COOLING SYSTEM

I t d ti
Introduction
{ I.C Engines at best can transform about 25-30 % of
the chemical energy from the fuel in to mechanical
energy.
{ About 35 % of the heat generated is lost to the cooling
medium remainder being dissipated through exhaust
and lubricating oil.

z 1/3 Heat to Useful Work

z 1/3 Heat to cooling System
z 1/3 Heat to exhaust system
The Purpose of Cooling System

{ Prevent Overheating
z Excess Heat generated in engine
z Peak
P k ttemperatures
t exceed
d melting
lti point
i t off
metal

{ Regulate the most efficient Temperature

z Regulate Temperature
z Allow engine to warm up in cool weather
z Maintain engine in optimum range.
Consequence of engine running too hot:
z Pre-ignition
Pre ignition, Detonation/Knock
{ – All result in very high pressure rise and possible
damage to engine
z Heat Fatigue off components
{ Burnt Pistons
{ Burnt Valves
z Failure of lubrication system
{ Oil breakdown
{ Oil film
fil att cylinder
li d destroyed
d t d att 200C
z Scoring of piston & sleeves
z Warping & fracture of components
 Consequence of Engine Running Too Cold

z Unnecessary Wear
z Poor Fuel Economy
{ Incomplete Combustion
{ Lower coolant Temperature
z More energy transferred out of cylinder
z Energy from is wasted & not available for work (Power)
z Promotes corrosive conditions in engine
{ Water of combustion reacts with sulfur oxides in exhaust
z Forms acids
{ Allows water & sludge to accumulate in crankcase
{ Over time, fuel diluting the oil will accumulate
z Normally lighter volatile fuel will evaporate as temp. rises
Variation of Gas Temperature Piston Temperature Distribution
 H tT
Heat Transfer
f
{ As a result of combustion, high g temperature
p are
produced, inside the engine cylinder
{ Considerable heat flow from the gases to the
surrounding
di metal
t l walls
ll
{ Shearing of the oil film
{ Heat transfer from gases to the cylinder walls may
occur predominantly by Convection & Radiation
{ Heat transfer through the cylinder wall occurs only by
conduction
{ The temperature
p profiles across the cylinder
p y barrel wall
{ For water cooled engine

{ Air cooled engine

Cylinder Wall Temperature Profile
 Parameters Affecting Engine Transfer
{ Engine heat transfer depends upon many parameters,
unless the effect of these parameters is known, the
design of a proper cooling system will be difficult.
{ Fuel-Air Ratio:
z A change in fuel-air ratio will change the temperature
of the cylinder
y gases and affect the flame speed.
g p
Maximum gas temperature occurs at equivalence
ratio of 1.12. But maximum heat loss occurs at
slightly lean air fuel ratio.
ratio
{ Spark Advance:
z More or less spark advance from the optimum value
will result in increased heat rejection to the cooling
system
{ Pre-ignition
i i i and
d knocking:
k ki
z Negligible effect on overall heat transfer
{ Engine output:
z Engines which are designed for high M.E.P or
high piston speeds, heat rejection will be
less
{ Cylinder wall temperature:
z Increase in gas temperature has very little
effect on wall temperature difference and on
heat rejection
Characteristics of an efficient cooling system
The two main characteristics desired of an efficient cooling
system are:
{ It should capable of removing about 30 % of the heat
generated in the combustion chamber while maintaining
the optimum temperature of the engine under all
operating conditions of the engine
{ It should remove heat at a faster rate when engine is
hot. However during starting of the engine the cooling
should be minimum, so that the working parts of the
engine reach their operating temperatures in a short
time
 Types of cooling System
There are two types
yp of system
y in g
general
z Liquid or indirect cooling system
z Air or direct cooling system

Liquid Cooling System

{ Mainly water/coolant is used and made to circulate through
the jackets provided around the cylinder, cylinder head,
valve ports and seats where it extracts most of the heat

{ The heat transferred from the cylinder wall and other parts
by convection and conduction

{ The heat from liquid in turn is transferred to air.

air Hence it is
called the indirect cooling system
Methods of Water-cooling System

Water cooling can be carried out by any one of

the following five methods
z Direct or non return system

z Thermosyphon system

z Forced circulation cooling system

z Evaporation cooling system

z Pressure cooling system

 Direct or Non return System
{ This system is useful for large installations where
plenty of water is available.

{ The water from a storage tank is directly supplied

through an inlet valve to the engine cooling water
j k
jacket

{ The hot water is not cooled for reuse but simply

discharged.
 Th
Thermosyphon
h System
S t
{ Heat is supplied
pp to the fluid in the tank A
{ Due to relatively lower density, the hot fluid travels up
{ Its place being taken up by comparatively cold fluid from
th Tank
the T k B through
th h the
th pipe
i p2
{ The hot fluid flows through the pipe P1 to the tank B
where it gets cooled
{ The fluid circulates through the system in the form of
convection current
{ Tank A –represents
p the cylinder
y jjackets
{ Tank-B- represents a radiator and
{ water acts as the circulating fluid.
{ The advantages are
z Its simplicity
z Automatic circulation of cooling water
{ The man limitation of the system
s stem is its inability
inabilit to
meet the requirement of large flow rate of water,
particularly for high output engines.
 Forced circulation Cooling System
{ This system
y is used in a large
g number of Automobiles.
{ Here the flow of water from radiators to water jackets
is by convection assisted by a pump
{ Water or coolant is circulated with through jackets around
the parts of the engine to be cooled is kept in motion by a
centrifugal pump which is driven by the engine
{ The water is passed through the radiator where it is cooled
by the forward motion of the vehicle
{ A thermostat is used to control the water temperature
required for cooling
{ This system consists of 4 components
z Radiator
z water pump
z Fan
z thermostat
 Basic Schematic Layout

Cab heat
exchanger

Heater Control Thermo-

stat

Fan Radiator
Engine Block &
Cylinder head
Water Jacket Water
Pump
Parts of Engine Cooling System
 Cooling System Construction
Radiator
Cap

Top Hose Radiator

Thermostat Fan

Water
Engine Block Pump
& Water
Jacket
 C ld Engine
Cold E i

When an engine is
cold, the thermostat is
cold.
Coolant flow is through
the bypass hose and
the water jackets.
This allows the engine
g
to warm up evenly.
The thermostat should
start
t t to
t open att 77 oC
and fully open at 85 oC
 Warm Engine

The thermostat opens

when the engine warms
up.

This allows coolant to

circulate through the
radiator
di t andd the
th water
t
jackets.
Water Jackets
{ Defined as the open
p space
p within in the cylinder
y
block and cylinder head where coolant flows
{ Water jackets are designed to allow coolant flow
t the
to th right
i ht spots
t flow
fl t the
to th right
i ht spots
t so that
th t
maximum cooling can be obtained
 Water Pump
{ It purpose is to circulate the water through the cooling system
{ Located on the front part of the engine
{ In most of the vehicles it is driven by a belt is attached to the
crankshaft
{ As the crankshaft turns the fan belt turns
 Thermostat
{ One of the most important parts of the cooling system

{ Its p
purpose
p is to keep
p the engine
g coolant at most
efficient temperature

{ The thermostat is used to bring the coolant

temperature up to operating as quickly as possible

{ It is designed to sense the temperature of the coolant

Th
Thermostat
t t
Fig. Engine Thermostats
Bellows type with short sealed
tube containing ether. Ether
expands when heated causing the
thermostat to open.

Bimetallic strip
p uncoils when
heated causing the thermostat to
open.
 Radiator
{ Its p
purpose
p is to allow fresh air reduce the
temperature of the coolant.
{ As the coolant passes through the tubes air is forced
around the tube
{ This causes a transfer of heat from the hot coolant to
th cooler
the l air.
i
{ In this case, heat is exchanged from the liquid
coolant to air.
air This is called a liquid
liquid-to
to air heat
exchanger
{ Coolant flows through the air fins

{ The fins and tubes are cooled core

Radiator Parts
 Radiator Pressure Cap
{ Pressure caps are designed to
z Increase the pressure on the cooling system
z Reduce cavitations
z Protecting the radiator hose
z Prevent or reduce surging
{ It is important to put pressure on the cooling system.
Radiator pressure caps are typically near 15 psi
{ As the pressure increases the boiling point of the
coolant also increases (about 3 degrees for each 1
psi increase)
P
Pressure Cap
C
Pressure cap
Pressure cap
E
Expansion
i ttankk
E
Expansion
i ttankk
Fan
Coolant Temperature Indicator
C l tT
Coolant Temperature
t Indicator
I di t
C l t
Coolant
C l t
Coolant
C l t
Coolant
 C l t
Coolants
{ Ethylene Glycol (C2H6O2) is the primary coolant
utilized in engines today.
{ Typical mixtures are 50% water and 50% ethylene
glycol.
l l
{ Chemical inhibitors, that are alkaline, are added to
the coolant to eliminate acid formation.
{ Ethylene glycol raises the boiling point and lower
the freezing point.
{ Additives reduce cavitation – a major source of
cylinder wall pitting.
{ Other additive inhibit rust and corrosion.
corrosion
 Ai C l d S
Air-Cooled System
t
{ IIn an air
i cooled
l d system
t a currentt off air
i is
i made
d to
t
blow past the outside of the cylinder barrel whose
outer surface area has been considerably
i
increaseddb
by providing
idi cooling
li fi
fins.
{ This method will increase the rate of cooling

This method is mainly applicable to

engines in motor cycles,
cycles small cars,
cars
airplanes and combat tanks where the
motion of vehicle gives velocity to cool the
g
engine