Internal Combustion Engine

Source:3/2/2009
John Deere FOS Series AST335_2000 1
 Engine Components
• Cylinder Block
• Main housing of Engine
• Cylinder Head
• Valves, Intake & Exhaust Passages, Injectors (Spark Plugs)
• Valve Train
• Camshaft, Opens and closes the valves
• Rocker Arm
• Piston, Connecting Rod
• Piston
• Connecting Rod
• Crankshaft, Flywheels, Balancers
• Flywheel, maintains momentum
• Balancers,
B l Dampen
D Forces
F
• Bearings
• Main Bearing
• Bearing
B i Inserts
I t

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 Engine Cylinder
• Types Cylinders
• EnBloc
• Dry Liner
• Wet
W Liner
Li
• Wear
• Taper
– Larger Dia at Top
• Out-of-roundness
– Perpendicular to Crankshaft
– Major Thrust Face
– Minor Thrust Face
• Replace 0.005” (0.13mm)
• Honing of Cylinders
• Cross-Hatch Pattern
– Rings catching
– Provide Lubrication

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John Deere FOS Series AST335_2000 4
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John Deere FOS Series AST335_2000 5
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John Deere FOS Series AST335_2000 6
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John Deere FOS Series AST335_2000 7
 Cylinder Head
• Cylinder
C li d Head
H d
– Iron and Copper, Aluminium
– Oil Ports,, Valves,, Intake & Exhaust Ports
– Cylinder Head Gasket

• Cylinder
C li d Head
H d Warping
W i
– Tightening sequence
Source: John Deere FOS Series
• Order of tightening
• Multiple stage process
» Torque 1, Torque 2
» Additional 1/x turns

• Leaks and Cracks

– Water & Air Method
– Magnetic Crack Detector

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John Deere FOS Series AST335_2000 9
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John Deere FOS Series AST335_2000 10
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John Deere FOS Series AST335_2000 11
 Four Stroke Engine
• Intake Stroke
• Piston TDC Piston BDC
» Intake Valve Open (10o before TDC)
» Intake Valve Closes (50o after BDC)

• Compression Stroke
• Piston BDC Piston TDC
» All Valves
V l Closed
Cl d

• Power Stroke (Ignition/Injection at TDC)

• Piston TDC Piston BDC
• Exhaust
E h Stroke
S k
• Piston BDC Piston TDC
» Exhaust Valve Open (50o before BDC)
» Exhaust Valve Closes (10o after TDC)
Source: John Deere FOS Series
 Two Stroke Engine (Roots Blower)

Source: John Deere FOS Series

 Two Stroke Engine (Crankcase Scavenging)

Source: John Deere FOS Series

Source: John Deere FOS Series
 Characteristics of Four Stroke
Compression Ignition & Spark Ignition Engines
Characteristics Compression-Ignition Engine Spark- Ignition Engine

Compression Ratio 14-22 : 1 5-8 : 1

Ignition Compression Electric Spark
Thermal Efficiency 30-60% 25-30%
Fuel induction Injector Carburettor (Fuel Injection)
Fuel System Fuel Oil / Diesel Gasoline (LP gas)
Fi Hazard
Fire H d L
Less G t
Greater
Power Variation Increase in Fuel Increase in Air/Fuel Mixture
Air Induction Constant Variable
Air-Fuel Ratio 15-100 : 1 10-20 : 1
Relative Fuel Consumption Lower Higher
Energy per litre of fuel Higher Lower
Manifold Throttle Absent Present
o o
Exhaust Gas Temperature 482 C / 900 F 704 C / 1300 F
Starting Harder Easier
Lubricants Heavy duty oils Regular and Premium Oils
Speed Range Limited (600-3200 rpm) Wide range (400-6000 rpm)
Engine Mass per Horsepower 8 kg (17.5 lb) Average 4 kg (9 lb)
Initial Cost High Much Lower
Lugging ability (Torque) Excellent Less
Time Before Maintenance Good Fair
Continuous Duty Good Fair
 The Valve Train
• Valve Actuation
• Valve Timing – Camshaft
• Camshaft Profile
– Base Circle, Flank, Nose, Valve Lift

• Valve Sealing – Cam Follower (Tappet)

• Hydraulic Lifter
– Push Rod
• No used in overhead cam
– Rocker Arm
• Valve Clearance (Adjustment Screw)
– Hot Clearance, Cold Clearance

• Valve Seating
– Valve Face, Valve Seat
• Tight
g Sealingg of air ((narrow contact area))
• Heat Transfer (wider contact area
– Valve Inserts
• Valve Stem Clearance
– Valve guides
• Cooling, Oil consumption
• Valve Rotators
– Release, Positive Rotators
• Crush Deposits
• Even Temperature

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John Deere FOS Series AST335_2000 19
 Valve Timing and Cam Profile

Source: John Deere FOS Series

• Valve Overlap
Intake & Exhaust valve open
• Valve Profile
• Base Circle
• Flank
• Nose
• Valve Lift

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 Valve Actuation
• Valve Lift
• Distance the valve lifts off the valve seat
• Valve (Tappet) Clearance
• The gap betweem the top of the valve
stem and rocker arm when the valve
follower is on the camshaft base
• Typical
i l Clearance
l (Hot/Cold
( / ld ?))
» Intake 0.25-0.50mm (0.010-0.020”)
» Exhaust 0.3-0.75mm (0.12-0.030”)
• Clearance too small
» Valve opens early, closes late
» Valve may not close
• Clearance too large
» Valve open late, closes early
» Valve may remain closed

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John Deere FOS Series AST335_2000 22
 Valve Seating and Cooling
• Valve Seating
• Valve Face, Valve Seat
• Valve Inserts
• Seating Width
– Wide Seating Width (3/32”), Better Cooling
– Narrow Seating Width (1/64”), crushing of deposits
– Interference Seating, good crushing but hotter valve

• Intake
ta e / Exhaust
aust Valves
Va ves
• Exhaust Valves
– Smaller, less heat Transfer
• Intake Valves
– Reduce ppressure losses causingg “vacuum”

• Heat Loss
• Valve Seat / Valve Guides
– Heat Transfer to head
• Incorrect Seating / Valve Clearance
– Hot gas blow-bay, Greater Heating
– Burnt Valves

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 V l R
Valve Rotators
t t

• Wiping Action
• Heat Distribution

Source:3/2/2009
John Deere FOS Series AST335_2000 24
 Major Cause of Valve Failures
• Distortion of Valve Seat
• Cooling,
C li Out O t off Round
R d & loose
l seats,
t Warped
W d Head/Block,
H d/Bl k Incorrect
I t grinding
i di
• Deposits on Valve
• Blow-by, weak springs, tappet clearance, sticking valves, wide valve seats, lack valve
rotation
• Burnt Valves
• Cooling system, Tappet clearance,
• Pre-ignition
– Timing,
g, Chamber deposits
p ((Longg Idling,
g, Rich mixtures,, Oil Burning,
g, High
g Heat pplugs,
g,
Compression ration, fuel

• Valve Erosion
• Incorrect fuel, Incomplete burning, Lean Air/Fuel Ratios
• Cracked Valves
• Thermal Fatigue
– Temperature & Pressure
• Impact Damage
– W
Worn guides,
id valve
l clearance
l

• Warn Guides
• Consequences
– Bad Seating, Impact at angle, oil burning, carbon deposits
• Causes
– Worn rockers, poor lubrication, carbon deposits, cocked springs

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John Deere FOS Series AST335_2000 26
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John Deere FOS Series AST335_2000 27
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John Deere FOS Series AST335_2000 28
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John Deere FOS Series AST335_2000 29
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John Deere FOS Series AST335_2000 30
 Piston and Connecting Rod
• Piston
• Eye, Shank, Head, Cap, Bearing Inserts, Piston Pin

• Major
j Thrust
h Face (Left
( f off Piston)
i )
» Greater side thrust
» Connecting Pin slightly Offset
• Minor Thrust Face

• Major Diameter (Perpendicular to Piston Pin

• Minor Diameter (Parallel to Piston Pin)
– Uneven expansion of piston as it heats up
– Round when hot

• Top Piston slightly smaller than bottom skirt

– Uneven expansion

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John Deere FOS Series AST335_2000 32
Source: John Deere FOS Series
Source:3/2/2009
John Deere FOS Series AST335_2000 34
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John Deere FOS Series AST335_2000 35
 Piston Design
Direct Combustion
– Low Surface area per unit vol
– Higher Premix Combustion
– Swirl

Swirl Ratio = Swirl Speed (rpm) / Engine Speed

(rpm)

Indirect Combustion
• Precombustion Chambers
– 20% to 30% clearance volume
– High Temp (600 to 750°C).

• Swirl Chambers or Turbulence Chamber

– 50% to 90% clearance volume
– clean burning low levels of smoke, NOx, and HC

• Air Cell or Energy Cells

– 5% to 15% clearance volume
– Ignition occurs in the main chamber
– 60% of the unburned fuel into the auxiliary chamber.
– Lower peak pressures Low indicated thermal efficiency
 Piston Rings
• Compression Rings, Oil Ring

• g
Rectangular
• Inexpensive
• Taper Ring
• Good Wiping
p g of oil on down stroke, Seats qquickly,
y only
y fair control blowby
y
• Barrel Ring
• Small contact area (low friction), Greater sealing pressure, lower blowby
• Inside Barrel
• Twists in groove to form tighter seal during combustion
• Keystone Ring
• Resist stickingg of ring
g in carbon deposits
p

• Ring require both side clearance and end clearance

3/2/2009 AST335_2000 37
Source:3/2/2009
John Deere FOS Series AST335_2000 38
 Oil Consumtion and Blow-By
• Causes
– Pumping by worn rings
• See figure
– Rings incorrectly installed
– Stuck Rings, plugged oil ring
• Deposits freeze rings
– Heat, Unburnt fuel, oil breakdown
(sludge), PreIgnition, Broken Rings,
worn grooves
g
– Wear Piston, rings, cylinder
• Abrasive wear
• Scuffing & scouring
• Corrosive wear
– Physical Damage

3/2/2009 AST335_2000 39
 Major Cause of Piston Failures
• Stuck Broken Rings
• S ffi and
Scuffing d scouring
i off Pi
Piston
• Local Hot spot
• Corrosive wear
• Physical Damage
• Piston Pin locking
• Pre-Ignition
– Lean Mixture, Low Octane, Advanced Timing, Over-fuelling, High Torque, Over-heating

Major Cause of Bearing Failures

• Dirt, (85%)
Dirt
• Lubrication (15%)
• Assembly (14%)
• Misalignment (10%)
• Overload (8%)
• Corrossion (5%)

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John Deere FOS Series AST335_2000 41
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John Deere FOS Series AST335_2000 42
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John Deere FOS Series AST335_2000 43
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John Deere FOS Series AST335_2000 44
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John Deere FOS Series AST335_2000 45
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John Deere FOS Series AST335_2000 46
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John Deere FOS Series AST335_2000 47
 Firing Interval & Order
• Average Firing Interval
– Av. Interval = (B * 180o) / (# cylinders)
– b=4 Four stroke, b=2 Two Stroke

• Firing Order (4 stroke)

• 2 Cylinder
– 1,2
12
• 3 cylinder
– 1,2,3
• 4 cylinder
– 1,2,4,3 or 1,3,4,2
• 6 cylinder
– 1,5,3,6,2,4
Source: John Deere FOS Series
Source: John Deere FOS Series
 Crank Dynamics

TDC
s = r + l − r cosθ − l cos φ
2 2 2
s l cos φ = sqrt
q (l − r sin θ )
s = r + l − r cosθ − sqrt (l 2 − r 2 sin 2 θ )
Stroke

l
BDC
ωr 2
2 sin ωt cos ωt
M
ds/dt = ωr sin ωt + *
2 sqrt (l 2 − r 2 sin 2 ωt )
l

ωr 2
sin( 2ωt )
ds/dt = ωr sin ωt + *
r q (l 2 − r 2 sin 2 ωt )
2 sqrt
2

ωr 2 2 cos(2ωt ) r 2 sin 2 (2ωt )

/d = ω r cos ωt +
2
d s/dt 2 2
*{ + }
2 sqrt (l 2 − r 2 sin 2 ωt ) 4 * sqrt (l 2 − r 2 sin 2 ωt )3
 Crank Dynamics

Position
Velocity
0 50 100 150 200 250 300 350 400 Accel_1
 Crank Dynamics

Accel_1
Accel_2
Accel_3
0 50 100 150 200 250 300 350 400 Accel_4
_Accel
 Types of Engines
• Fuel Type
• Spark Ignition (Gasoline, LP-gas)
• Compression Ignition (Diesel)
• Cylinder Arrangement
• In-Line
• V-Type
• Opposed
• Valve Arrangement
• I-Head
• H Head
H-Head
• L-Head
• T-Head
Source: John Deere FOS Series
 Intake and Exhaust Systems
• Intake
• Air Filters
• Blower/Supercharger Intercooler
Blower/Supercharger,
• Intake Manifold
• Intake Valves
• Exhaust
E h t
• Exhaust valves
• Exhaust Manifold
• Turbocharger Turbine
• Muffler
Source: John Deere FOS Series
 Cooling System
• Regulate Engine Temperature
• Prevent overheating

• Air Cooling
• Small engines,
engines aircraft,
aircraft Deutz

• Liquid Cooling
• Water (anti-freeze)
• Radiator
• Pump
Source: John Deere FOS Series
 Lubrication
• Reduce Friction
• Dissipated Heat
• Seal Piston Rings and Walls
• Clean and Flush Parts
• R d
Reduce N i
Noise
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series
Source: John Deere FOS Series