Automotive engineering

History of Automobile

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 1.1 Spark Ignition (SI) & Compression Ignition (CI) engines

SI Engines CI Engines

1 Uses spark plug to initiate combustion Autoignition- fuel injected to combustion

chamber - highly compressed high temp air

2 Used for Petrol or Gas engines Used for diesel engines

3 Employs lower C.R (9-12) Higher C.R (15 - 22)

4 Fuel is mixed with air externally (Carburetor or Intake Fuel and air mixes in combustion chamber
Manifold in MPFI)

5 Used in light passenger vehicle - cars Used in heavy commercial vehicle - Truck,
Buses

6 Spark plug is present No spark plug but fuel injector is present

7 Less fuel efficiency due to lower C.R More fuel efficient

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8 Engines are lighter in weight and runs at high RPM Heavy in weight , runs at low RPM
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1.2 Cylinder – arrangements and their relatives merits

Single Cylinder
● Generally employed in two wheelers
● Power stroke - once in 2 rev - every 720 deg
crank angle rotation
● Max size allowed - 500 - 600 CC
● Higher the size - more unbalanced forces, higher
flywheel size and and more weight

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1.2 Cylinder – arrangements and their relatives merits

Two Cylinder
● More uniform torque
● Better balancing
● Rarely employed
● Luxury bykes like
Harley Davison, BMW
etc

BMW MOTORRAD Harley Davison Street 750

TWO CYLINDER PARALLEL TWIN 800 CC V type 750 CC

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1.2 Cylinder – arrangements and their relatives merits
Two cylinder Merits Demerits
Arrangement

1 In line side by Power impulse every 360 deg Balancing difficult

side

2 In line side by Good balancing Unequal firing

side 180 deg
out of phase

3 V-type 1. More compact, single crank case 1.Uneven firing order (270,
2. Less weight per Volume ratio 450)
3. Small crankshaft, runs smoothly 2.Cost of Manufacturing high
3.Difficult balancing

4 Opposed type 1. Power impulse at even intervals, every 360 Length of too high
deg Consumes more space
2. Perfectly balanced
3. High possible speed, smooth running
4. Low centre of gravity, better vehicle stabilty 8
1.2 Cylinder – arrangements and their relatives merits

Three Cylinder
➢ Power every 240 deg crank rotation- even
intervals
➢ Dynamically well balanced
➢ Reduced weight, length and drag, better fuel
efficiency compared 4 cylinder

Maruti 800 engine

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4 cylinder Inline vertical engine

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Volvo 9400 XL 7 litre 6 in-line
cylinder diesel engine
Honda 2.4 litre V8 F1 engine13
 Radial Engines
•Generally odd number is used – 5,
7, 9.
•High BHP/weight ratio
•Construction – simple compared
to in-line
•Very large frontal area – creates
difficulty in streamlining the
vehicle shape
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Components of engine
● Cylinder Block
● Cylinder Head
● Piston
● Piston rings
● Liners
● Piston pin
● Connecting rod
● Crankshaft
● Valves
● Others
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● Open combustion chamber:Medium and high speed engines, Injector at
centre, grove at piston or cylinder head
● Pre combustion chamber: High speed engines, Auxillary chamber - smaller
in size, Orifice, creates turbulence
● Swirl Combustion Chamber: Swirl is a circular motion given to incoming air
during suction stroke (Vortex type - cylindrical chamber in the head, Comet
type - spherical chamber connected tangentially through a narrow passage
● Squish Combustion Chamber: Squish is the flow of air from periphery to the
centre of cylinder.
● Air cell and Energy Cell (Lanova) Combustion chamber: Small chamber
connected to main through narrow passage

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 Liners
● Overcome the problem of cylinder wear
● Liners -replaced when worn out
● Material
■ Al alloy with chromium coating(improves wear
resistance)
■ Special Alloy - Silicon, Manganese, Ni & Chromium
● Centrifugal casting
● Two types - Dry and Wet

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 Difference between dry and wet liners
Sl. No Dry liner Wet liner

1 No leak proof joint required Leak proof joint between block and liner

2 Robust in design Liner is supported only at top and bottom of

block

3 Can be used in multi cylinder arrangement Can be used only where coolant passage is
siamesed adjacent cylinder bores provided

4 Casting design is complex Casting of cylinder block is simple

5 Comparatively poor cooling Better cylinder cooling

6 Finishing depends on fitting - shrinkage Finished before fitting

stress

7 Requires accurate finishing - both sides Not required

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 Piston
Functions
1. To transmit force of explosion to crankshaft
2. To form a seal - prevent escaping of
combustion chamber gases
3. To serve as guide and bearing for small end
of connecting rod
Characteristics
1. Silent in operation
2. Not seize - good design
3. Corrosion resistance
4. Shortest possible length
5. Lighter in weight - less inertia
6. High thermal conductivity 7. Long life
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 Features of piston
● Head: part of combustion chamber
● Lands: support the rings against gas pressure and guide
● Skirt: guides and absorbs side thrust (inclination of
connecting rod with cylinder axis) - gas pressure
● Material: Al alloy containing silicon - 3 times lighter than
Cast iron, high k….
○ Causes abrasion - soft metal- absorbs lubricating oil-
reduces cylinder life
○ Unequal thermal expansion - used with cast iron
cylinder 31
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 Expansion control in pistons
1. By keeping heat away from lower part of pistons
(Horizontal, vertical and T slots, Split skirt)
2. By making heat dam
3. Taper pistons
4. By cam grinding pistons (Elliptical shape to circular)
5. Use of special alloys - “Lo Ex”- 12%-15% Si, 1.5-3% Ni and 1% each Mg and
Cu.
6. Autothermic pistons
7. Bi-Metal Pistons
8. Offset Pistons

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Piston rings

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 Piston rings
Functions
1. To provide pressure seal to
prevent blow by of exhaust gases.
2. To form the main path of
conduction of heat from piston
crown to cylinder walls
3. To control flow of oil to the skirts
and rings themselves in adequate
quantity
Material: Fine grained alloy cast iron

Types: 1. Compression ring (2 to 3)

2. Oil Ring (One) 36
 Connecting Rod

● Convert linear motion of

piston into rotary motion of
crankshaft
● I- cross section
● Forged steel or Al alloy
● Strong, rigid and light in
weight

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 Crankshaft
● First part with rotary motion
● Centre distance between
crankshaft and crankpin is
half of stroke length
● Casting or forging of heat
treated alloy steel
● Front end connected to gear
to drive camshaft, vibration
damper and fan belt pulley.
● Rear end- flywheel

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 Valves
● Poppet, sleeve and rotary types
● Motion of popping up
● Similar to mushroom
● Inlet valves larger than exhaust valve
● Exhaust valves subjected to more
thermal stresses, longitudinal cyclic
stresses
● Material
○ Inlet valve: Silico chrome steel
○ Exhaust valve: Austenitic steel

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 Valve cooling

Valve temperature drops by

100 deg C
Sodium - high k
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Valve actuating mechanism

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Need for cooling system

The cooling system has four primary functions. These

functions are as follows:

1. Remove excess heat from the engine.

2. Maintain a constant engine operating temperature.
3. Increase the temperature of a cold engine as quickly as
possible.
4. Provide a means for heater operation (warming the
passenger compartment).
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Types of cooling system:

The different Types of cooling system are

1. Air cooling system
2. Liquid cooling system
3. Forced circulation system
4. Pressure cooling system

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Air cooling system

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Glycerine (Boiling point 290 deg C) and ethylene glycol (Boiling point 195 deg C)
used as coolant

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Thermo-syphon cooling system

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Forced circulation system

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 Components of Forced circulation system

1. Radiator
2. Thermostat
3. Pump
4. Fan
5. Water jackets

Thermostat: does not permit water below

70 deg C

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 cont...
● The thermostat lies in the small cylinder located on the
engine-side of the device.
● This cylinder is filled with a wax that begins to melt at
perhaps 180 degrees F
● A rod connected to the valve presses into this wax.
● When the wax melts, it expands significantly and pushes
the rod out of the cylinder, opening the valve

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Objectives
Primary:

1. To reduce friction between moving parts

2. To reduce wear of moving parts

Secondary:

1. To provide cooling effect

2. To provide cushioning effect
3. To provide cleaning action
4. To provide a sealing action

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Types
1. Petroil system
2. Splash system
3. Pressure system
4. Dry-Sump system

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Problems with lubricating system
High pressure in the system

Low pressure in the system

High oil consumption

Overheating of the engine

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