Engines, Motors, and

Mobility
[ME F317]
BITS Pilani Dr. Saket Verma
Department of Mechanical Engineering
Pilani Campus
 BITS Pilani
Pilani Campus

Lecture No.: 2
Construction of IC Engine and
Working Fundamentals
Introduction

 The reliability of an IC engine depends on the proper construction of

the engine components. Following are the main component of a
reciprocating engine.
1. Cylinder block
2. Cylinder head
3. Cylinder liners
4. Pistons
5. Piston rings
6. Connecting rods
7. Valves
8. Valve-operating mechanism
9. Crankshaft
10.Crankcase
11.Spark plugs/diesel injector

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CYLINDER BLOCK

 All the major engine components, are installed on or in

the engine block.
• These components including
the cylinder bores, are
machined very precisely.
• Special grinding stones
produce small groves in the
cylinder walls, which collect oil.
• These grooves help to lubricate
the piston rings and piston
skirts
• Previously, most cylinder
blocks were made of cast iron
or grey iron as the material was
easy to machine.
• Engine blocks are now being
cast from lightweight aluminum
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CYLINDER HEAD

 Cylinder head bolts to the top of the engine block,

sealing off the cylinders
• Two/four valves per cylinder in
combustion chambers
• Intake valve is the larger
• Several other valve parts
• Intake manifold: bolted to side
of a head or between cylinder
heads
• Exhaust manifold: bolted to
cylinder head

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CYLINDER HEAD

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CYLINDER LINERS
 The cylinder liner is a sleeve in which the piston of an engine reciprocates.
The life of a cylinder between its re-bores depends on two main factors:
(i) Abrasion, and (ii) Corrosion

• For cylinder liners nickel-chromium iron

has been popularly used.
• The nickel-chromium iron used
contains carbon 3.5%; manganese
0.6%; phosphorous 1.5%; sulphur
0.05%; silicon 2%; nickel 2%; and
chromium 0.7%
• The cylinder liners or sleeves are of
two types:
1. Dry liners
2. Wet liners Dry Liner

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PISTONS

 A piston of an internal combustion engine is in the form of an

inverted bucket shape and it is free to slide in the cylinder barrel

• A piston of an internal
combustion engine serves
three functions:
• 1. It forms a moveable wall of
the combustion chamber.
• 2. It transmits turning force to
the crankshaft via the
connecting rod.
• 3. It functions like a
crosshead and transmits side
thrust, which is due to the
angularity of the connecting
rods to the cylinder walls.

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 PISTONS

Variation of BHP and Sp. Fuel

Consumption with the Use of Piston Temperatures at Various Stages
Aluminium Alloy and CI Piston

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PISTON RINGS

 Piston rings are those rings which are fitted in the grooves provided
in pistons.
• The piston rings perform
three functions:
1. The piston rings seal the
combustion gas leak
2. They provide a path for
conducting heat from the
piston head to the cylinder
walls
3. The crankcase oil, which is
used for engine lubrication
and is splashed by the
crank, is prevented from
passing into the combustion
chamber.

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CONNECTING RODS

 The connecting rod is a link, which connects the

reciprocating piston and the rotating crank.
• Most connecting rods are
made of medium-carbon steel
which has 0.35% to 0.45%
carbon.
• However, the connecting rods
heavy-duty engines are made
of chrome-nickel and chrome-
molybdenum steel.
• The connecting rods are drop-
forged.

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VALVES

 The valves used in an engine following four-stroke cycle

are mushroom-shaped with a conical seating surface
• The valve head rests in the
cylinder head on conical
seating, the angle of the cone
being 45°.
• The valve stem passes through
a guide, which has a plain hole.
• The valve guide is fitted in the
cylinder head casting.
• The valve is closed and
pressed on its seat by a spring
or springs coiled in opposite
directions.

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VALVES

Valve Assembly

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Valve-operating mechanism

 The poppet valves are lifted from

their seats by means of cams and
the valves are closed by springs.
 The lifting and dropping of the valve
must be gradual so that the valve
gear operates without noise.
 the cam follower is connected to a
push rod. The cam follower may be
a roller or a flat or in some cases a
lever.
 The follower pushes the push rod
to actuate a lever, which is known as
a rocker arm. This rocker arm
depresses the valve stem against
the valve springs and lifts the valve
from its seat
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Valve-operating mechanism

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CRANKSHAT

 The crankshaft is an important part of the engine which

converts the reciprocating motion of the piston into rotary
motion.
• The motion of the piston is
transmitted to the crank by the
connecting rod
• The crankshaft is subjected to
torsional and bending stresses
and is supported on the
crankcase structure on large
bearings.
• A crankshaft is composed of
crankpins, crank arms, crank
journals, and driving ends.
Generally, cranks are made of
medium carbon steel and
forged in a single piece.
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CRANKSHAT

Bearings in Crank

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CRANKCASE

 The cylinder block and the upper part of the crankcase

form an integral cast.
• Thus a crankcase is usually
divided into an upper and a
lower section.
• The lower section is known as
the ‘oil pan’ and acts as a
reservoir for the storage of
lubricating oil.
• The lubricating oil is splashed
due to the rotation of the crank
and is also pumped to the
engine bearings, thus
lubricating the various engine
parts.

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https://www.youtube.com/watch?v=eTMpe
MQC8Qk

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Video links

How an engine works - comprehensive

tutorial animation featuring Toyota
engine technologies
https://www.youtube.com/watch?v=zA_19b
HxEYg

Dissecting an Engine, The Basic Parts

and Their Functions
https://www.youtube.com/watch?v=saPGX-
1qC4M

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 BITS Pilani
Pilani Campus

IMPORTANT ENGINE CHARACTERISTICS

IMPORTANT IC ENGINE GEOMETRIC
CHARACTERISTICS

• Geometric terms
– TDC: Highest position of piston
– BDC: Lowest position of piston
– Stroke: The motion of piston from BDC to
TDC (or reverse) is known as one stroke of
the piston
– Stroke length (L): The distance covered in
one stroke is called stroke length.
– Cylinder bore (B or d): The nominal inner
diameter of the cylinder is called bore.
– Stroke volume (Vs): The Volume covered
by piston in one stroke is called stroke
volume.
– Clearance volume (Vc): Volume available
in clearance is called clearance volume.

22
• Geometric terms
• Clearance Ratio (C) : Ratio of
clearance volume to stroke volume.
Vc
C
Vs
• Volume ratio: The ratio of larger
volume to lesser volume during any
process.
L arg er Volume
Volume Ratio 
Lesser Volume
• Compression ratio (r): It is the
volume ratio during the compression
process. It is constant for an engine.
Volume at BDC V1 Vs  Vc
r  
Volume at TDC V2 Vc

Vs
r 1
Vc

mean piston speed (Up) : 2 LN

Up 
60
where L is the stroke and N is the rotational
speed of the crankshaft in rpm. 23
Numerical Problem

Q: The capacity (cubic) of a four-stroke spark-ignition engine is 245 cc. The bore
to stroke ratio is 1.1 (over-square engine). The clearance volume is 27.2 cc.
Calculate the bore, stroke and compression ratio of the engine.

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Numerical Problem

Q: A three liter spark-ignition V-6 engine (v-shaped, 6 cylinder) operates on

four stroke cycle at 3000 rpm. The compression ratio is 9 and the engine is
square (B=L).
Find the followings:
(a) The cylinder bore and stroke length
(b) The average piston speed
(c) The clearance volume of one cylinder

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Working principle of the reciprocating IC engines
Classification of IC Engines

Based on
Based on type of
cycle used number of
strokes/cycle

Diesel cycle =
Otto cycle = Spark Four stroke Two stroke
Compression
Ignition (SI) engine engine engine
Ignition (CI) engine

1 cycle = Two 1 cycle = One

rotation of crank rotation of crank
shaft = Four shaft = Two stroke
stroke engine engine

27
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4-Stroke SI Engine

• Four strokes needed to complete operating cycle

1. Intake stroke/suction stroke
2. Compression stroke
Combustion process/Heat addition
3. Power stroke
Heat rejection
4. Exhaust stroke
• Two strokes occur during each crankshaft revolution
• Two crankshaft revolutions complete one operating cycle

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4-STROKES OF SI ENGINE

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SUCTION STROKE

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COMPERSSION STROKE

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POWER STROKE

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EXHAST STROKE

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REAL-TIME WORKING

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Diesel or Compression Ignition
( C.I. Engine )
Four stroke Diesel Engine

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Operation

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Working

1. Suction stroke :
Due to pressure difference inlet valve opens and air is sucked into
the cylinder
Piston moves from TDC to BDC.
Crankshaft rotates through 180 degree.
2. Compression stroke :
Inlet and Exhaust valve are closed
Piston moves from BDC to TDC.

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Working

Pressure and temperature of charge increases.

Crankshaft rotates through 360 degree i.e. one complete
revolution.
3. Expansion stroke :
Fuel is injected through fuel injector before the piston reaches
TDC.
Temperature of air is high enough to ignite the Fuel.
Sudden increase in the temp. and pressure.

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Working

Combustion products pushes the piston in the downward

direction due to high pressure.
Heat energy transform to mechanical energy.
Piston moves from TDC to BDC
Crankshaft rotates through 540 degree.
Both inlet and exhaust valves are closed.
4. Exhaust stroke :
Exhaust valve opens as the piston moves
from BDC to TDC

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Working

Piston pushes the product of combustion through exhaust valve

into atmosphere.
Examples of Four stroke engines:
In addition to passenger vehicles, CI engines are suitable for
Heavy vehicles (due to high torque requirement):
Buses
Trucks
Tractors.
Earth moving machines.

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Operation of the 4-stroke
diesel engine

41
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Comparison of SI and CI
Engines

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Comparison of SI and CI
Engines

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Two stroke Petrol Engine
( S.I. Engine )

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2-Stroke SI Engine
Exhaust
• Two strokes needed to complete the port

operating cycle.
Fuel-air-oil
mixture
compressed

Check
valve
Expansion Exhaust Intake (“Scavenging”)
Crank
shaft

Fuel-air-oil
mixture

Compression Ignition

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Fuel Transfer

• Piston is at BDC, transfer port is

open
• Partly compressed charge rushes
through port into combustion
chamber and pushes out leftover
exhaust gases of previous cycle.
• At BDC, both transfer port and
exhaust port is open at the same
time.
• Piston crowning is done to
improve scavenging.

46
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Intake into Crankcase

• Piston moving upward

• Crankcase pressure drops
• Intake port open (30% of comp.
stroke)
• Intake air through carburetor (inlet
or suction port) pulls fuel and oil
into crankcase
• Air+fuel gets compressed in the
combustion chamber

47
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Ignition-Power

• Near TDC, Spark ignites air-fuel

mixture
• Combustion takes place
• Piston driven downward
• Creates crankshaft motion

48
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Exhaust

• Piston moving downward

• Inlet port gets closed (70% of
power stroke)
• Exhaust port exposed (92-95% of
power stroke)
• Exhaust gases expelled
• Complete exhausting occurs when
transfer ports are opened
• New charge rushes in and cycle
repeats.

49
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Four-Stroke advantages and
disadvantages
Advantages Disadvantages
1. More efficient engine 1. More complicated. Valves
2. Pollute less than two and their operation.
stroke engines 2. Half as powerful as two
3. Less maintenance. Last stroke engines (for
longer than two stroke equivalent engine size)
engines 3. Turning moment diagram
is less uniform – need
heavier flywheel than two-
stroke engine.

50
Two-Stroke advantages and
disadvantages
Advantages
1. Less expensive because of
its simpler design.
2. They produce twice the
power than four stroke
engines.
3. Lower weight-to-power
ratio because it is much
lighter.
Disadvantages
1. They last less. Lubrication
is not as efficient as in a
four-stroke engine with
heavy oil.
2. Do not use gas efficiently.
3. Pollute more.
4. Faster wear and shorter
engine life than a four
stroke due to the lack of a
dedicated lubricating
system. 51