INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR.

KEERTHI KUMAR N

BMS
Institute of Technology and Management

Department of Mechanical Engineering

NOTES
of

INTRODUCTION TO MECHANICAL
ENGINEERING
BESCK204D

by

Dr. Keerthi Kumar N

Assistant Professor,
Department of Mechanical Engineering
BMS Institute of Technology and Management
Yelahanka, Bangalore

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

Module 2
Internal Combustion Engines

Introduction
An Internal combustion engine more probably called as IC Engine, is a heat engine which converts heat
energy released by the combustion of fuel taking place inside the engine cylinder into mechanical work.
It has advantages such as high efficiency, light weight, compactness, easy starting, adaptability,
suitability for mobile applications, comparatively lower initial cost has made its use as a prime mover.

Classification of IC engines
 Nature of thermodynamic cycle as
1. Otto Cycle engine. 2. Diesel engine. 3. Dual combustion cycle engine.
 Type of Fuel used as
1. Petrol Engine 2. Diesel engine. 3. Gas engine. 4. Bi-fuel engine.
 Number of strokes as
1. Four stroke engine. 2. Two stroke engine.
 Method of ignition as
1. Spark ignition engine, known as S.I engine.
2. Compression ignition engine, known as C.I. Engine.
 Number of cylinders as
1. Single cylinder engine. 2. Multi cylinder engine.
 Position of cylinder as
1. Horizontal engine. 2. Vertical engine. 3. V- engine. 4. Opposed cylinder engine.
5. Radial engine.
 Method of cooling as
1. Air cooled engine. 2. Water cooled engine.

Different parts of I.C. engine

The different parts of an internal combustion engine are shown in Fig. 1.

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

Fig.1. Different parts of I.C engine

Cylinder: This is the heart of the engine. It is a hollow metallic cylinder with cylinder head attached at
the top. The fuel combustion takes place inside this cylinder only. It also houses, the valves, the spark
ignition or fuel injector and also the inlet and exhaust manifolds. Bottom portion of the cylinder is
connected to the crank case.

Piston and Piston ring: It is also a metallic cylindrical block which moves inside the cylinder bore very
precisely. The outside diameter of piston matches precisely with inside bore/diameter of the cylinder. It
has 2 or 3 grooves on its periphery to accommodate the piston rings, which provides an airtight
combustion chamber when the piston reciprocates within the cylinder and also it prevents the leakage of
combustion gases and pressure. The piston transmits the power developed by the combustion of fuel to
crank shaft through the connecting rod.

Connecting rod: It connects the piston to the crankshaft through a crank. The function of the connecting
rod is to convert the reciprocating motions of the piston into the rotary motion of the crankshaft.

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

Crank: This part connects the connecting rod to the crankshaft and rotates continuously and transmits
power from connecting rod to crankshaft.

Crankshaft: this is the main shaft which gets power of the engine and is mounted on the bearings. It
carries fly wheel on it.

Valves: These are mounted on the top of the cylinder and inside and exhaust manifolds. The valves are
the device which controls the flow of intake and exhaust gases to and from the engine cylinder. These
valves are operated by means of cam driven by the crankshaft through a timing gear.

Crankcase: It is a lower part of the engine serving as an enclosure for the crankshaft and also acts as a
sump for lubricating oil.

Flywheel: It is a heavy mass of rotor mounted on the crankshaft and it stores mechanical energy.

Fuel injector: It is mounted on the cylinder head through which the fuel is injected into the cylinder and
used only for diesel engine.

Spark plug: It generates the spark which is used for ignition of petrol and air mixture in petrol engines.

Terminology of I.C. engines

Fig. 2. Terminology of I.C. engines

Bore: It is defined as the inner diameter of an engine cylinder or outside diameter of piston.

Dead center: It is defined as the extreme position of the piston near the engine cylinder.

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

Top dead center (TDC): It is the extreme position of the piston near to the cylinder head of the engine.

Bottom dead center (BDC): It is the extreme position of the piston near the crankcase of the engine.

Stroke (L): It is the linear distance travelled by the piston from top dead center position to bottom dead
center position is called stroke.

Clearance volume (Vc): It is the volume inside the engine cylinder between cylinder head and top face
of the piston when it is at TDC.

Swept volume (Vs): It is the maximum volume is swept by the piston inside the cylinder during its
movement. It is also known as Swept volume.
𝜋𝑑2
Stroke volume Vs = ∗ 𝐿, in m3
4

Total cylinder volume: It is the total volume of the cylinder from top end of cylinder to the bottom dead
center. This is sum of clearance and stroke volume.
Total volume Vt = Vc + Vs, in m3

Compression Ratio (rc): It is the ratio of total cylinder volume to the clearance volume.
𝑉𝑐+𝑉𝑠
Compression ratio 𝑟𝑐 = 𝑉𝑐

Piston speed: The total linear distance travelled by the piston per unit time is called piston speed. It is
expressed in m/min and is given by,
Piston speed = 2LN m/min
L = length of stroke in m
N = speed of the engine in rpm.

Four stroke petrol engine (SI engine)

In four stroke cycle engine, the cycle of operation is completed in four stroke of piston or two revolutions
of the crankshaft. Each stroke is consists of 180° of crankshaft rotation and hence a cycle consists of 720°

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

of crankshaft rotation. The series of operations of an ideal four stroke spark ignition engine are as follows.
The four stroke cycle petrol engine operates on Otto (Constant volume) cycle.

Fig. 3. Working of four stroke petrol engine

A four stroke petrol engine consists of a cylinder with one of its end fitted with a cover plate or cylinder
head. The cylinder head is provided with the inlet and exhaust valves which are operated by cams which is
connected to the crankshaft. The spark plug fitted in the cylinder head which starts the ignition of the petrol
and air mixtures. A freely moving piston reciprocates inside the engine cylinder. The connecting rod and the
crank converts the reciprocating motion of the piston into the rotatory motion of the crank shaft.

Fig. 4. Theoretical PV diagram for Otto cycle

1. Suction stroke: At the start of this stroke piston is at top dead center (TDC) and inlet valve is
kept open and exhaust valve is remains closed. During this process piston moves from top dead
center (TDC) to bottom dead center (BDC) and pressure difference occurs between the inside
and outside cylinder. Due to suction created by the motion of the piston towards bottom dead
center, the fresh mixture of fuel and air is drawn into the cylinder. At the end of this stroke the

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

inlet valve closes. The energy required to perform this stroke is supplied by cranking during the
first cycle at timing of starting, but while running the fly wheel supplies the energy stored by it
during the working stroke of the previous cycle. The horizontal line A-B on PV diagram
represents this process.

2. Compression Stroke: During this stroke piston moves from BDC to TDC and both inlet and
exhaust valves are kept closed. The fresh mixture of fuel and air is taken into the cylinder during
suction stroke is compressed to high pressure and high temperature as the piston moves upward.
This process is a reversible adiabatic process (isentropic) and is represented by curve B-C on the
PV diagram. The air occupied the whole cylinder volume is now compressed into clearance
volume. Just before the end of the compression stroke the fuel and air mixture is ignited with the
help of an electric spark between the electrodes of spark plug located in combustion chamber
wall. Burning takes place when the piston is almost at the TDC. During the burning process the
chemical energy of the fuel is converted into heat energy, producing a temperature rise of about
2000° C and pressure is also increased considerably. A line C-D (Constant volume process) on
PV diagram represents heat addition process.

3. Expansion Stroke: When the fuel and air mixture is ignited by the spark plug the hot gases are
produced which throw the piston from TDC to BDC and thus work is obtained in this stroke.
This linear motion of the piston causes the piston to produce mechanical work which will be
transmitted to the crankshaft by the connecting rod and the crank. This makes crankshaft to rotate
at higher speed. This process of expansion is a reversible adiabatic process (Isentropic) and it is
represented by a curve D-E on the PV diagram. Towards the end of this stroke exhaust valve gets
opened and burnt gases escapes to the atmosphere. This will suddenly bring down the cylinder
pressure to that of atmospheric pressure at constant volume and it is represented by a curve E-B
on the PV diagram.

4. Exhaust Stroke: During this stroke piston moves from BDC to TDC and inlet valve kept closed
and exhaust valve is opened. As the piston moves upward burnt gases exhaust to atmosphere
through the exhaust valve. This process is represented by the line B-A on the PV diagram. One
cycle is completed.

Four stroke diesel engine (CI engine)

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

The four stroke compression ignition engine is similar to the four stroke spark ignition engine. In this
engine instead of spark plug, a fuel injector is mounted in its place and a fuel pump supplies the fuel oil
to the injector at high pressure. The diesel engines work on the principle of theoretical Diesel cycle also
known as constant pressure heat addition cycle. The four stroke diesel engine cycle also comprises of
suction, compression, working and exhaust stroke as shown in the figure below.

Fig. 5. Working of four stroke diesel engine

Fig. 6. Theoretical PV diagram for diesel cycle

1. Suction stroke: At the start of this stroke piston is at Top dead center (TDC) and inlet valve is
kept open and exhaust valve is remains closed. During this process piston moves from TDC to
BDC and pressure difference occurs between inside and outside of the cylinder. Due to suction
created by the motion of the piston towards the bottom dead center, the fresh air is drawn from
the atmosphere into the cylinder. At the end of this stroke the inlet valve closes. The required to
perform this stroke is supplied by cranking during the first cycle at timing of starting but while
running the fly wheel supplies the energy stored by it, during the working stroke of the previous
cycle. The horizontal line A-B on the PV diagram represents this stroke.

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

2. Compression stroke: During this stroke, piston moves from BDC to TDC and both inlet and
exhaust valves are kept closed. The fresh air is drawn into the cylinder during the suction stroke
is compressed to high pressure and temperature as the piston moves upward. This process is a
reversible adiabatic process and it is represented by a curve B-C on PV diagram. Towards the
end of this stroke fuel injector injects fuel into compressed air and initiates the ignition of the
mixture. There by chemical energy of the fuel is converted into heat energy. A line C-D (constant
pressure heat addition) on PV diagram.

3. Expansion or Working stroke: During this stroke piston moves from TDC to BDC and both
inlet and exhaust vales are closed. The piston moves due to expansion of hot gases produced by
the combustion of fuel and air mixture. This linear motion of the piston causes the piston to
produce mechanical work, which will be transmitted to the crankshaft by the connecting rod and
crank. This makes crankshaft to rotate at higher speed. This process of expansion is a reversible
adiabatic process and it is represented by a curve D-E on the PV diagram. Towards the end of
this stroke exhaust valve gets opened and brunt gases escapes to atmosphere. This will suddenly
bring down the cylinder pressure to that of atmospheric pressure at constant volume and it is
represented by a curve E-B on the PV diagram.

4. Exhaust Stroke: During this stroke piston moves from BDC to TDC and inlet valve kept closed
and exhaust valve is opened. As the piston moves upward burnt gases exhaust to atmosphere
through the exhaust valve. This process is represented by the line B-A on the PV diagram. One
cycle is completed.

Difference between SI and CI engines

Sl SI Engines CI Engines
No (Petrol engine) (Diesel engine)
1 Ignition of the fuel by spark plug Ignition of the fuel by spraying fuel to
compressed air at high temperature
2 Works on theoretical Otto cycle Works on theoretical Diesel cycle
3 Fuel used is petrol Fuel used is diesel
4 A mixture of air and petrol is drawn during Only air is drawn during suction stroke
suction stroke

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

5 Combustion is at constant volume Combustion is at constant pressure

6 Low compression ratio ranging from 7:1 to High compression ratio ranging from 16:1 to
10:1 22:1
7 Fuel cost is high Fuel cost is low
8 Power output will be less Power output will be more
9 Used for light duty vehicles like motorcycles, Used in heavy duty vehicles like truck, bus,
car ships, generators.
10 Due to the presence of spark plug, starting is Due to compression ignition, starting the is
easy difficult in cold condition

Formulae

Mean effective pressure (Pm): The mean effective is defined as mean or average pressure acting on a
piston throughout the power stroke. It is also the average pressure developed inside the engine cylinder
of an IC engine.
It is expressed in Bar. ( 1 bar = 105 N/m2) pressure of an engine.
The mean effective pressure of an engine is obtained from PV diagram.
S∗a
Pm = , in N/m2
l
Where: S is Spring value, in N/ m2/m
a is area under PV diagram, in m2
l is length of PV diagram, in m

Indicated Power (IP):

Indicated power is defined as the total power developed inside the engine cylinder due to combustion of
fuel. It denoted by IP and is expressed in kW.
nPm LANk
If P is in N/m2 IP = , in kW
60∗1000
10
If P is in bar IP = nPm LANk ∗ ( 6 ) , in kW

Where: n number of cylinder

Pm is mean effective pressure in N/m2
L is length of stroke in m
𝜋∗𝑑2
A is cross section area of cylinder = , in m2
4

d is diameter of cylinder in m

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

N is speed of crank shaft in rpm

k depends on number of stroke, i.e. k = ½ for 4 stroke engine
k = 1 for 2 stroke engine

Brake Power (BP):

The net power available at the crank shaft of the engine for performing useful work is called brake
power. It is denoted by BP and expressed in kW.
2πNT
B.P. = 60∗1000 , in kW

Where: T = Torque in N-m

N = Speed of the engine in rpm

Torque (T):
Torque is defined as product of force and distance. Torque is measured by using i) Belt dynamotor and
ii) Rope brake dynamotor, for both the method torque formula is T = Force * distance in N-m
(i) Belt dynamotor
T= (T1 - T2) * R, in N-m
Where: T1 = Tension in tight side of the belt in N
T2 = Tension in slack side in N
R = Radius of pulley in m
(ii) Rope brake dynamotor
T= (W-S) * R, in N-m
Where: W = Load on brake drum in N
S = Spring balance reading in N
D+d
R = Radius of pulley or brake drum, i.e R= in m
2

D = Diameter of pulley in m
d = Diameter of rope in m

Friction power (FP):

Amount of power lost due to friction of moving parts inside the cylinder. It can also be defined as
difference between indicated power and brake power.
FP = IP-BP in kW
Mechanical Efficiency (ηmech):
It is the efficiency of the moving parts of mechanism transmitting the indicated power to the crankshaft.
Therefore it is defined as the ratio of the brake power and the indicated power. It is expressed in percentage.

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 INTRODUCTION TO MECHANICAL ENGINEERING (BESCK204D) DR. KEERTHI KUMAR N

BP
ηmech = IP ∗ 100 in %

Thermal Efficiency (ηth):

It is defined as the ratio of power output to the heat liberated by the combustion of fuel. It is expressed
in percentage.
Power output
ηth = Heat supplied ∗ 100 in %

Where: Heat supplied = mf ∗ CV in kW

kg
Mf = mass of fuel in sec
kJ
CV = Calorific value of fuel in
kg

Brake thermal efficiency (ηbth)

Is defined as the ratio of the brake power to the heat supplied by the fuel. It is expressed in percentage.
BP
ηbth = Heat supplied ∗ 100 in %

Indicated thermal efficiency (ηith)

Is defined as the ratio of brake power to the heat supplied by the fuel. It is expressed in percentage.
IP
ηith = Heat supplied ∗ 100 in %

Specific fuel consumption (SFC):

SFC is defined as the amount of fuel consumed by an engine for one unit of energy that is produced.
SFC is used to express the fuel efficiency of an IC engine. It measures the amount of fuel required to
provide a given power for a given period. It is expressed in kg/MJ or kg/kW – hr.
SFC is two types, based on IP and BP. i.e Indicated specific fuel consumption and Brake specific fuel
consumption.
mf Kg
ISFC = , in
IP kW−hr

m Kg
BSFC = BPf , in kW−hr

NOTE:
1. For finding Specific fuel consumptions, mf must be in kg/hr
2. If specific gravity of oil and volume of fuel is in lt/min or m3/min is given, than
SG = density of fuel / density of water
mf = volume of fuel * density of fuel.

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