TITLE

Modification of Two Stroke Petrol Engine with Test Rig

ABSTRACT
The two stroke engines were very popular throughout the 20th century in
motorcycles and small engine devices, such as chainsaws and outboard motors,
and were also used in some cars, tractors, etc. Now they are largely used in
ships, boats, etc. The lower cost to rebuilt and maintain made the two stroke
engines incredibly popular.
Two stroke engines still have their applications where high power is required in
string trimmers and chainsaws. They are also used in mopeds, under bones,
scooters, tuk-tuks, snow-mobiles, lawn-mowers, etc.
In this project work, we will repair a two stroke petrol engine with test rig. We
will modify a two stroke petrol engine that was used in Bajaj Chetek scooter.
The engine is fitted on a frame and its output power is calculated from the
extended shaft which is attached to the crankshaft of the engine by means of a
coupling.
The engine and test rig is not in working condition. Hence we’ll repair it in
Thermal lab.
This test rig is an addition to the existing experimental setups and is capable of
performing various experiments such as performance analysis, alternative fuel
testing etc. This test rig will be of a great help for the students in the future.

KEYWORD:-
Engine test rig
Carburetor
Engine performance parameters
Two stroke petrol engine
Overhauling

1
 INTRODUCTION
In many two stroke engines the mechanical construction is greatly simplified by
using the piston as a slide valve in conjunction with intake and exhaust ports
cuts in the side of the cylinder. If the engine is running on Otto cycle, the charge
consists of correct mixture of fuel and air where as for petrol or duel
combustion cycles the charge will consists of pure air.
Working of two stroke petrol engine:-
Stroke 1A: Piston at BDC
In the diagram the piston is at BDC (Bottom Dead Centre -
meaning it is at the lowest point of travel within the
cylinder). The air, petrol and oil mixture within the
crankcase is forced into the cylinder and exhaust gases are
driven out.
Stroke 1B: The Instroke
The piston moves upwards and covers the air intake and
exhaust ports closing them. The charge of fresh air is
compressed to about 5:1 (20%) of its original volume. The
act of compressing the air heats it tremendously. This
happens on every upward stroke of the piston.
Stroke 2A: Piston at TDC
Just as the piston reaches the uppermost portion of it's travel
at Top Dead Centre (TDC) the spark plug is fired causing
combustion of the compressed mixture within the cylinder.
At the same time petrol and oil vapour is being drawn into
the crank-case in preparation for the next stroke.
Stroke 2B: Piston nearing BDC
During the downward stroke the exhaust port opens, and the
cylinder is swept clean of burnt fuel by fresh air from the
inlet port. The petrol, oil and air charge within the crank-
case is compressed during this stroke in preparation for the
next stroke.This entire cycle is repeated for every revolution
of the crank shaft.

2
 BRIEF LITERATURE REVIEW

Basic test rig block diagram :-

Parts of two stroke petrol engine test rig :-

Engine: The engine ignites fuel at every upward stroke, so there are two strokes
for every ignition of fuel. They are called upward and downward stroke. As the
piston moves in upward direction from bottom to top in the first stroke the air
and fuel mixture gets compressed and ignited by spark plug as upward stroke
comes to end. This results in an explosion of mixture which forces the piston to
move downwards thereby producing power.
Rope brake dynamometer: rope brake is a simple device for measuring Brake
power of an engine. it consists of number of turns of rope wound around the
rotating drum attached to the output shaft. one side of the rope is connected to
the spring balance and other to the loading device the power absorbed is due to
friction between rope and the drum.
Thermocouples : Thermocouple is a device mounted on different areas of the
engine to measure stroke temperatures.
Engine speed indicator : The function of the speed indicator is to measure the
number of revolution per minute of the engine shaft, this is done by using a
speed sensor which is displayed in the digital indicator.
Fuel Measuring Device : Fuel tank mounted on sturdy iron stand,burette
tube, three way cock, connecting tube & a stop clock.

3
Air Intake Measurement : Air Intake reservoir of size 0.3mx 0.3m x 0.5 m.
with orifice plate, U-Tube manometer of 0.5 m height for the measurement of
air flow rate.
Exhaust Gas Calorimeter : Water cooled exhaust gas calorimeter , shell and
coil type to study the heat lost to exhaust gases.
Multichannel digital temperature indicator for measuring inlet and outlet
temperatures of exhaust gases and water.

Specifications

Type Horizontal, totally enclosed spark ignition,

two stroke cycle, and petrol engine.

Make Bajaj chetak

Stroke length 57 mm
Bore 57 mm
Maximum power 7.50 bhp(5.93 kw)@5500 rpm
Maximum torque 10.8 Nm@3500 rpm

Capacity of fuel tank 300 ml

Circumference of brake wheel 364.24 mm
Ignition CDI Electrnic
Chassis type Monocoque
Cooling type Forced air cooled
Carburetor Spaco SI-20-20 mm venturi carburetor
Compression ratio 7.4/1.5:1

The test rig is designed to provide self-contained facility for teaching spark
Ignition engine principles. Test rigs are used to find out the performance of an
IC engine. The unit is instrumented so that the following experiments can be
carried out.
BHP Measurement
Brake Thermal Efficiency
Fuel Consumption Measurement
Air Intake Measurement
The Engine Test Rig Facilitate To Evaluate The Following:-
1). Performance at various throttle position.
2). BHP measurement from no load to full load.

4
 METHODOLOGY
Petrol engine is tested for the performance calculations. The testing is carried
out at various loads starting from no load condition to rated full load
conditions.The engine performance is indicated by the term efficiency.
Important engine efficiencies and other related engine performance parameters
are given below:

Indicated Thermal Efficiency (ith)

Indicated thermal efficiency is the ratio of energy in the indicated power, (i.p.),
to the input fuel energy in appropriate units.

Brake Thermal Efficiency (bth)

Brake thermal efficiency is the ratio of energy in the brake power, (b.p.), to the
input fuel energy in appropriate units.

Mechanical Efficiency (m)

Mechanical efficiency is defined as the ratio of brake power (delivered power)
to the indicated power (power provided to the piston).
It can also be defined as the ratio of the brake thermal efficiency to the indicated
thermal efficiency.

Volumetric Efficiency (v)

Volumetric efficiency is defined as the volume flow rate of air into the intake
system divided by the rate at which the volume is displaced by the system.
Mean Effective Pressure (Pm)
Mean effective pressure is the average pressure inside the cylinders of an
internal combustion engine based on the calculated or measured power out-put.
Calorific Value (Cv)
Calorific value of a fuel is the thermal energy released per unit quantity of the
fuel when the fuel is burned completely and the products of combustion are
cooled back to the initial temperature of the combustible mixture.
Specific Fuel Consumption (sfc)
The fuel consumption characteristics of an engine are generally expressed in
terms of specific fuel consumption in kilograms of fuel per kilowatt-hour. It is
an important parameter that reflects how good the engine performance is. It is
inversely proportional to the thermal efficiency of the engine.

5
 PLAN OF ACTION

Existing situation of two stroke petrol engine test rig :-

After studying two stroke petrol engine test rig we found following problems
which are mentioned below :
1. Piston damage
2. Carburetor
3. Sensor missing
4. Piston ring damage
5. Corrosive cylinder head
6. Calorimeter not working properly
7. Requiring overhauling of engine (all parts)
All these parts of two stroke petrol engine test rig are either misplaced or
damage. System is not in working condition, so testing cannot be performed.

Modification of two stroke petrol engine test rig:-

After study of system, we found many problems so these steps will be carried
out by our team:
1. We have to check the parts which are not working properly or misplaced so
that they can be replaced and repaired to remove the fault.
2. After study over this test rig, to remove the fault we require the new once so
market analysis will be done. In this we will purchase the parts of system in
a very economic price, which are of good quality and reliable.
3. After purchasing the parts from market the assembly of parts will be done in
test rig.
4. After assembling the parts in proper manner, we will check whether it is in
working condition or not.
5. After checking its working condition criteria, we will test the engine
performance.

6
Approximation cost of estimation :-
Piston cost – 150-200 Rs.
Piston rings cost – 60-70 Rs.
Engine assembling cost – 150-200 Rs.
Carburetor cover – 70-80 Rs.
Sensors cost – 1000 Rs.
Over-hauling cost – 2000 Rs.
Total cost – 5000 Rs.
Completion of project till march end.

POSSIBLE OUTCOME
After modification in two stroke petrol engine test rig we will find out that the
engine is in working condition. When many test will be performed after
modification, then outcome results are satisfactory.

DECLARATION BY THE CANDIDATES

We are the students of Btech. final year in Mechanical Engineering,
Government Engineering College, Bikaner hereby declare that we are fully
responsible for the information, result and conclusions etc. Provided in this
project “MODIFICATION OF TWO-STROKE PETROL ENGINE TEST RIG”
submitted to Engineering College Bikaner (Mechanical Engineering).
We have completely taken care acknowledging the contributions of others in
this academic work. We further declare that in case of any violation of
intellectual property rights or copyrights found at any stage, we will be
responsible for that.
Name University Roll No. Sign
Rekha Gusainwal (15EEBME205)
Sanjiv (15EEBME206)
Radhika Gurjar (14EEBME041)
Suyash Dwivedi (14EEBME055)
Vivek Tripathi (15EEBME210)
Guided by:
Arun Kumar Purohit