Mechanical Engineering Internal Combustion Engines Comprehensive Theory with Solved Examples and Practice Questions La [itn | MADE EASY PublicationsMADE EASY Publications Pvt. Ltd. Corporate Office: 44-44, Kalu Sarai (Near Hauz Khas Metto Station), New Delhi-110016 E-mail infomep@madeeasyin Contact 011-45124660, 8860378007 Visit us at: www madeeasypublicat n.0°9 Internal Combustion Engines © Copyright by MADE EASY Publications Pvt. Ltd Alltights are reserved. No part ofthis publication may be reproduced, stored in or introduced into a retvieval system, or transmitted in any form or by any means (electronic, mechanical, photo-copying, recording or otherwise), without the prior written permission of the above mentioned publisher of this book. First Edltion: 2075 Second Edition: 2016 Third Edition: 2017 Fourth Edition: 2018 Fifth Edition: 2019 Sixth Edition: 2020 Seventh Edition: 2021 All ights reserved by MADEEASY PUBLICATIONS Pv. Ld. No partofthisbook may be reproduced or utliaen any the writen permission fom the publisher em toutContents Internal Combustion Engines 1 1 20 20 2 2 22 58 59 60 64 6s 66 70 70 n Chapter 1 Basics and Air Standard Cycles sss 11 Introduction 12. Classification of Engines 12 Components of Engines 14 BasicTerminology 15. OTTOG«le Engines: Petro Engines 16 Diesel Engines 17 Constant Volume or OTTO cycle 18 Constant Pressure or Diese Cycle 19 Dual Combustion Cycle 1.10 Comparison offour stroke and two-stroke engines. 1.11. Comparison of Engines working on Ottoand Diesel cycle 1.12. Performance Parameters of Engine 1.13 Assumption of deal At Standard Cycle 1.14 Comparison among Ott, Diese and Dual exces Objective Brain Teasers Student's Asignment Chapter 2 Combustion in SI and Cl Engines......59 21 SlEngines 22 Stages of Combustion 23. Rateof Pressure Rise 2A Rate Pressure Rise. 25 Knockin Sl Engine 26 ClEngines 27 Spray Characteristics 28 Stages of Combustion 29 Physical Factor Affecting Delay Period B 0) 210 Rate of Pressure Rise 76 2.11 Kockand ClEngine 7 212. Combustion Chamiber Design PrNC pI avnnn-79 2.13. Comparison in Knocking Phenomenon of SIEngine and Cl Engine 79 2.14 ClEngine Combustion Chamber 30 Objective Brain Teasers. 81 Stadent'sAsignment 2 Chapter 3 FUeds — cccsssessssccssseesssccsnneseeees sesesseeee BS, 3.1. Requirement fran IC Engine Fuel 2 32 The Constituents of Crude Petroleum and ther Properties 2 33 Important Products of Refining Process of Crude Petroleum 2 24 Effect of Volatility on Petrol Engine Performance 84 35 Octane Number 34 36 Requirement of Diesel Ful 84 37 Cetane Number 85 38 Alternative Fuels for. Engines 35 Objective Bran Teasers. 6 Student’ Assignment s7 Chapter 4 Ignition, Engine Friction, Lubrication and Cooling... severe BB 4 Introducton, se 42 Energy Requirement 8 43. Requirements of An ignition System, 39 44 Battery anion System 89 45 Magneto-gnition System 2 46 Friction Power 247 Components of engine Friction. 93 Chapter 5 48° Total Friction Work 94 ir ir is Supercharging, Engine Testing and 49° Some Nore Components of Engine Fiction... 95 Performance.. 4.10 Friction Mean Effective Pressure. 95, 5.41 Supercharging, 126 4.11. Mechanical Friction, 96 5.2. Methods of Supercharging 7 412, Mechanical Fiction in Major Engine 5.2. Thermodynamic Cycle With Supercharging ...129 Components *% 54 Supercharging of SparkIgnition Engine.....131 415 Blowby Losses ° 5.5. Supercharging of Compression-lanition 4.14 Effect of Engine Variables on Friction 99 Engine ie 415 Side Thrust On the Piston r 516 Advantages of Supercharging Over High 4.16 Lubrication 101 Compression 12 4.17 Functions ofa Lubricant 102 52 eects ofSuperchorging i 438 Lubrication Principles 1 58 Supercharging Limits 134 419 Bearing Lubrication ws 5.9. Basic Performance Parameters of IC Engine... 135 420 Properties of Lubricants 106 10 Base Measurements bs 421. Additives for Lubricants 108 S11 Heat balance sheet iat 422 SAEViscosty Number me 5.12 Variation of Efciency with Speed 143 423, Lubricating Systems mm 5.13. Variation of Various Mean Effective Pressures 4.24 CRANKCASE VENTILATION. 14 imeptth Speed vas 425. Engine Performance And Lubrication us 5.14 Variation of Torque, Mean Effective Pressure 428. Cooling System uw (mep), bp. & Specific Fuel Consumption with 427 Type of Cooling system 16 Speed vas 428 Advanced Cooling Concepts 120 Objective Bran Tones as 429. Common Coolant. 12 Students Assignment 150 Objective Brain Teasers. 124 Students Assignment. 125, Chapter 6 Engine Emission....ssssesenseneeneeneT ST 6.1 Exhaust Emissions 151 62. Non-Exhaust Emission 155 63. Various method used to control emission... 155 64 Exhaust Gas Recirculation (EGR) 159 65 Engine Design Modification 159 Objective Brain Teasers. 160 (iv)CHAPTER Fuels 3.1 Requirement for an IC Engine Fuel It should take very litle time for combustion It should have high energy density Low deposit forming tendency. 3.2 The Constituents of Crude Petroleum and their Properties Paratfins (C, Ho,,z) like methane, propane, Iso-octane, n-Heptane. They are saturated and stable compound. Branch chain or isoparatfins are highly knock resistant in S| engine than straight chain paraffins. Olefins (C, H,,) like ethylene, propylene, They are unsaturated and unstable compound. They cause gummy deposit after oxidation. Napthenes (C,H,,) ike cyclo butane, cyclo hexane. They are cyclic and saturated compound They are more stable than olefin. ‘Aromatics. They have ring structure of benzene (C,H,) 2s central structure. They are highly active or even explosive (Like Toluene) 3.3 Important Products of Refining Process of Crude Petroleum Natural Gas. They are pataftinic compound mainly Methane. Liquified Petroleum Gas (LPG). These are also paraffinic compound propane and butane. They can be liquified in ambient condition by applying pressure. Gasoline or Petrol. Itis the highest liquid petroleum fraction. All liquid traction having boiling point upto 200°C are gasoline. Its specific gravity is 0.70 to 0.78. Kerosene. These have boiling range 150°C to 300°C and specific gravity 0.78 to 0.85. These are heavier than petro! Diesel. These have boiling range 200°C to 370°C and wide range of specific gravity, These are having more specific gravity than petrol (snwwmadeeasypublications.org MADE EASY ‘Theory with Solved Examples wMechanical ars 84 | Engineering armecee) MADE EASY 3.4 Effect of Volatility on Petrol Engine Performance + Volatity is the tendency of fuel to go from a liquid to a gaseous state on slow heating of fuel Quantity of fuel evaporated with temperature is measured which is called distillation andi this is a measure of volatility of the fuel. ‘* Frontend volatility (0-20% evaporation) Cold starting, hot starting and vapour lock are three important performance characteristics which are affected by the front end volatility of the gasoline used. 1. Cold starting: High front end volatility is required for easy starting of engine 2. Hot starting: Ifthe front end volatility is very high, it will create problem in hot and more vapours will be present in the combustion chamber making the mixt ignite 3. Vapour lock: Low front end volatility is required so that sufficient amount of liquid fuel could be pumped as more vapourization makes air fuel mixture lean because of less quantity of vapour and liquid fuel ‘+ Mid range volatility (20%-80% evaporation) 1. Engine warm up, acceleration, smoothness and fuel economy: The mid range volatility should be sufficient enough to get all these performances of the engine. 2. Carburetor icing: A low mid range volatilty is required to prevent carburettor icing. More Volatile fuel evaporates rapidly, lowering the temperature of carburettor body, With high humiaity ‘content, water vapour in the fuel condense and freezes ‘+ Tail end volatility (80%-100% evaporation) {igh tail end volatility causes less crankcase dilution, less engine depos spark fouling arting as more fe too rich to gum formation and + Aldehydes and peroxides formed after oxidation of unsaturated hydrocarbon are knock inducing compounds. So Alphanaphthol is used as antioxidant. ‘+ Sulphurin fuel causes corrosion, odour and poor explosion characteristic in petro. 3.5 Octane Number * _ Itis percentage of iso-octane in the fuel containing iso-octane and n-Heptane that gives the same knocking intensity as that of the fuel whose octane number is calculated. Octane number 8 means the fuel is equivalent to 100% mixture of iso-octane and n-Heptane where iso-octane is 80% and n- Heptane is 20%, © Octane number of a fuel can be increased by adding Tetra ethyl lead (TEL) + TEL causes spark plug fouling so ethylene dibromide is used to avoid lead deposits for spark plug fouling. 3.6 Requirement of Diesel Fuel re at which a visible flame occurs for less than 5 seconds. It should * Fire point: Itis the temperature at which the flame can sustain for more than, § seconds. It should be high. + Cloud point: tis the temperature at which the wax content of the diesel separates outin the form of solid, It should be low, itis the temperature below which the entire fuel freeze, It should also be very low. MADE EASY www.madeeasypublications.org )POSTAL Inte | Combustion Engi MADE EASY eiecOee Interns! Combustion Enotes | 85 3.7. Cetane Number ‘+ tis the percentage by volume of cetane (C,, H,,) in a mixture of cetane and a-methyl napthalene (C.y H, CH,) that has the same performance in the standard test engine as that of the fuel whose celane number is calculated. So if a fuel is equivalent to 100% mixture of cetane and a-methy! naphthalene where cetane is 85% and a-methy| naphthalene is 15% then cetane number of the fuel 85. + High cetane number of Diesel engine fuel reduce its knocking tendency. * Octane number and cetane no. are related as 104- (ON) 25 (ON 3.8 Alternative Fuels for I.C. Engines LPG + [tis a mixture of mainly propane and some butane and iso-butane. ‘+ Cheaper than gasoline + High knock resistant andl do not pre-ignite easily. * Better manifold distribution. * — Crankease oil dilution is small iciency of engine is lower due to high heat of vapourization. * Itrequires higher compression ratio to have the above said advantages. Methanol (CH,OH) ‘+ The octane number of methanol is greater than petrol so with m petrol engine can be obtained due to higher compression ratio, ‘+ Methanol engine has greater thermal efficiency. * The mass of methanol consumed is 10% more than petrol due to lower calorific value of methanol. ‘anol, 20% greater output than ‘+ Methanol can be obtained from coal c+ Ho —Pétileonbation cg 4H, u Lu Sykes got Coal Steam CO + 2H, —Se2nIS CH, OH Syne wae + Methanol can also be obtained from municipal solid waste ‘+ Methanolis used in racing cars because of increased power due to high compression ratio Ethanol (C,H,OH) + Its octane number is greater than petrol so more thermal efficiency than petrol engine. + The volumetric efficiency is also increased, So mean effective pressure and thus power output is more than petrol engine. thanol can be obtained from any feed stock containing carbohydrate such as corn, wheat potatoes, starch in carbohydrate www.madeeasypublications.org MADE EASY Theory with Solved Examples w uugarcane,Mechanical 86 | Engineering Enzyme ‘Starch in carbohyerate Sugar: MADE EASY Fermentation by yeast Ethanol * Vegetable oil particularly sunflower ol can be blencled wit diesel to reduce the consumption of ciesel CNG (Compressed Natural Gas) * Its amixture of 90% Methane and remaining Ethane + Iti good SI engine fuel due to high Octane number. © Fuel availabilty is large + Itis cheap, odourless and safe in operation. + Lowengine emissions. Summary ‘* tis percentage of iso-octane in the fuel containing iso-octane and n-Heptane that gives the same knocking intensity as that of the fuel whose octane number Is calculated © Octane number 80 means the fuels equivalent to 100% mixture of iso-octane and n-Heptane where iso-octane is 80% and n-Heptane is 20%. + Octane number of a fuel can be increased by adding Tetra ethy! lead (TEL). ‘+ tis the percentage by volume of cetane (C,,H,,) in a mixture of cetane and a-methyl napthalene (C,. H, CH,) that has the same performance in the standard test engine as that of the fuel whose cetane number is calculated. So if a fuel is equivalent to 100% mixture of cetane and a-methyl naphthalene where cetane is 85% and a-pmethyl naphthalene is 15% then cetane number of the fuel is 85, ‘* High cetane number of Diesel engine fuel reduce its knocking tendency, g Objective Brain Teasers Q.1 For determining the ignition quality of (0) The cetane number of alcohol fuels is very compression ignition engine fuels, the reference high which prevents their ignition by fuels used are compression (@) Is0-0olane and n-heptane (c) The octane number of alcohol fuels is very (b) Cetane and a-methyinapthalene low which prevents their ignition by (6) Hexadecane and r-heptane compression (a) Cetane and iso-octane (@) None of the above Q.2 Alcohols are unsuitable at diesel engine fuels @.3 Methane bums with stoichiometric quantty of because air. The air-fuel ratio by weight is (@) The cetane number of a alcohol fuels is very @4 (0) 147 low which prevents their ignition by (0) 15 (a) 17.16 compression MADE EASY Cy Meery with Soived Exam; www.madeeasypublications.org >a as a. 4 Match List- (Fuels) with Listll (Characteristics! usages) and select the correct answer using the codes given below the lists: List A. Semi-bituminous coal B. High-speed dieselol C. Biogas D. LPG List 1. Methane and carbon dioxide 2. Propane and butane 8. Calorific value of 10,600 kealkg 4. Power plants Codes: A BC OD 3 4 1 2 4 3 21 (3 4 21 @4 3 14 2 5 Inapetrol engine car, which one of the following performance characteristic is affected by the front-end volatility gasoline used? (a) Hot starting and vapour lock eue022) ar Internal Combustion Engines Fuels 87 2. Compressed natural gas is a mainly composed of methane. 3. Producer gas has a Predominant component of hydrogen with lesser proportion of cartoon, monoxide 4. Cetane number of fuel used in diesel engines in India is in the range of 80 to 90. Which of these statements ate correct? (@) tand2 (b) tand3 (©) 2.3and4 — (¢) 1,2, 3and4 Which one of the following fuels can be obtained by fermentation of vegetable matter? (@) Benzene (b) Diesel (6) Gasoline —_(d) Alcohol Answers @ 2@ 3@ 40 5@ @ 7. @ = eee Discuss the important qualities of a SI engine fuel What is vapour lock? What do you mean ay ignition quality of a fuel? Discuss the basic qualities of a good Cl engine fuel Briefly discuss the rating of Cl engine fuels, (0) Engine warm-up and sparkplug fouling 4 (6) Spark plug fouling and hot starting (@) Vapourlock. engine warm-up andsparkplug gg fouling as .6 Consider the following statements: 1. Motor gasoline is a mixture of various 24 hydrocarbons with amajor proportional being aromatic hydrocarbons. as MADE ERS - www.madeeasypublications.org Theory with Eamples [3