School of Mechanical & Manufacturing Engineering (SMME)

LAB REPORT 01
IC ENGINES

STUDENT DETAILS:
NAME : FAISAL AMIN
CLASS : ME-12 (A)
CMS ID : 338606
DATED : 21-FEBRUARY-2024
TABLE OF CONTENTS:
Objective: ........................................................................................................................................................................................... 3
Equipment and Apparatus .............................................................................................................................................................. 3
Theoretical Background .................................................................................................................................................................. 3
INTRODUCTION TO IC Engines........................................................................................................................................ 3
Applications of ICEs .................................................................................................................................................................. 3
Types of ICEs: Spark-ignition vs. Compression-ignition ..................................................................................................... 3
The 4-Stroke Cycle ...................................................................................................................................................................... 4
Internal vs. External Combustion............................................................................................................................................. 4
Type of Fuel: ................................................................................................................................................................................ 4
Combustion Type: ....................................................................................................................................................................... 5
Number of Strokes: ..................................................................................................................................................................... 5
Engine Cycle: ................................................................................................................................................................................ 5
Cooling System:............................................................................................................................................................................ 5
Engine Head Description........................................................................................................................................................... 5
Valve Control ............................................................................................................................................................................... 6
Oil Ducts ....................................................................................................................................................................................... 6
Coolant Ducts .............................................................................................................................................................................. 7
Spark Plug ..................................................................................................................................................................................... 7
Injection Valves (Petrol Engine) ............................................................................................................................................... 7
Engine Block Diagram ............................................................................................................................................................... 8
Cooling System............................................................................................................................................................................. 9
Lubrication System: ..................................................................................................................................................................... 9
Ignition System: ........................................................................................................................................................................... 9
Fuel System ................................................................................................................................................................................... 9
Exhaust System .......................................................................................................................................................................... 10
Suspension System .................................................................................................................................................................... 10
Powertrain: .................................................................................................................................................................................. 11
Procedure ......................................................................................................................................................................................... 12
Observation: .................................................................................................................................................................................... 12
Safety Precautions .......................................................................................................................................................................... 13
CONCLUSION AD DISCUSSION ......................................................................................................................................... 13
OBJECTIVE:
In this lab, we are required to:

1. Get an overview of the basic Component of an Internal Combustion (IC) Engine.

2. Get an overview of the different system included in a vehicle.
3. Identify the component studied on a Vehicle Chassis (including Engine) model present in the lab.

EQUIPMENT AND APPARATUS

1) VB-5340E Vehicle Chassis (Gasoline Engine)

Figure 1: VB-5340E Vehicle Chassis

THEORETICAL BACKGROUND

INTRODUCTION TO IC ENGINES
An ICE is a type of heat engine that transforms the chemical energy stored in fuel, like gasoline or diesel, into
mechanical energy. This conversion happens through a fascinating process:

Fuel Ignition: Inside a sealed cylinder, the fuel mixes with air. In spark-ignition engines (common in gasoline
vehicles), a spark plug ignites this mixture, causing a rapid burn. In compression-ignition engines (found in diesel
vehicles), the heat from compressing the air-fuel mixture triggers combustion.

Expansion and Power Generation: The burning fuel generates hot, high-pressure gas. This gas expands rapidly,
pushing against a piston within the cylinder. The movement of the piston translates into the rotation of a crankshaft,
creating the mechanical work that powers various applications.

APPLICATIONS OF ICES
ICEs are incredibly versatile and can be found in a multitude of applications, including:

Transportation: Powering cars, trucks, motorcycles, airplanes, and more.

Power Generation: Supplying electricity through stationary engines.

Lawn and Garden Equipment: Making yard work a breeze with mowers, trimmers, and chainsaws.

Industrial Workhorses: Driving pumps, compressors, generators, and various industrial equipment.

TYPES OF ICES: SPARK-IGNITION VS. COMPRESSION-IGNITION

The world of ICEs isn't a one-size-fits-all scenario. There are two main categories:
Spark-ignition (SI) engines: These engines rely on a spark plug to ignite the fuel-air mixture. They are commonly
used in gasoline-powered vehicles and smaller generators.

Compression-ignition (CI) engines: In CI engines, the heat generated from compressing the air-fuel mixture
ignites the fuel. These engines are typically found in diesel-powered vehicles and larger engines.

THE 4-STROKE CYCLE

To understand how an ICE functions, let's delve into the 4-stroke cycle, which is the fundamental process powering
most IC engines:

Intake Stroke: The piston moves downward, drawing in a fresh air-fuel mixture through an open valve.

Compression Stroke: The piston moves upward, squeezing the air-fuel mixture in the cylinder, increasing its
pressure and temperature.

Combustion Stroke: The spark plug ignites the compressed mixture (in SI engines) or the heat from compression
ignites the mixture (in CI engines), causing a rapid burn and pushing the piston down with force.

Exhaust Stroke: The piston moves up again, expelling the burnt gases out of the cylinder through the exhaust
valve.

This cycle repeats continuously, generating the power that drives various machinery with the help of the rotating
crankshaft.

INTERNAL VS. EXTERNAL COMBUSTION

Internal combustion engines: Combustion occurs inside the engine cylinder, and the expanding hot gases directly
push the piston. Examples include gasoline and diesel engines.

External combustion engines: Combustion takes place outside the engine, and heat from the burning fuel is used
to heat a separate working fluid (like steam) that then expands and drives a turbine or piston. Examples include
steam engines and Stirling engines.

Internal combustion engines (IC engines) can be differentiated based on various parameters, each leading to distinct
characteristics and applications. Here's a detailed breakdown of some key parameters:

TYPE OF FUEL:
Gasoline: Clean burning, readily available, but lower energy density compared to diesel. Used in spark-
ignition (SI) engines.
 Diesel: Higher energy density, more efficient, but higher emissions. Used in compression-ignition (CI)
engines.

COMBUSTION TYPE:
Spark-ignition (SI): Uses a spark plug to ignite the air-fuel mixture. Offers smoother operation, lower
emissions with advanced technologies, but generally less efficient than CI engines.
Compression-ignition (CI): Uses the heat of compression to ignite the fuel. More efficient than SI
engines, especially at higher loads, but historically higher emissions. Newer technologies are improving
emission performance.

NUMBER OF STROKES:
Two-stroke engines: Simpler design, lighter weight, but less efficient and higher emissions compared to
four-stroke engines. Used in small engines like motorcycles and lawnmowers.
Four-stroke engines: More complex design, heavier, but more efficient and lower emissions than two-
stroke engines. Used in most cars, trucks, and larger engines.

ENGINE CYCLE:
Otto cycle: Used in most SI engines. Four-stroke cycle with constant-volume combustion.
Diesel cycle: Used in CI engines. Four-stroke cycle with constant-pressure combustion.

Cooling System:
Air-cooled: Simpler design, lighter weight, but less effective at high loads. Used in small engines.
Liquid-cooled: More complex design, heavier, but more efficient at high loads. Used in most cars, trucks,
and larger engines.

ENGINE HEAD DESCRIPTION

Inlet and Exhaust Port

In the intricate system of an internal combustion engine, the

inlet and exhaust ports play crucial roles in the combustion
process and engine performance. These ports are openings in
the engine cylinder through which air (or air-fuel mixture)
enters and exhaust gases exit, respectively. Their design and
efficiency significantly impact the engine's power output, fuel
efficiency, and emissions.

Figure 2: 4 Stroke Single Cylinder Engine

Inlet Ports
The inlet port, also known as the intake port, serves the primary function of allowing the entry of air (or air-fuel
mixture in case of fuel-injected engines) into the combustion chamber. The design of the inlet port influences the
engine's volumetric efficiency, which is the ratio of the amount of air that fills the cylinder during the intake stroke
to the cylinder's displacement. A well-designed inlet port ensures smooth and efficient airflow into the cylinder,
optimizing combustion efficiency. Key features inlet port are as follows:

Optimized Flow: The shape and geometry of the inlet port are carefully engineered to minimize airflow restrictions
and turbulence, allowing a smooth passage for the incoming air. This promotes better mixing of air and fuel,
enhancing combustion efficiency.
Velocity and Swirl Control: Inlet ports may incorporate features such as intake manifolds, runners, and valve
designs to control airflow velocity and induce swirl or tumble in the intake charge. Swirl and tumble help in
achieving better air-fuel mixing and combustion stability.

Tuned Length: The length and diameter of the intake runners are tuned to optimize airflow velocity and resonance
characteristics, particularly in high-performance engines.

Exhaust Ports:
The exhaust port is responsible for expelling the combustion by-products, primarily exhaust gases, from the
combustion chamber to the exhaust system. Efficient exhaust port design is essential for ensuring proper scavenging
of exhaust gases, minimizing back pressure, and maximizing engine power output. Key features exhaust port are as
follows:

Scavenging Efficiency: Exhaust ports are designed to facilitate the removal of exhaust gases from the cylinder
during the exhaust stroke. Proper timing and shape of the exhaust port are critical for efficient scavenging,
preventing residual exhaust gases from mixing with the fresh intake charge.

Back Pressure Reduction: A well-designed exhaust port minimizes back pressure, which refers to the resistance
encountered by the exiting exhaust gases in the exhaust system. Reduced back pressure helps the engine expel
exhaust gases more effectively, improving overall engine performance and efficiency.

Heat Management: Exhaust ports are often designed to dissipate heat efficiently to prevent overheating of the
surrounding components. Heat-resistant materials and cooling strategies may be employed to enhance the durability
and longevity of exhaust ports.

VALVE CONTROL
Valve control is a fundamental aspect of internal combustion engine operation, governing the intake of air (or air-
fuel mixture) and the expulsion of exhaust gases from the combustion chamber. This process is crucial for
regulating engine performance, fuel efficiency, and emissions. Valve control mechanisms, such as camshafts, timing
systems, and variable valve timing (VVT) technologies, play a key role in optimizing engine operation across
different driving conditions.

• Camshafts
• Timing Systems
• Variable Valve Timing (VVT):
• Variable Valve Lift (VVL):
• Electronic Valve Control (EVC):

OIL DUCTS
Oil ducts are integral components within internal combustion engines designed to ensure proper lubrication of
moving parts. These ducts facilitate the flow of engine oil to critical areas, such as bearings, pistons, camshafts, and
valvetrains, reducing friction, heat, and wear. Below are the functions for the oil ducts in an IC engine.

1. Lubrication
2. Cooling
3. Cleaning
 Figure 3: Oil and Cooling Ducts for 4-Cylinder 4 Stroke Engine

COOLANT DUCTS
Coolant ducts are essential components within internal combustion engines designed to manage and regulate engine
temperature. These ducts facilitate the circulation of coolant fluid through the engine block, cylinder head, and other
critical components, helping to dissipate excess heat generated during combustion. Following are the functions of
the coolant ducts in an IC engine.

• Taming the Heat

• Maintaining the Perfect Balance
• Preventing Thermal Meltdown

SPARK PLUG
Spark plugs are vital components in internal combustion engines responsible for initiating the combustion process
by igniting the air-fuel mixture within the combustion chamber. This ignition is crucial for engine operation, driving
power output, fuel efficiency, and overall performance.

INJECTION VALVES (PETROL ENGINE)

Injection valves, also known as fuel injectors, are vital components in petrol engines responsible for precisely
delivering fuel into the combustion chamber. They play a critical role in optimizing engine performance, fuel
efficiency, and emissions control by ensuring accurate metering and atomization of fuel. Following are the Functions
of Injection Valves

1. Fuel Delivery
2. Atomization
3. Control
 Figure 4: Injection Nozzle (Left) and Glow Plug (Right)

ENGINE BLOCK DIAGRAM

The engine block is the main structural component of an internal combustion engine, housing several crucial parts
and providing support for various systems. Here's a brief overview of the components typically found in an engine
block diagram:

Cylinder:

The cylinder is the primary chamber where combustion occurs in the engine. It houses the piston, which moves up
and down to compress the air-fuel mixture and drive the engine's power strokes. Cylinder bores are machined into
the engine block to provide a smooth surface for the piston to move within. Proper cylinder bore dimensions and
surface finish are essential for efficient engine operation.

Oil Passageways

Oil passageways are channels or galleries machined into the engine block to facilitate the circulation of engine oil to
various components. These passages deliver oil to critical areas such as the crankshaft bearings, camshaft bearings,
pistons, and valvetrain components, providing lubrication and reducing friction.

Figure 5: Engine Block

Deck

The deck refers to the flat, upper surface of the engine block where the cylinder head is mounted. It provides a
mating surface for the cylinder head gasket, ensuring a tight seal between the engine block and cylinder head. The
deck height, or distance between the deck surface and the crankshaft centerline, affects engine compression ratio
and piston-to-head clearance.
Crankcase

The crankcase is the lower portion of the engine block that houses the crankshaft and provides support for the
engine's rotating assembly. It contains the main bearing saddles, which support the crankshaft journals and maintain
proper alignment. The crankcase also serves as a reservoir for engine oil, with an oil pan or sump attached to the
bottom to collect and store oil for lubrication.

COOLING SYSTEM
The cooling system in a vehicle is designed to regulate the temperature of the engine and prevent it from
overheating during operation. It consists of several components working together to dissipate heat generated by the
engine:

• Radiator
• Water Pump
• Thermostat
• Coolant
• Cooling Fans

LUBRICATION SYSTEM:
The lubrication system in a vehicle ensures that moving parts within the engine are properly lubricated to reduce
friction, wear, and heat generation. It consists of several components working together to distribute oil throughout
the engine:

• Oil Pump
• Oil Pan
• Oil Filter
• Oil Galleries
• Oil Cooler

IGNITION SYSTEM:
The ignition system in a vehicle is responsible for generating the high-voltage spark needed to ignite the air-fuel
mixture in the engine's cylinders. It consists of several components working together to produce and deliver the
spark:
• Ignition Coil
• Spark Plugs
• Distributor
• Ignition Control Module
• Crankshaft Position Sensor

FUEL SYSTEM
The fuel system in a vehicle is responsible for storing, delivering, and metering fuel to the engine for combustion. It
consists of several components working together to supply fuel to the engine:

1. Fuel Tank: The fuel tank stores the vehicle's fuel, typically gasoline or diesel. It is located at the rear
of the vehicle and is connected to the fuel filler neck, through which fuel is added.
2. Fuel Pump: The fuel pump draws fuel from the fuel tank and delivers it to the engine at the correct
pressure. It is typically located inside the fuel tank and is either mechanical or electrically powered.
3. Fuel Filter: The fuel filter removes contaminants such as dirt, rust, and debris from the fuel before it
reaches the engine. It helps protect fuel injectors and other fuel system components from damage.
 4. Fuel Injectors: Fuel injectors are responsible for delivering fuel to the engine's cylinders in precise
amounts and at the correct timing. They are electronically controlled and use solenoids to open and
close fuel passages.
5. Fuel Pressure Regulator: The fuel pressure regulator maintains a consistent fuel pressure within the
fuel system, regardless of changes in engine load or speed. It ensures that the fuel injectors receive fuel
at the correct pressure for optimal combustion.

EXHAUST SYSTEM
The exhaust system in a vehicle is responsible for removing exhaust gases from the engine and reducing harmful
emissions. It consists of several components working together to route and treat exhaust gases:

1. Exhaust Manifold: The exhaust manifold collects exhaust gases from the engine's cylinders and
routes them to the rest of the exhaust system. It is typically made of cast iron or stainless steel and is
attached to the engine's cylinder head.
2. Catalytic Converter: The catalytic converter is a emissions control device that reduces harmful
pollutants in the exhaust gases, such as carbon monoxide (CO), nitrogen oxides (NOx), and
hydrocarbons (HC). It uses catalysts to promote chemical reactions that convert these pollutants into
less harmful substances.
3. Muffler: The muffler, also known as a silencer, is a noise-reducing device that attenuates the sound
produced by the engine's exhaust gases. It consists of chambers and baffles that absorb and dissipate
sound energy.
4. Exhaust Pipe: The exhaust pipe carries exhaust gases from the exhaust manifold to the rest of the
exhaust system. It is typically made of steel or stainless steel and may include bends or flex sections to
accommodate vehicle packaging constraints.
5. Oxygen Sensor: The oxygen sensor, also known as the O2 sensor, measures the oxygen content in
the exhaust gases and provides feedback to the engine control unit (ECU). It helps the ECU adjust the
air-fuel mixture to maintain optimal combustion efficiency and reduce emissions.

SUSPENSION SYSTEM
The suspension system in a vehicle is responsible for providing a smooth and comfortable ride, as well as
maintaining stability and control during driving. It consists of several components working together to support the
vehicle and absorb road shocks:

1. Springs: Springs are the primary components of the suspension system and provide support for the
vehicle's weight. They absorb and distribute forces from road irregularities, ensuring a smooth ride
and preventing excessive vehicle body movement.
2. Shock Absorbers: Shock absorbers, also known as dampers, dampen the oscillations of the springs
and control the rate at which the suspension compresses and rebounds. They help maintain tire
contact with the road surface and prevent excessive bouncing or jolting.
3. Struts: Struts are a type of suspension component that combines the functions of a spring and shock
absorber into a single unit. They provide structural support for the suspension system and help
maintain proper wheel alignment.
4. Control Arms: Control arms, also known as wishbones or A-arms, connect the suspension
components to the vehicle's frame or subframe. They help control the motion of the wheels and
maintain proper alignment during cornering and braking.
5. Stabilizer Bars: Stabilizer bars, also known as anti-roll bars, help reduce body roll and improve
stability during cornering. They connect the suspension components on opposite sides of the vehicle
and transfer forces between them to resist vehicle sway.
POWERTRAIN:
The powertrain in a vehicle is responsible for transmitting power from the engine to the wheels and propelling the
vehicle forward. It consists of several components working together to transfer and control power:

1. Engine: The engine is the primary source of power in a vehicle and converts fuel into mechanical
energy. It typically consists of a combustion chamber, pistons, crankshaft, and other internal
components.
2. Transmission: The transmission transfers power from the engine to the wheels and allows for
variable gear ratios to optimize engine performance and fuel efficiency. It may be manual or automatic
and consists of gears, clutches, and other components.
3. Driveshaft: The driveshaft, also known as a propeller shaft, transfers power from the transmission to
the differential or axle assembly. It typically consists of a rotating shaft with universal joints at each
end to accommodate vehicle movement.
4. Differential: The differential distributes power from the driveshaft to the wheels and allows for
variable wheel speeds during cornering. It consists of gears housed within a housing attached to the
axle assembly.
5. Axles: Axles transmit power from the differential to the wheels and support the weight of the vehicle.
They consist of shafts with splines or other connections to engage with the wheels and differential.
 Figure 6: Rack Type Steering Box

PROCEDURE
1. Setup the VB-5340E Vehicle Chassis by Connecting it to 220 Volts Power Supply
2. Turn on the Engine form the Operation Panel of the Chassis
3. Observe the Operation of Mechanical Part of the Vehicle System
4. Identify the Classification of the Engine System
5. Observe the Cutaway model of the Engine with an emphasis on the piston displacement and valve
Timing.
6. Observe and Identify various part of the component, cross sections, lubricating circuits, Fuel system,
Cooling System etc.

OBSERVATION:
Classification of the Engine
Number of Cylinder 4
Number of Valves 8
Type of Fuel Petrol
Strokes 4
Gear Box 5 Forward Speeds + reverse
Differential Differential With Hybrid Crown Wheel and Pinion
Camshaft Twin Overhead Camshaft driven by a Toothed Belt
Ignition Electronic (Spark)
Front Suspension McPherson Suspension
Rear Suspension Leaf Spring Suspension
Steering Box Rack Type Steering Box
Front Brakes Disc Brakes
Rear Brakes Drum Brake
Component Identification (Results)

7
3
8

5
4

1 2

Figure 7: Image 1
Image 1
1. Rear Leaf Spring Suspension 6. Front Disc Brakes
2. Rear Drum Brakes 7. McPherson Suspension
3. Battery 8. Rack Type Steering Box
4. Hybrid Crown Wheel and Pinion Differential 9. Engine
5. Gear Box

SAFETY PRECAUTIONS
• Clean up your workspace and properly store tools and equipment.
• Wash your hands thoroughly, especially after handling chemicals.
• Report any damaged tools or malfunctions to the appropriate person.
• Stay alert and avoid distractions.

CONCLUSION AD DISCUSSION
The students embarked on a deep dive into the world of internal combustion engines (IC engines). We explored the
diverse classifications based on factors like fuel type, working cycle, ignition systems, valve mechanisms, stroke
count, cooling, injection, and cylinder arrangement. This comprehensive exploration provided a solid foundation for
understanding the fundamentals of IC engines.