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BASIC CIVIL& MECHANICAL ENGINEERING (Module-4)

Basic Mechanical Engineering- Module 1
Part B- I C Engines
1. Heat engines
 Heat engines absorb energy in the form of heat and convert part of it into mechanical
energy and deliver it as work, the balance being rejected as heat.

 These devices derive the heat energy from the combustion of a fuel.

 Based on the location of the combustion process, heat engines are classified into
internal combustion and external combustion engines.

Internal combustion engines (IC engines) are those where the combustion of the fuel takes
place inside the engines – eg. automobile engines. In the case of external combustion
engines, combustion of fuel occurs outside the engines and the working gas so heated is then
admitted into the engines for conversion and work extraction – eg. steam generated in a
boiler is then admitted to steam engines for producing work.
2. Classification of I C Engines
i) On the basis of Basic engine design:-
(1) Reciprocating
(2) Rotary (Wankel)
(ii) On the basis of Working cycle:-
(1) Otto cycle (SI Engine)
(2) Diesel cycle (C I Engine)
(iii) On the basis of Strokes:-
(1) Four stroke Engine
(2) Two stroke Engine

(iv) On the basis of Fuel:-

(1) Petrol
(2) Diesel, CNG& LPG
(v) On the basis of Fuel supply:-
(1) Carbureted types
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(2) Injection types

(vi) On the basis of Ignition:-
(1) Battery ignition
(2) Magneto ignition
(vii) On the basis of Cooling Method:
Method:-
(1) Water cooled
(2) Air cooled
(viii) On the basis of cylinder arrangement:
arrangement:-
(1) In line Engine
(2) V Engine
(3) Radial Engine etc.
3. Parts of an IC engine
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1. Cylinder head. This is the top cover of the cylinder and holds the inlet and exhaust valves,
their operating mechanisms, and the spark plug or fuel injector, as the case may be. The
valves along with their operating mechanism are together called the valve gear.
2. Cylinder
der block and cylinder liner. The cylinder head is fitted over the cylinder block and
liner. The space between the block wall and cylinder liner acts as the cooling water jacket.
3. Piston. The piston is of cylindrical shape to fit the inside bore of the cylinder.
c Gas
tightness is ensured by means of the piston rings in the slots on the outer cylindrical surface
of the piston.
4. Connecting rod. This is the link connecting the piston to the crankshaft for transmission
of the forces from and to the piston. The pin connecting it to the piston is called the gudgeon
pin and that connecting it to the crankshaft as the crank pin.
5. Crankshaft. This iss a shaft with radial cranks, which converts the reciprocating motion of
the piston into rotary motion of the shaft.
6. Crank case and sump. Crank case is the engine casing having the main bearings in which
the crank shaft rotates. The bottom cover of the engine is the sump which usually acts as a
lubricating oil reservoir.
4. Nomenclature of I C Engines

1) Cylinder bore (D):- The nominal inner diameter of the working cylinder.
2) Piston area (A):- Cross sectional area of the piston. This is equal to cylinder
cyli bore area
3) Stroke (L):- The nominal distance between TDC & BDC
4) Dead Center: - End points of the strokes
(i) Top dead center (TDC):
(TDC):- Farthest position of piston from crank shaft. It is also called,
Inner Dead Center (IDC)
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(ii) Bottom Dead Center (BDC):- Nearest position of piston form crank shaft. It is also
called Outer Dead Center (ODC)

5) Swept Volume (Vs) :-- The nominal volume generated by the piston when travelling
from one dead center to next. i.e., TDC to BDC ,

Vs = A×L

6) Clearance Volume (Vc):

(Vc):- The nominal volume or volume for combustion, which is
just above the TDC.

7) Cylinder Volume (V) ::- The sum of swept volume and clearance volume.

V = Vs + Vc

8) Compression ratio (r) ::- Ratio of cylinder volume to clearance volume;

5. Four Stroke I C Engines

In a four-stroke
stroke engine, the cycle of operations is completed in four strokes of the piston or
two revolutions of the crankshaft. During the four strokes, there are five events to be
Completed, viz., suction, compression, combustion, expansion and exhaust. Each stroke
consists of 180° of crankshaft rotation and hence a four
four-stroke
stroke cycle is completed through
720° of crank rotation. The cycle of operation for an ideal four
four-stroke
stroke SI engine consists of
the following four strokes:

1. Suction Stroke (0 -180°)

2. Compression Stroke (180°
(180°-360°)
3. Expansion Stroke (360°-540°)
540°)
4. Exhaust Stroke (540°-720°)
720°)
6. Working principle of a Four Stroke SI Engine or Petrol Engine

A spark-ignition
ignition engine, also known as a gasoline engine or petrol engine, is an internal
combustion engine that operates on the principle of igniting a mixture of air and fuel
using a spark plug
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1. Suction Stroke
Piston moves from TDC to BDC. Inlet valve opens and the fuel
fuel- air mixture is drawn into
the engine cylinder. Exhaust valve remains closed.
2. Compression Stroke
Piston moves from BDC to TDC and compresses the air – fuel mixture. Both valves
remain closed. Just before the end of the compression stroke, the spark plug initiates a
spark, which ignites the mixture and combustion takes place at constant volume. Both the
valves remains closed.
3. Expansion stroke or Power Stroke
Piston moves from TDC to BDC and thus work is done by the hot high pressure gas after
combustion. Both valves remain closed.
4. Exhaust Stoke
Piston moves from BDC to TDC for the removal of the burnt gases. Inlet valve remains
closed and exhaust opens. This completes the cycle and the engine is ready to suck the
charge again

7. Working principle of a Four Stroke CI Engine or Diesel Engine

CI Engine

 In compression-ignition
ignition engines, air alone is inducted into the cylinder.
 The fuel is injected directly into the engine cylinder just before the combustion process is
required to start.
 A high pressure fuel pump and an injec injector
tor are provided to inject the fuel into the
combustion chamber.
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1. Suction Stroke
Piston moves from TDC to BDC. inlet valve opens and the only Fresh -Air
Air is drawn into
the engine cylinder. Exhaust valve remains closed
2. Compression Stroke
Piston moves from BDC to TDC and compresses the air. Both valve remains closed. Just
before the end of the stroke, the fuel is injected in the form of fine spray through fuel
injection valve, the temperature of the compressed air is sufficiently high to ignite the
fuel and combustion takes place. The injection of fuel is continued for some time
tim and is
cut off at point. Both the valves remains closed
closed.
3. Expansion stroke or Power Stroke
Piston moves from TDC to BDC and thus work is done by high pressure hot gas.
gas Both
valves remain closed.
4. Exhaust Stoke
Piston moves from BDC to TDC for the removal of the burnt gases. Inlet valve remains
closed and exhaust opens. This completes the cycle and the engine is ready to suck air
again.
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8. Comparison of S I and C I Engine

1. Basis of Cycle Otto Cycle Diesel Cycle
Constant Volume heat addition Constant pressure heat addition

2. Fuel highly volatile non-volatile

3. Introduction of air + fuel introduced into the cylinder only air introduced into the
fuel cylinder

4. Ignition Spark plug Self ignition due to high

temperature

5. Compression ratio 6 - 10 16 - 20
Bikes ,cars Diesel cars & trucks

6.Speed Due to light weight, they are high low speed engines
speed engine

7.Thermal Efficiency Because of lower CR η is lower th

ηth

η is higher or
th

8. Weight lower peak pressure, engines are Heavier

lighter

9.Air System of SI Engine

 For burning of fuel, oxygen is required.

 Oxygen is obtained from the atmospheric air.
 Air is mixed with fuel in the correct ratio using carburetor.
 For complete combustion the air air-fuel ratio must be about 15:1 by weight
 Range of air-fuel
fuel ratio is 8:1 to 20:1.
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10. Fuel System for SI Engine

Simple Block Diagram

Detailed diagram with air flow path

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11. Fuel System For CI Engines

Two types of fuel injector systems

Air injection – fuel is forced into the cylinder by means of compressed air
Solid injection (Mechanical injection) – pump is used to supply measured quantity of fuel at high
pressure to the injector.

12. Hybrid Engines

 A hybrid vehicle is a vehicle that uses two or more distinct power sources to move the
vehicle.eg. A conventional internal combustion engine and also a high voltage electric
motor.
 Concept of hybrid drive combines the best aspects of IC engines and Electric drives
Series Hybrid
 The petrol(gasoline) engine turns a generator, and the generator can either charge the
batteries or power an electric motor that drives the transmission.
In Engine mode operation
 Engine operates a generator, that operates a motor, which in tu
turn
rn drive the wheels
In Battery mode operation
 Battery directly drives the motor which in turn drive the wheels
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Parallel Hybrid
 Fuel tank supplies gasoline to the engine and a set of batteries that supplies power to the
electric motor.
 Depending on requirement, Engine alone or Motor alone or Engine and Motor together
can drive the wheels
 This system permits the engine to recharge the battery while powering the vehicle

Two-stroke Engine
As already mentioned, if the two unproductive strokes, viz., the suction and exhaust
could be served by an alternative arrangement, especially without the movement of the piston
then there will be a power stroke for each revolution of the crankshaft. In su
such
ch an arrangement,
theoretically the power output of the engine can be doubled for the same speed compared to a
four-stroke
stroke engine. Based on this concept, Dugald Clark (1878) invented the two-stroke
two engine.
In two-stroke
stroke engines the cycle is completed in oone
ne revolution of the crankshaft. The main
difference between two-stroke
stroke and four stroke engines is in the method of filling the fresh charge
and removing the burnt gases from the cylinder. In the four
four-stroke
stroke engine these operations are
performed by the engine
ine piston during the suction and exhaust” strokes respectively. In a two-
two
stroke engine, the filling process is accomplished by the charge compressed in crankcase or by a
blower. The induction of the compressed charge moves out the product of combustion through
th
exhaust ports. Therefore, no piston strokes are required for these two operations. Two strokes are
sufficient to complete the cycle, one for compressing the fresh charge and the other for
expansion or power stroke. The air or charge is inducted into the crankcase through the spring
loaded inlet valve when the pressure in the crankcase is reduced due to upward motion of the
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piston during compression stroke. After the compression and ignition, expansion takes place in
the usual way.

During the expansion stroke the charge in the crankcase is compressed. Near the end of the
expansion stroke, the piston uncovers the exhaust ports and the cylinder pressure drops to
atmospheric pressure as the combustion products leave the cylinder. Furthe
Furtherr movement of the
piston uncovers the transfer ports, permitting the slightly compressed charge in the crankcase to
enter the engine cylinder.
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The top of the piston has usually a projection to deflect the fresh charge towards the top of the
cylinder before flowing to the exhaust ports. This serves the double purpose of scavenging the
upper part of the cylinder of the combustion products and preventing the fresh charge from
flowing directly to the exhaust ports.

Advantages of two-stroke engines

1. A two-stroke engine has a power stroke every revolution of the crankshaft. Therefore its power
to weight ratio is higher than that of a four-stroke engine.
2. The torque is more uniform in a two-stroke engine, hence it requires a lighter flywheel than that
for a four-stroke engine.
3. Two-stroke engines are simpler in construction than four-stroke engines due to the absence of
valves and their operating mechanism.
4. The friction loss is less in two-stroke engines, therefore it gives higher mechanical efficiency
than four-stroke engines.
5. The capital cost of two-stroke engines is less than that of four-stroke engines.
6. The starting of two-stroke engines is easier than starting of four-stroke engines.
Disadvantages of two-stroke engines
1. The overall efficiency is less than that of four-stroke engines due to (i) inadequate scavenging as
some combustion products are left in the cylinder (ii) loss of fresh charge during scavenging, and
(iii) less effective compression ratio for same stroke long.
2. The engine is always overheated due to power stroke in every revolution.
3. The consumption of lubricating oil is higher as it is subjected to higher temperatures.
4. The exhaust of two-stroke engines is noisier needing more baffling in the silencers.
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MPFI Engines

MPFI stands for Multi-Point Fuel Injection. It is an automotive engine technology that involves
injecting fuel directly into multiple points within the intake manifold or cylinder for combustion.
This is in contrast to the earlier single-point or throttle-body fuel injection systems.
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In a Multi-Point Fuel Injection system:

Multiple Injectors: The system uses multiple fuel injectors, each positioned close to an intake
port or directly in the cylinder.

Precision Fuel Delivery: Fuel is sprayed directly into each intake port or cylinder at precise
timings, optimizing the air-fuel mixture for combustion.

Improved Combustion: MPFI systems allow for better control over the fuel delivery to each
cylinder, resulting in improved combustion efficiency, power output, and fuel economy.

Better Performance: MPFI systems contribute to better engine performance, responsiveness, and
reduced emissions compared to earlier fuel injection technologies.

Individual Cylinder Control: With individual injectors for each cylinder, the engine control unit
(ECU) can adjust the fuel delivery independently for each cylinder, optimizing performance and
emissions.

Cold Start Performance: MPFI systems often improve cold start performance by delivering the
right amount of fuel to each cylinder during startup.

While MPFI has become a common technology in modern vehicles, more advanced systems like
Gasoline Direct Injection (GDI) and other fuel injection variants have also been developed to
further enhance efficiency and performance. Each system has its advantages and considerations,
and the choice of fuel injection technology depends on factors such as cost, performance
requirements, and emissions standards.

CRDI Engines
CRDI stands for Common Rail Direct Injection. It is a modern fuel injection technology used in diesel
engines to improve efficiency, performance, and reduce emissions. Here are the key features and
advantages of CRDI engines:
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Common Rail System: In a CRDI engine, fuel is injected into a common rail, which is a high-pressure
reservoir that supplies fuel to individual injectors. This allows for precise control over the fuel injection
process.

High Pressure: The fuel in the common rail is maintained at a high pressure, typically ranging from 1,000
to 2,000 bar. This high pressure allows for finer fuel atomization and more precise injection timing.

Precise Fuel Injection: CRDI engines can inject small amounts of fuel multiple times during each
combustion cycle, leading to better combustion efficiency. This precision helps in achieving optimal
power output and fuel economy.

Improved Combustion: The high-pressure injection and precise control of fuel delivery in CRDI engines
result in better combustion, reduced emissions, and improved overall engine performance.

Reduced Noise and Vibration: CRDI engines often produce less noise and vibration compared to
traditional diesel engines. The precise control over the combustion process helps in minimizing
undesirable engine characteristics.

Better Fuel Economy: The efficient combustion and precise control of fuel injection contribute to
improved fuel economy in CRDI engines, making them more environmentally friendly and cost-effective.
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Turbocharging Compatibility: CRDI engines are often paired with turbochargers to further enhance
performance. The combination of common rail injection and turbocharging results in increased power
and torque.

Meeting Emission Standards: CRDI technology helps diesel engines meet stringent emission standards by
reducing harmful emissions such as nitrogen oxides (NOx) and particulate matter.

CRDI technology has become widely adopted in diesel engines, especially in passenger cars, commercial
vehicles, and even some high-performance applications. It allows for better control over the combustion
process, leading to engines that are more efficient, powerful, and environmentally friendly compared to
traditional diesel engines with older fuel injection systems.

Cooling and Lubrication system of IC Engines

The cooling and lubrication systems are crucial components of internal combustion (IC) engines,
ensuring proper functioning and longevity. Let's explore each system:

Cooling System:

Radiator: The radiator is a key component of the cooling system. It consists of a network of
tubes and fins through which coolant (usually a mixture of water and antifreeze) flows. As hot
coolant circulates through the radiator, heat is dissipated into the surrounding air.

Water Pump: The water pump is responsible for circulating the coolant through the engine and
radiator. It is typically driven by a belt connected to the engine's crankshaft.

Thermostat: The thermostat regulates the flow of coolant based on the engine temperature. It
stays closed when the engine is cold, allowing it to warm up faster. As the engine reaches the
optimal temperature, the thermostat opens, allowing coolant to flow through the radiator.

Coolant Reservoir: The coolant reservoir provides a place for excess coolant to expand into as
the engine heats up. It also allows for easy monitoring and topping up of the coolant level.

Air Cooled System Air cooled system is generally used in small engines say up to 15-20 kW and in aero
plane engines. In this system fins or extended surfaces are provided on the cylinder walls, cylinder head,
etc. Heat generated due to combustion in the engine cylinder will be conducted to the fins and when
the air flows over the fins, heat will be dissipated to air. The amount of heat dissipated to air depends
upon : (a) Amount of air flowing through the fins. (b) Fin surface area. (c) Thermal conductivity of metal
used for fins.
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Types of Water Cooling System There are two types of water cooling system : Thermo Siphon System In
this system the circulation of water is due to difference in temperature (i.e. difference in densities) of
water. So in this system pump is not required but water is circulated because of density difference only.

Pump Circulation System In this system circulation of water is obtained by a pump. This pump is driven
by means of engine output shaft through V-belts.
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Lubrication System:

Oil Pan: The oil pan, or sump, is located at the bottom of the engine and holds the engine oil. It
acts as a reservoir from which the oil is drawn for lubricating engine components.

Oil Pump: The oil pump is responsible for circulating the engine oil throughout the engine. It
draws oil from the oil pan and pressurizes it before sending it through the engine's oil passages.

Oil Filter: The oil filter removes contaminants from the engine oil, ensuring that only clean oil
circulates through the engine. Regular replacement of the oil filter is essential for maintaining
proper lubrication.

Oil Cooler: Some high-performance or heavy-duty engines may have an oil cooler. This
component helps regulate oil temperature by dissipating excess heat, especially in situations
where the engine operates under heavy loads.

Pressure Relief Valve: The pressure relief valve prevents excessive oil pressure by allowing
excess oil to flow back into the oil pan. This helps protect engine components from damage due
to over-pressurized lubrication.

Both the cooling and lubrication systems work in tandem to ensure the engine operates within
the optimal temperature range and is adequately lubricated. Proper maintenance, including
regular coolant and oil changes, is crucial for the health and longevity of the internal
combustion engine.