EMM3504

Mechanic of Machine
Reciprocating Machine 3
Theory Of Operation
 Reciprocating Engine Theory Of
Operation
Engine Operating Principles
 Reciprocating Engine Theory Of
Operation
Operating Cycles

Two-Stroke

Requires only one upstroke and one downstroke of

the piston to complete the required series of events
in the cylinders.
Completes the operating cycle in one revolution of
the crankshaft.

What are the sequence of events that take

place to convert the chemical energy into
mechanical energy?
 Reciprocating Engine Theory Of
Operation
Intake

Compression

Ignition

Power

Exhaust
 Reciprocating Engine Theory Of
Operation
Two-Stroke
 Reciprocating Engine Theory Of
Operation
Four-stroke

Four strokes required

to complete the events.

Two revolutions of the

crankshaft (720) are
required to complete
the four strokes.
 Reciprocating Engine Theory Of
Operation
Engine Power And Efficiency

Work = Force x Distance

Horsepower = ft-lb per min or ft-lb per sec

33,000 550
 Reciprocating Engine Theory Of
Operation
Piston Displacement

The greater the piston displacement the greater

the horsepower an engine will develop.

The volume displaced by a piston is its

displacement.

Expressed in cubic inches.

 Reciprocating Engine Theory Of
Operation
Piston Displacement

PD = Area of cross section of cylinder

multiplied by total distance the piston moves.

V=AxH
 Reciprocating Engine Theory Of
Operation
Compression Ratio

Comparison of the volume of space in a

cylinder when the piston is at the bottom of the
stroke to the volume of space when the piston
is at the top of the stroke.

The higher the engine compression ratio, the

higher the engine efficiency (horsepower
output) will be.
 Reciprocating Engine Theory Of
Operation
Manifold Absolute Pressure (MAP)

Average absolute pressure of the fuel/air

charge in the intake manifold.

Measured in units of inches of mercury (Hg).

Dependent mostly on ambient air pressure,

engine speed, and throttle setting.

Supercharging increases MAP.

 Reciprocating Engine Theory Of
Operation
Compression Ratio & Manifold Pressure.
Determines the pressure in the cylinder when
both valves are closed.

Pressure of charge before compression is

determined by the manifold pressure.

Pressure at the height of compression is

determined by manifold pressure times the
compression ratio.
 Reciprocating Engine Theory Of
Operation
Absolute & Gauge Pressure.

Absolute Pressure

Identifies the pressure measurement as one

that is based on a comparison of the
pressure in the manifold with pressure at
absolute zero.

Gauge Pressure

Compares the pressure being measured

against ambient pressure.
 Reciprocating Engine Theory Of
Operation
Indicated Horsepower

Horsepower calculated from the indicated

mean effective pressure and the other factors
which affect the power output of an engine.

The power developed in the combustion

chamber without reference to the friction
losses within the engine.
 Reciprocating Engine Theory Of
Operation
Brake Horsepower (BHP)

The power delivered from the engine to the

propeller for useful work.

Total horsepower lost due to friction is

subtracted from indicated horsepower.

The measurement of an engines BHP involves

the measurement of torque.
Torque = Force times distance
 Reciprocating Engine Theory Of
Operation
Friction Horsepower

Indicated horsepower minus brake

horsepower.
 Reciprocating Engine Theory Of
Operation
Friction And Brake Mean Effective Pressure

Indicated Mean Effective Pressure

Pressure used to create frictionless power.

Friction Mean Effective Pressure

The pressure used to overcome internal
friction.

Brake Mean Effective Pressure

The pressure used to produce useful work.
 Reciprocating Engine Theory Of
Operation
Thrust Horsepower
The result of the engine and propeller working
together.

The ratio of thrust horsepower and brake

horsepower delivered to the propeller shaft will
never be equal.

Determines the performance of the engine-

propeller combination.
 Reciprocating Engine Theory Of
Operation
Efficiencies

Thermal Efficiency
The ratio of useful work done by an engine
to the heat energy of the fuel it uses,
expressed in work or heat units.

Mechanical Efficiency
The ratio that shows how much of the power
developed by the expanding gases in the
cylinder is actually delivered to the output
shaft.
 Reciprocating Engine Theory Of
Operation
Efficiencies

Volumetric Efficiency

A comparison of the volume of fuel/air

charge inducted into the cylinders to the
total piston displacement of the engine.
Engine Balancing
 Balancing engines
For smoother engine operation & longevity

Forces multiply as engine RPM increase

Copyright 2003 Gary Lewis Dave Capitolo

Balancing engines
First step in diagnosing engine vibration

Isolate engine mounts/insulators

Balancing engines
Weight groups for balancing
Rotating weights
Housing bore end of rods
Rod journals
Rod bearings
Oil

Reciprocating weights
Pistons, pins, rings, locks
Pin end of rods
Balancing engines
Weighing connecting rods
Record rotating weight of rod
Record reciprocating weight of rod
Balancing engines
Weighing piston assemblies
Record weight of . . .
Piston
Pin
Ring set
Locks
Balancing engines
Balancing connecting rods
Equalize the housing bore end of the rods first
Equalize the pin end of the rods
Balancing engines
Balancing piston assemblies
Reduce piston assembly weights from . . .
Piston or . . Pin
Balancing engines
Vibration forces in 4 cyl. in-line
Primary vibration
Up and down vibration
Counterweights used to cancel
Secondary vibration
Differences in acceleration rates
Balance shafts used to counteract
Balancing engines
In-line crankshaft design

Counterweights are equal in force to crank pins

(Primary vibration)

If rotating weights are the same, they cancel

each other in in-line 6 cyl engines
Balancing engines
4 cylinder in-line crankshaft design
Reciprocating forces do not completely cancel
Acceleration is greater as the piston passes
TDC and starts down
Balance shafts can counteract these forces
Balancing engines
4 cylinder in-line unbalanced forces
Pistons reach max velocity at 70 to 75 ATDC
(When connecting rod is 90 to crankpin)
Peak acceleration is between TDC and max veloc
Force is acceleration times reciprocating weight
Balancing engines
4 cylinder in-line crankshaft design (cont.)

Unbalanced forces are minimized by . . .

Reducing reciprocating weights
Shorter stroke
Longer connecting rods
Balancing engines
6 cylinder in-line crankshaft design

If reciprocating forces are equal,

they cancel each other
 Balancing engines
V-block crankshaft design

Counterweights are equal in force to . . .

Rotating weight at crankpins plus a
Percentage of the reciprocating weight

Percentage of reciprocating weight in counterweight

design, varies with the amount that the forces cancel
between cylinders
Balancing engines
V-block crankshaft design
V-6 engines have rocking couples
Greater in 90 V-blocks than 60
Even firing V-6 engines
Reciprocating weights do not cancel
Counterweights do not fully compensate
Balancing engines
Externally balanced engines
Weights added to outside of crankshaft
Limited room for counterweights in crankcase
Can be converted to internal using heavy metal
Balancing engines
Balance specifications
A balanced engine has . . .
-Reciprocating forces that cancel
-Wobble that does not exceed oil clearance,
6 grams or less at 1 radius for computerized bala
Balancing engines
Balancing procedure
Record piston weights and lighten heavy pistons
to match lighter pistons
Equalize rotating weights
Equalize reciprocating weights
Balancing engines
Balancing procedure
Crankshafts are dynamically balanced in 2 planes
to eliminate wobble
Corrections are made to the end counterweights
Balancing engines
Balancing procedure
Dimensions needed:
Radius from center to counterweights
Distance between counterweights
Distance between counterweight and suppo
Balancing engines
Balancing procedure
Balancing equipment locates point of correction
Weight is either added to one side
or removed from the other
Amount varies with the radius
Balancing engines
Balancing procedure
In-line engines do not require bob weights
V-block engines use bob weights
 Balancing engines
Balancing procedure
Bob weight calculations
V8 engines
60 V6 engines
90 odd-fire V6 engines
90 even fire V6 engines
90 V6 engines w/ 18 splayed crankshaft
V6 engines with balance shaft
100% rotate, 50% recip
100% rotate, 50% recip
100% rotate, 50% recip
100% rotate, 36.6% recip
100% rotate, 46% recip
100% rotate, 50% recip
Balancing engines
Flywheels and clutches
Add to flywheel and balancer to balanced cranksh
Then add pressure plate
Mark assembly with punch
Balancing engines
Torque converter warning
Chrysler 360 with cast crankshafts
Externally balanced by adding weight to conve
If special tools are not available,
do not balance crankshaft
Mark assembly with punch
Balancing engines
Balancing with heavy metals (no, not Metallica)
Holes filled with Tungsten alloy
For external to internal change
Expensive for conventional balancing