses of the engine. It releases this energy between power impulses, thus assuring less fluctuation in engine speed and smoother engine operation.

Engine Flywheel
A flywheel is an inertial energy-storage device. It absorbs mechanical energy and serves as a reservoir, storing energy during the period when the supply of energy is more than the requirement and releases it during the period when the requirement of energy is more than the supply.

 The main function of a fly wheel is to smoothen out variations in the speed of a shaft caused by torque fluctuations. If the source of the driving torque or load torque is fluctuating in nature, then a flywheel is usually called for. Many machines have load patterns that cause the torque time function to vary over the cycle. Internal combustion engines with one or two cylinders are a typical example. . Piston compressors, punch presses, rock crushers etc. are the other systems that have fly wheel.

Engine Flywheel
All internal combustion engines need to have a flywheel. The fact that the explosive forces inside the cylinders are brief and irregular means that there is NOT a consistent torque acting to turn the crankshaft. A heavy enough flywheel smooth out the irregularity. It also has another effect which will be noted momentarily. Early cars had VERY heavy flywheels. Whether hand-cranked or with electric starters, that aided the starting of engines, as it permitted variations in how much gasoline had gotten into each cylinder, by allowing ANY cylinder which fired to increase the spinning speed so that the other cylinders could start behaving correctly.

Flywheel Design
Objective: Maximize energy per unit mass Assume: Thin rim flywheel of radius r and mass m Energy: K = I2, where = rotational velocity (rad/s) and polar moment of inertia I = mr2 K = mv2 = mr22 where rim velocity v = r Want high strength, low density & high velocity

Flywheel Pros & Cons

Cons
Developing technology Currently expensive Potentially low energy per unit mass (due to bulky containment) Uncertain safety in a burst event: fragmentation & ejection of material sudden release of energy

Pros
High round-trip efficiency in shortterm use (80-95%) Potentially long product life (measured in tens of years) Low toxicity of constituents High power per unit mass (fast, equal charge & discharge times) Easy to determine state of charge

Camshaft
The camshaft is enclosed in the engine block. It has eccentric lobes (cams) ground on it for each valve in the engine. As the camshaft rotates, the cam lobe moves up under the valve tappet, exerting an upward thrust through the tappet against the valve stem or a pushrod.

Crankshaft assembly

Function
It ties together the reactions of the pistons and the connecting rods, transforming their reciprocating motion into rotary motion. It transmits engine power through the flywheel, clutch, transmission, and differential to drive your vehicle.

1.3 AUXILIARY ASSEMBLIES

The fuel system includes a fuel pump and carburetor mounted on the engine. In diesel engines the fuel injection mechanism replaces the carburetor. An electrical system is provided to supply power for starting the engine and for igniting it during operation.

AUXILIARY ASSEMBLIES
The operation of an internal combustion engine requires an efficient cooling system. Water-cooled engines use a water pump and fan while air-cooled engines use a blower to force cool air around the engine cylinders.

AUXILIARY ASSEMBLIES
The operation of an internal combustion engine requires an efficient lubrication system too. It can make the engine works fluently. In addition, an exhaust system is provided to carry away the burned gases exhausted from the engine cylinders.

Design of Flywheel

L-, I-, and F-valve arrangement

the shape of the combustion chamber resembles the form of the letter.

L-head
both valves are placed in the block on the same side of the cylinder. The valve-operating mechanism is located directly below the valves, and one camshaft actuates both the intake and exhaust valves.

I-head
the valves mount in a cylinder head above the cylinder. requires a tappet, a push rod, and a rocker arm above the cylinder to reverse the direction of the valve movement.

F-head
the intake valves normally are located in the head, while the exhaust valves are located in the engine block. The valves in the head are actuated from the camshaft through tappets, push rods, and rocker arms . the valves in the block are actuated directly from the camshaft by tappets .

Valves and Valve Mechanisms

The purpose of the valve-actuating mechanism is to overcome the spring pressure and open the valves at the proper time. The valve-actuating mechanism includes the engine camshaft, camshaft followers (tappets), pushrods, and rocker arms.

valve-actuating mechanism

Camshaft

This thrust over-comes the valve spring pressure as well as the gas pressure in the cylinder, causing the valve to open. When the lobe moves from under the tappet, the valve spring pressure reseats the valve.

Gear Trains

Function
Timing gears keep the crankshaft and camshaft turning in proper relation to one another so that the valves open and close at the proper time. Some engines use sprockets () and chains (),.

Timing gears, and the position of camshaft