06 I C Engines

Internal Combustion Engines
(I. C. Engines)
1
I. C. Engine
The internal combustion (I.C) engine is a heat
engine that converts heat energy of the fuel into
mechanical energy and is made available on a
rotating output shaft.
2
Classification of I.C Engines
According to:
(i) Nature of Thermodynamic Cycle:
Otto cycle engine
Diesel cycle engine
(ii) Type of the Fuel used:

Petrol engine
Diesel engine
LPG & CNG engine
Dept. of Mech & Mfg. Engg. 3

(iii) Number of Strokes:
2 - stroke engine
4 - stroke engine
(iv) Method of Ignition:

Spark Ignition engine [S.I. Engine].
Compression Ignition engine [C.I. engine].
(v) Number of Cylinders:

Single cylinder engine.
Multi-cylinder engine.

(vi) Position of the Cylinder:
Horizontal engine
Vertical engine
In-line engine
V- engine
(vii) Method of Cooling:
Air cooled engine
Water cooled engine

I. C. Engine Parts

I C Engine terms & Definitions
Spark plug
TDC (Top Dead Center): Valve
Clearance
It is the top extreme position of the TDC
volume
Bore
piston towards the cylinder head.
Stroke
BDC (Bottom Dead Center):

The lower extreme position of the BDC
Piston
piston towards the crank end side of

the cylinder.

Stroke:
It is the linear distance
travelled by the piston from
TDC to BDC.
Bore:
It is the inner diameter of the Bore
engine cylinder.

Swept / Displacement / Stroke
volume:
It is the volume swept by the
piston from TDC to BDC.

Clearance volume:
It is the volume of the
cylinder above the piston,
when it is at TDC.

Total volume = Swept volume + Clearance volume.
Compression ratio (r) :

It is the ratio of Total volume to Clearance volume.
Total volume
r
Clearance volume
Value of (r):
Petrol engine lies between 7 to 9.

Diesel engine lies between 15 to 22.

Working of 4-stroke Petrol engine
Petrol engines work on the principle of “OTTO CYCLE”,
also known as “Constant Volume combustion cycle”.
Charge admitted into the cylinder is a mixture of Petrol

and Air.
Petrol and air is mixed in proper proportions and sent to

the cylinder by a device known as “Carburetor”.

4 stroke petrol engine consists of the following:
1. Suction stroke
2. Compression stroke
3. Working, power or expansion stroke
4. Exhaust stroke
Ignition in petrol engine is due to a spark produced by a

spark plug and hence called as Spark Ignition (SI)
engines.

Petrol & Air Exhaust
mixture gases
SUCTION COMPRESSION POWER EXHAUST
I.V = Inlet valve, E.V = Exhaust valve, E.C = Engine cylinder

C.R = Connecting rod, C = Crank, S.P = Spark plug
1. INTAKE [Suction]:
During this stroke, the inlet valve is opened & the piston
moves down ward, drawing a fresh charge (Petrol & Air
mixture).
Pressure [P]
TDC
A B
BDC
Volume [V]
2.Compression Stroke:
During this stroke both inlet & exhaust valves are closed
& the piston moves from BDC to TDC, thus compressing
the charge thereby increasing the pressure and
temperature.
Pressure [P]
TDC
C
BDC A B
Volume [V]
Compression Stroke (contd.):
Just before the end of this stroke the spark plug initiates a
spark which ignites the mixture and combustion takes
place at constant volume as shown by the line CD.

3. Working (Power) Stroke:
During this stroke both inlet & exhaust valves remain

closed & the combustion gases exerts a pressure on the
piston. Thus the piston moves from TDC to BDC and
thus the work is obtained in this stroke as shown by the
line DE.
Pressure [P] D
TDC
BDC A
B

Volume [V]
Working (Power) Stroke (Contd.):
At the end of the power stroke, the exhaust valve is opened
& greater part of the burnt gases escapes because of
their own expansion. The drop in pressure at constant
volume is represented by the line EB.
Pressure [P] D
TDC
BDC
A
B
Volume [V]
4. Exhaust Stroke:
During this stroke the piston moves from BDC to TDC
and pushes the remaining burnt gases to the
atmosphere. This stroke is represented by the line BA on
the P –V diagram.
Pressure [P] D
TDC
BDC
A
B
Volume [V]
P V diagram for
S.I/ Otto cycle/Constant volume
combustion cycle
Pressure
D
TDC
A
BDC B
Volume
Theoretical Otto cycle

Working of 4-S Diesel engine
The basic construction of a 4 stroke diesel engine is same
as that of 4 stroke petrol engine.
Instead of a Spark plug, a FUEL INJECTOR is used.
Only Air is drawn into the cylinder during the suction

stroke and it will get compressed during the compression
stroke.
Fuel is injected into the cylinder by the injector at the end

of compression stroke in the form of fine spray.

When the fine spray diesel comes in contact with hot air
in the cylinder, it auto (self) ignites leading to
combustion of the fuel.
Since ignition occurs due to the temperature of the

compressed air, they are also called Compression
Ignition Engines.

Exhaust
Air
gases
SUCTION COMPRESSION POWER EXHAUST
I.V = Inlet valve, E.V = Exhaust valve, E.C = Engine cylinder

C.R = Connecting rod, C = Crank, F.I = Fuel injector
1. INTAKE [Suction]:
During the intake stroke, as the piston moves from
TDC to BDC, AIR is drawn into the cylinder which is
represented by the line AB on the P-V diagram.
Pressure [P]
TDC
A
BDC B
Volume [V]
2. Compression Stroke:
C D
Pressure [P]
TDC
BDC A
B
Volume [V]

3. Working Stroke:
C D
Pressure [P]
TDC
A
BDC B
Volume [V]

4. Exhaust Stroke:
C D
Pressure [P]
TDC
A
BDC B
Volume [V]

P V diagram for
C. I Engine / Diesel cycle engine
D
Pressure
C D
TDC
A B
BDC
Volume
Theoretical Diesel cycle

Comparison between
Petrol & Diesel Engine
Petrol engine Diesel engine

1 It works on Otto cycle. It works on diesel cycle.
2 Air and petrol are mixed Diesel is fed into the
in the carburetor before cylinder by fuel injectior
they enter into the and is mixed with air
cylinder. inside the cylinder.
3 Method of ignition: Method of ignition :
Spark Ignition Compression Ignition

Cylinder is fitted with a Cylinder is fitted with a fuel
4 injector.
spark plug.
5 Less thermal efficiency More thermal efficiency

Compression ratio ranges Compression ratio ranges
6 from 7:1 to 9:1 from 15:1 to 22:1
Less initial cost and more More initial cost and less
7
running cost. running cost.
Light weight and occupies Heavy and occupies more

8
less space. space.

Easy to start even in Difficult to start in cold
9 cold weather. weather and requires
heater plugs.
Used in light vehicles Used in heavy duty
10 like cars, motor cycle, vehicles like trucks, buses,
scooters, etc. tractors, etc.

Two Stroke Engine
In a two stroke engine, one working cycle is completed by
the two strokes of the piston.
Suction and Compression takes place in one stroke and
Power and exhaust takes place in the next stroke.
Instead of valves, ports are provided.
Ports are opened and closed by the movement of the
piston.

Working of 2 - Stroke Petrol Engine
Downward movement of Upward movement of

the piston the piston

First stroke (Downward):
As soon as the charge is ignited, the hot gases evolved force
the piston downwards, thereby rotating the crankshaft and
producing useful work.
The downward movement of the piston first uncovers the
exhaust port causing the burnt gases to escape to the
atmosphere.
Further downward movement of the piston covers the inlet
port, thereby stopping the entry of fresh charge into the
crankcase.

Further movement of the piston uncovers the transfer port
and the compressed charge from the crankcase enters into
the cylinder.
As the compressed charge enters the cylinder, it pushes out
the gases from the cylinder and this process is known as
scavenging.

Second stroke: (upward)
Here, as the piston moves from BDC to TDC first transfer
port is covered thereby stopping the entry of fresh charge
into the cylinder.
Further upward movement of the piston uncovers the Inlet

port thereby admitting the fresh charge into crankcase.
Further movement of the piston covers the exhaust port and

the charge gets compressed.
The compressed charge is then ignited by the spark plug

and the cycle of events are repeated.

Working of Two Stroke Diesel Engine
Air
First stroke Second stroke

First stroke (Downward):
Combustion starts once the hot compressed air comes in
contact with the injected diesel. The combustion gases
evolved force the piston downwards, thereby rotating the
crankshaft and producing useful work.
The downward movement of the piston first uncovers the
exhaust port causing the burnt gases to escape to the
atmosphere.
Further downward movement of the piston covers the inlet
port, thereby stopping the entry of fresh charge (air) into the
crankcase.

Further movement of the piston uncovers the transfer port
and the compressed charge from the crankcase enters into
the cylinder.
As the compressed charge enters the cylinder, it pushes out
the gases from the cylinder and this process is known as
scavenging.

Second stroke: (upward)
Here, as the piston moves from BDC to TDC first transfer
port is covered thereby stopping the entry of fresh charge
into the cylinder.
Further upward movement of the piston uncovers the Inlet

port thereby admitting the fresh charge into crankcase.
Further movement of the piston covers the exhaust port and

the charge gets compressed.
The compressed charge is then ignited by the injected diesel

and the cycle of events are repeated.

Comparison between
4 - stroke & 2 - stroke Engine
4 – stroke engine 2 – stroke engine

One power stroke for One power stroke for
1 every two revolution of every revolution of the
the Crank shaft crank shaft
Cycle is completed in Cycle is completed in one

2 two revolutions of the revolution of the crank
crank shaft shaft
3 Less fuel consumption More fuel consumption.

4 Higher thermal efficiency Lower thermal efficiency
5 Engine design is complicated Engine design is simple.
Lesser rate of engine wear Higher rate of wear and

6
and tear. tear.
It has inlet and exhaust It has inlet and exhaust

7
valves ports

For the same power, the
8 Engine is heavy & bulky. engine is light and compact.
It requires lesser cooling It requires greater cooling

9
and lubrication and lubrication
10 Higher initial cost Lower initial cost.
Higher running noise and
Lower running noise and
11 vibration due to the sudden
vibration
release of the burnt gases.
Used in cars, trucks, Used in mopeds, motor
12
buses, tractors, etc. cycles, scooters, etc.

CARBURETOR
Function:
The main function of a carburetor is to vaporize & atomize
the fuel & to mix thoroughly with air at the appropriate
proportion.
Vaporization:
Change in state of fuel from liquid to vapour.
Atomization:
Breaking up of the fuel into small particles.

Working of a Simple Carburetor
Needle valve
Float chamber
Petrol – Air mixture

to cylinder

As the fuel level drops, the float comes down thereby
opening the needle valve and enabling the petrol to enter
into the float chamber.
Purpose of needle valve is to maintain the constant level of
petrol in the float chamber.
During suction stroke, pressure at the throat reduces and
because of the negative pressure developed in the venturi
region petrol comes out of the nozzle as a fine spray &
gets vaporized.
The mixture of air & petrol vapour in correct proportion
passes through the throttle valve into the engine cylinder.
The throttle valve is operated by the accelerator.
Important Definitions
Brake Power [B.P]:
It is the power available at the output shaft.
2 NT
Brake Power  kw
60000
Where, N = Speed of the crank shaft in rpm.
T = Torque applied on the brake drum due to load “W” in (N)
T=W*R Nm
R = Radius of the brake drum (m)

Indicated Power [I.P]:
It is the power developed inside the engine cylinder
i  Pm  L  A  n
Indicated Power  kW
60000
Where, i = No. of cylinders
,
n = No. of working cycles/min.
n = N/2, for 4 stroke engine
n = N, for 2 stroke engine
L = Stroke length (m), D = Bore diameter (m)
Pm = Indicated mean effective pressure (N/m2)

A = Area of the cylinder, A  D2 , m2
4 49
Frictional Power [F.P]:
It is the difference between the indicated power and the
brake power.
F.P = [I.P – B.P] KW
Mechanical Efficiency [ηmech ]:
It is the ratio of the brake power and the indicated power.
B.P
Mechanical efficiency,mech  100%
I .P
50
Brake thermal Efficiency [ηbth ]:
It is the ratio of brake power to the heat supplied by the fuel.
B.P  3600
bth  *100%
m  Cv
Where, m = mass of fuel supplied (kg/hr)
CV = Calorific value of the fuel (kJ/kg)
Indicated thermal Efficiency [ηith ]:
It is the ratio of indicated power to the heat supplied by the
fuel.
I.P  3600
ith  *100%
m  Cv
51
Problem 1:
A four-stroke petrol engine, with 40 mm bore and 60 mm
stroke was tested under a constant speed of 600 rpm.
Diameter of belt dynamometer (brake drum) pulley = 1 m.
Tight side tension in the belt = 800 N
Slack side tension in the belt = 400 N
Determine the brake power developed.
52
Problem 2:
The following observations were obtained during a trial on
a 4 stroke diesel engine.
Cylinder (bore) diameter = 25 cm
Stroke of the Piston = 40 cm
Crankshaft speed = 250 rpm
Net load on the brake drum = 700N
Brake drum diameter = 2 m
Mean effective pressure = 6 bar
Diesel oil consumption = 0.0013 Kg/sec
Specific gravity of diesel = 0.78
Calorific Value of diesel = 43,900 kJ/kg
Find: B.P, I.P, F.P, Mechanical Efficiency, Brake Thermal
Efficiency & Indicated Thermal Efficiency
53
Problem 3:
The following observations were obtained during a trial on
a 4 stroke diesel engine.
Cylinder diameter = 25 cm
Stroke of the Piston = 40 cm
Brake load = 70 kg
Brake drum diameter = 2 m
Diesel oil consumption = 100 cc/min (0.1 litres/min)
Specific gravity of diesel = 0.78
Calorific Value of diesel = 43.9 MJ/kg
Determine: B.P, I.P, F.P, ηmech, ηbth, ηith

54
Problem 4:
The following observations refer to a trial on a single
cylinder diesel engine. B.P = 75 kW, ηbth = 35%, ηmech =
90%, Cv = 40 MJ/kg. Determine I.P, F.P, Fuel
consumption per brake power hour.
55
Problem 6:
A 4 cylinder, 4 stroke I.C engine develops an I.P of 50 kW
at 25 cycles/second. The stroke of the engine is 90 mm and
bore is 0.8 times the stroke.
Find the mean effective pressure in each cylinder.
If mechanical efficiency is 80%, what effective brake
load would be required if the effective brake drum
circumference is 1m.
56
To find the effective brake load “W” if brake drum
circumference is 1m.
BP BP
 mech   100% 80   100%
IP 50
 BP  40kW
2NT
Brake Power  kW
60000
Now, Substituting the value of BP in the below formula to find
Torque „T‟ .
 T  127.32Nm
57
We have torque T = W x R
But circumference of the brake drum, 2R= 1 m.
R = 0.159 m
T = 127.32 = W x 0.159
W = 800 N
58
Problem 7:
The following data refers to a twin cylinder 4 stroke petrol
engine.
Cylinder diameter = 200 mm
Stroke of the Piston = 300 mm
Effective Brake load = 50 kg
Mean circumference of the brake drum = 4 m
Calculate:
• Brake Power
• Indicated Power
• Mechanical Efficiency
59
Problem 8:
A 4 cylinder, 2 stroke petrol engine develops an indicated
power of 15kW at 1000 rpm. The indicated mean effective
pressure is 0.55 MPa. Calculate the bore and stroke of
the piston if the length of stroke is 1.5 times the bore.
Solution:
i = 4,
I.P = 15 kW, N = 1000 rpm, L = 1.5D,
Pm= 0.55 MPa = 0.55 x 106 N/m2
Since it is a 2 - stroke engine
n = N = 1000 cycles/min.
60
i Pm L An 
Indicated Power  where, A  D2
60000 4
 D 2
4  0.55 106  (1.5D) 1000
15  4
60000
4
 D  3.472 10
3
The bore diameter D = 0.0703 m = 70.3 mm
Length of stroke L = 1.5 D
= 1.5 x 70.3 = 105.45 mm

61
Problem 9:
Calculate the brake power of a twin cylinder four stroke
petrol engine, given:
Duration of the test = 1 hour
Diameter of brake drum = 600mm
Brake rope diameter = 3 cm
Dead weight = 24 kg
Spring balance reading = 4 kg
Total revolutions made = 27,000
62
Problem 10:
The following data refers to a test on a petrol engine:
I.P = 40KW, B.P = 35KW, Calorific value of fuel = 44,000
KJ/kg. Fuel consumption per brake power hour = 0.3kg.
Calculate Brake thermal efficiency.
63

06 I C Engines

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06 I C Engines

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Internal Combustion Engines

(ii) Type of the Fuel used:

Dept. of Mech & Mfg. Engg. 3

(iv) Method of Ignition:

(v) Number of Cylinders:

Dept. of Mech & Mfg. Engg. 4

Dept. of Mech & Mfg. Engg. 5

Dept. of Mech & Mfg. Engg. 6

TDC (Top Dead Center): Valve

BDC (Bottom Dead Center):

piston towards the crank end side of

Dept. of Mech & Mfg. Engg. 7

Dept. of Mech & Mfg. Engg. 8

Dept. of Mech & Mfg. Engg. 9

Dept. of Mech & Mfg. Engg. 10

Compression ratio (r) :

Petrol engine lies between 7 to 9.

Dept. of Mech & Mfg. Engg. 11

Charge admitted into the cylinder is a mixture of Petrol

Petrol and air is mixed in proper proportions and sent to

Dept. of Mech & Mfg. Engg. 12

Ignition in petrol engine is due to a spark produced by a

Dept. of Mech & Mfg. Engg. 13

SUCTION COMPRESSION POWER EXHAUST

I.V = Inlet valve, E.V = Exhaust valve, E.C = Engine cylinder

Dept. of Mech & Mfg. Engg. 17

During this stroke both inlet & exhaust valves remain

Dept. of Mech & Mfg. Engg. 18

Theoretical Otto cycle

Dept. of Mech & Mfg. Engg. 21

Instead of a Spark plug, a FUEL INJECTOR is used.

Only Air is drawn into the cylinder during the suction

Fuel is injected into the cylinder by the injector at the end

Dept. of Mech & Mfg. Engg. 22

Since ignition occurs due to the temperature of the

Dept. of Mech & Mfg. Engg. 23

SUCTION COMPRESSION POWER EXHAUST

I.V = Inlet valve, E.V = Exhaust valve, E.C = Engine cylinder

Dept. of Mech & Mfg. Engg. 26

Dept. of Mech & Mfg. Engg. 27

Dept. of Mech & Mfg. Engg. 28

Theoretical Diesel cycle

Dept. of Mech & Mfg. Engg. 29

Petrol & Diesel Engine

Petrol engine Diesel engine

Dept. of Mech & Mfg. Engg. 30

5 Less thermal efficiency More thermal efficiency

Light weight and occupies Heavy and occupies more

Dept. of Mech & Mfg. Engg. 31

Dept. of Mech & Mfg. Engg. 32

Dept. of Mech & Mfg. Engg. 33

Downward movement of Upward movement of

Dept. of Mech & Mfg. Engg. 34

Dept. of Mech & Mfg. Engg. 35

Dept. of Mech & Mfg. Engg. 36

Further upward movement of the piston uncovers the Inlet

Further movement of the piston covers the exhaust port and

The compressed charge is then ignited by the spark plug

Dept. of Mech & Mfg. Engg. 37

First stroke Second stroke

Dept. of Mech & Mfg. Engg. 38

Dept. of Mech & Mfg. Engg. 39