IC ENGINE AND RECIPROCATING MACHINES

1. INTRODUCTION

1.1.Internal Combustion (IC) engines

An Engine is a mechanical device used to convert heat energy into mechanical energy. And is
usually called a Heat Engine.

Basically there are two types of heat engines: External combustion and Internal Combustion (IC)
engines.

a) External combustion engine: is an engine in which combustion (burning of a fire) is taking

place outside of the engine. Eg. Steam engine

b) Internal combustion (IC) engine: is an engine in which combustion is taking place within
the engine itself. Eg. Gasoline engine

1.1. Historical development of Automotive:

History of Automotive History of Ethiopia

Year Event Year Event

Mr. LENOIR
1860 First Internal Combustion (IC)
Engine, using coal gas as fuel 1855
Emperor Tewodros
Mr. Nikolaus OTTO and Mr. - 1868
1867 Eugen LANGEN:

Improved IC engine

OTTO invents the 1872

Emperor Johannes IV
1878 "4-stroke-operating-principle" for -
gasoline engines
1889
Mr. Gottlieb DAIMLER and Mr.
1883 Wilhelm MAYBACH develop the
first high-speed 4-stroke engine

DAIMLER builds his first four- 1875

1886 Egypt Invasion
wheel car 1876
 Mr. DUNLOP produces the first
1889
pneumatic tires

DAIMLER establishes "Daimler

1890
Motor Company"

1891 First American made vehicle

1893 1889 Emperor Menelik

Mr. Rudolf DIESEL invents the
- principle of a self-ignition engine -
("heavy oil" engine)
1997 1913
MAYBACH invents carburetor
1893
with spray jets

1893
Mr. Henry FORD produces his first
-
vehicle (with petrol engine) 1896 Battle of Adwa
1896

Mr. Robert BOSCH establishes his

1896 workshop for mechanical &
electrical engineering

Mr. Adam OPEL starts production

1898
of Automotive Vehicles

1899 FIAT established in Italy

Bavarian Motor Company (BMW)

1917 1916
founded

The enterprises BENZ and M.A.N. - Emperor Haile Selassie

1923 produce first truck with diesel- 1974
engine

DAIMLER and BENZ merge

1926 - Teferi Mekonnen School
together 1925
- Berhanena Selam Newspaper
DAIMLER-BENZ begins
1936 production of passenger cars with 1936 -
diesel-engines Italian Occupation
1941
1939 - 1945 2nd World War (1933 - 45 - Fascism in Germany)

Begin of public Ethiopian Higher

Education with the foundation of
Invention of rotary-piston engine 1950
1958 AAU as "University College of
(WANKEL) Addis Ababa"

1955 New Constitution

Dergue /
1980 Strict Emission Control (USA) 1974
Death of Haile Selassie

Introduction of Catalytic New Government /

1985 Converters with Lambda-control 1991
and EFI worldwide Downfall of Dergue

DAIMLER and CHRYSLER

199? unite to the world’s biggest vehicle
manufacturing enterprise

IC engine terminology
 Spark Ignition (SI): An engine in which the combustion process in each cycle is started
by use of a spark plug.
 Compression Ignition (CI): An engine in which the combustion process starts when the
air-fuel mixture self-ignites due to high temperature in the combustion chamber caused
by high compression. CI engines are often called Diesel engines, especially in the non-
technical community.
 Top-Dead-Center (TDC): Position of the piston when it stops at the furthest point away
from the crankshaft. Top because this position is at the top of most engines (not always),
and dead because the piston stops at this point.
 Bottom-Dead-Center (BDC): Position of the piston when it stops at the point closest to
the crankshaft.
 Bore: Diameter of the cylinder or diameter of the piston face, which is the same minus a
very small clearance.
 Stroke: Movement distance of the piston from one extreme position to the other i.e TDC
to BDC or BDC to TDC.
 Clearance Volume: Minimum volume in the combustion chamber with piston at TDC.
 Displacement or Displacement Volume: Volume displaced by the piston as it travels
through one stroke. Displacement can be given for one cylinder or for the entire engine
(one cylinder times number of cylinders). Some literature calls this swept volume.
 1.2. 4S-SI engines
- Intake - Intake valve opens (theoretical stroke: at TDC)
- Exhaust valve is closed (theoretically: since TDC)
- Piston moves downward
- Distance TDC to BDC = 180° crank angle
- Suction occurs / partial vacuum (-0.1 to -0.3 bar)
- Air-fuel mixture (14.8 : 1) is drawn into the cylinder

- Compression - Intake valve closes (theoretical: at BDC)

- Exhaust valve still closed
- Piston moves upward (BDC  TDC = 180°)
- Volume decreases
- Air-fuel mixture gets compressed to (1/7 to 1/12)
- Air-fuel mixture is heated up (molecular motion)
- increasing heat causes higher pressure (18 bar)
- Higher heat improves mixing of the gases

- Power - Both valves are still closed (theoretically: till BDC)

- Combustion is initiated by the spark from the spark plug  IGNITION
- Time from start of combustion till complete combustion about 1/1000 s!
- Delay in flame propagation requires ignition before TDC
- Combustion speed up to 20 m/s
- Highest combustion pressure about 30 - 60 bar at around 4° - 10° a. TDC
- Expansion of hot gases (up to 2500° C) forces the piston from TDCBDC
- Heat energy is transferred into mechanical energy
- Exhaust - Exhaust valve opens (theoretically: at BDC)
- Intake valves remains closed (theoretically: till TDC)
- Due to rest pressure from combustion of 3-5 bar exhaust gases leave the cylinder
with sonic sound
- Exhaust gas temperature still be around 900° C
- Piston moves upward (BDC  TDC = 180°)
- Rest of exhaust gases pushed out with around 0.2 bars
Summary: - 4 strokes = 720° crank angle = 360° camshaft angle
- 4 strokes = 2 crankshaft rotations = 1 camshaft rotation
- Each theoretical stroke is 180° crank angle
- Spark ignition takes place at or before TDC

1.3. 4S- CI engines

General: - Draws in air only, not air-fuel mixture and compresses it to a much higher
pressure as compared to Otto engines
- Fuel is injected into its highly compressed air, no carburetor
- The highly compressed air is that hot that it ignites the fuel - "compression
ignition" or "self-ignition" are the terms for Diesel engines
- Internal mixture formation
- Diesel fuel has a high boiling point, flaming temp 320 - 380 C.
Induction / Intake Stroke: piston moves from TDC to BDC, intake valve opened, exhaust valve
closed,
Compression: both valves closed, piston moves from BDC to TDC, compression ratio up to 22:1,
compression pressure up to 55 bar, compression temperature 700 - 900  C;
injection starts 20 - 30  b. TDC, duration several degrees; ignition delay 0.001
second (time from injection to self-ignition)
Power / Expansion: both valves closed, piston moves from TDC to BDC (being forced); pressure
up to 90 bar;
Constant pressure combustion up to 60 a. TDC
Exhaust: exhaust valve open, piston moves from BDC to TDC, exhaust gas temperature up to
700  C.
 1.4. Comparison between four strokes and two strokes engines

Four stroke engine Two stroke engine

1. It consists of one working stroke in every 1. It consists one working stroke in every two strokes,
four strokes and crank shaft completes two and gives two working strokes in same period two
revolutions in a particular period of the cycle and crank shaft cycle. There by theoretically
cycle. producing approximately double power than four
2. It is Provided inlet as well exhaust valves stroke engine of same size.
which need the special attention of wear, 2. Inlet as well exhaust ports are provided instead of
tear and lubrication valves, which reduce the wear, tear and lubrication
3. It consists three idle strokes in a complete there by also reducing the special attention.
cycle of two revolutions of the crankshaft 3. It consists two idle strokes in the same period of two
4. If needs more space for producing equal cycles and one revolutions of the crank shaft
amount of power. 4. The space required is less to produce the same
5. It cannot be made reversible amount of power
6. Complete scavenging is not possible 5. It can be revisable it is of valve less
because the burnt gasses remain in the 6. The scavenging is more complete in low speed, as it
clearance space. does not leave the clearance space.
7. It needs heavier flywheel because there is 7. It needs lighter flywheel because there is more
more non uniform torque on the uniform torque on the crank shaft.
crankshaft. 8. The power required to overcome the friction of the
8. More power loss due to friction of idle, suction and exhaust strokes is saved.
suction and exhaust strokes. 9. Efficiency is lower because a portion of the fresh
9. Efficiency in more because none of the charge escapes with the exhaust gases while
portion of the change escapes with the scavenging.
exhaust gases. 10. It needs more lubricating oil mixed with the fuel
10. Due to working at half the speed, the wear, because the valve gear works at twice the speed.
tear and the consumption of lubricating oil 11. Due to its lesser weight and high speed, is
is loss. recommended as power plant for small moving
11. Due to its low speed, fuel economy, vehicles as well as for marine engines.
simplicity and heavier in construction is
recommended for small and medium
stationary power plants is also
recommended for medium speed running
vehicles.

1.5. Wankel engine

The Wankel engine is a type of internal combustion engine using an eccentric rotary design to
convert pressure into rotating motion. Over the commonly used reciprocating piston designs the
Wankel engine delivers advantages of: simplicity, smoothness, compactness, high revolutions
per minute and a high power to weight ratio. The engine is commonly referred to as a rotary
engine.