Introduction

to
AUTOMOBILE ENGINEERING

Unit-1
What is an Automobile?

A self-propelled vehicle used for transportation of goods &

passengers is called an Automobile.

A vehicle producing power within itself for its propulsion is known as a

Self propelled vehicle.
 Components of an Automobile:
An automobile is made of two main components namely

● Body (Superstructure)
● Chassis

• A vehicle arrangement without body is called Chassis.

The chassis supports the following parts...

 Contd...
Chassis:
1. The Basic structure
2. The Engine
3. The Transmission(Driving) system
4. The Auxiliaries
5. The Control System.

Explanation→
1. The Basic Structure:
It consists of the

● Frame
● Suspension system
● Axles
● wheels and tyres.
2.The Engine:

An engine is a machine designed to convert one form of energy into

mechanical energy. The engine for automotive used is IC type.
 Power Unit (Engine):

The power plant provides the motive power for all the various parts of the vehicle to function
properly.

It generally consists of Internal Combustion (I.C.) Engines, which may be either of S.I. or
C.I. type.

However,

● Gas turbines are used instead of C.I. engines for better performance, though the cost has
been a disadvantage.
● Electric motors powered by batteries used as a motive power plant for automobiles.
● Combination of (I.C. engine & Electric motor) have been used in Hybrid Vehicles.
● The future power plant is based on fuel cells which would give zero-emission.
 3.Transmission System:

● Clutch
● Gear box
● Propeller Shaft(Drive line)
● Differential
● Rear-axle.

It consists of a Clutch, a gear box giving four, five or even more different ratios of
torque output to torque input, a propeller shaft to transmit the torque output from the
gearbox to the rear axle and a differential is used to distribute the final torque equally
between the driving wheels.
https://www.youtube.com/watch?v=QPaUJfA1KsY
Components of Transmission System:
Engine:

The power is generated in the engine and is transferred to various parts of the automobile
to travel from one place to another place.

Clutch:

It’s purpose is to disconnect the drive from the road wheels instantaneously and to drive
from the engine to the road wheels gradually while moving the vehicle from rest.

Gear Box (Transmission):

The Transmission or the Gearbox provides the necessary leverage variation between the
road wheels and the Engine.
Universal Joint:

They provide for the relative movement between the engine and the driving wheels due to
flexing of road springs.

Differential:

While taking turns, the driving wheels must turn at different speeds and this is done with the
help of differential.
4.Auxiliaries:

● Starting system
● Charging system
● Lighting system
● Wiring system

5.Control System:

● Steering System
● Breaking System
 Classification of Chassis:
I. According to the fitting of engine
(a)Full Forward

(b)Semi Forward

(c)Bus Chassis

(d)Engine at back

(e)Engine at centre
iii.According to Drive
● Rear Wheel Drive
● Front Wheel Drive
● All Wheel Drive
● Left hand Drive
● Right hand Drive
Rear Wheel Drive
 Rear-Wheel Drive Pros (Advantages)

Traditionally, Vehicles are of Rear wheel drive only and now it is moving towards Front
Wheel Drive.

Mileage: In general, Rear-Wheel drive vehicle gets less mileage than FWD.

Complexity: It is less complex than FWD

Ruggedness:Much higher than FWD.

Handling:RWD is better because the front wheels are just to turn the vehicle whereas the
power will be given only to the Rear wheels

Vehicles:Toyota Fortuner, Toyota Innova, Mahindra Scorpio, Mahindra XUV 500, Mahindra
Xylo, Mahindra Quanto, Mahindra Bolero.
Front-Wheel Drive:
● Engine Power is transmitted to the front axle near the engine.
● It means the front wheels are being powered by the engine, and
the rear wheels just follow the front wheels.
● Propeller shaft is eliminated and the linkage for clutch and
transmission is simplified. This permits a low chassis height.
● Better road adhesion is obtained in the case of Front-wheel drive
where a large part of the weight of the automobile is taken on the
driving wheels.
● Engine pulls the car rather than pushing.
Advantages:

The engine and transmission are located directly above the front wheels, which can provide better
traction when climbing hills and driving on slippery roads

Front-wheel drive has less components than any other drive and it

● Makes the vehicle lighter and thus increase in mileage

● Complexity: It(Entire setup of Transmission) is more complex than RWD.

● Ruggedness:less than RWD.

Front-wheel drive is a simpler system and tends to be less expensive to buy and maintain.

Disadvantages:

Since all the weight is located in the front of the vehicle, front-wheel drive cars tend to understeer.

With all the weight up front, front-wheel drive can make handling more difficult.

Vehicles: Alto,I 20, Baleno, Celerio, Brezza etc.

Characteristics of Good Chassis
It should have

● Strength
● Durability
● Easy of Control
● Economy of Operation
● Stability
● Simplicity of Lubrication
● Fast Pickup and Safety
 Automobile Engines
#1.Definition of Heat Engine:

Any type of engine or machine which derives heat energy from the combustion of
fuel or any other sources and converts that energy into mechanical work is termed as
a heat engine.

#2.Classification of Heat Engines:

Heat engines may be classified into two types.

1.External Combustion Engine and

2.Internal Combustion Engine

Internal Combustion Engine:

In this case, combustion of the fuel occurs within the cylinder of the engine. The IC
Engines group includes engines employing mixture of combustible gases and air
known as gas engines.

Components of IC Engines: →
The components of IC Engines are as follows.

1.Cylinder:

It is a cylindrical vessel or space in which the piston makes a reciprocating motion.

The varying volume created in the cylinder during the operation of the engine is filled
with working fluid and is subjected to different thermodynamic processes.

2.Piston: It is a cylindrical component fitted into the cylinder for converting one form of
energy into another form. It fits perfectly into the cylinder providing a gas-tight space
with the Piston rings and the lubricant.

3.Cylinder head:

The main function of the cylinder head is to close the cylinder to make a confined
space. The valves(Inlet and Exhaust Valve), Spark plug, cam and camshaft are
4.Connecting rod:

It interconnects Piston and the crankshaft and transmits the gas forces from the Piston to the
crankshaft.

5.Crankshaft:

It is enclosed in a crankcase. It converts the reciprocating motion of the piston into useful rotary
motion of the output shaft.

6.Piston rings:

They are fitted into the slots around the piston, providing a tight seal between the piston and the
cylindrical wall thus preventing the leakage of combustion gases.

7.Gudgeon Pin:

It forms the link between the small end of the connecting rod and the Piston.
8.Inlet and Exhaust valves:They are provided on the cylinder head or on the side of the cylinder for regulating the
charge coming into the cylinder(inlet valve) and for discharging the products of combustion(exhaust valve) from the
cylinder.

9.Spark Plug:

It is a component to initiate the combustion process in SI engines and is usually located on the cylinder head.

10.Crankcase:

It is a stationary body of the engine which serves as an enclosure for moving parts.

11.Camshaft:

It is used to control the opening and closing of the two valves.

It also provides the drive to the ignition systems and the camshaft is driven by the crankshaft.

12.Cams:They are made as integral parts of the camshaft and are designed in such a way to open the valves at the
correct timing and to keep them open for the necessary duration.
 IC Engines Nomenclature
1.Cylinder Bore (d)

The nominal inside diameter of the engine cylinder is called a Cylinder bore.

2.Stroke

The distance travelled by the piston from Top Dead Centre to the Bottom Dead Centre is called Piston Stroke.

3.Dead Centre:

There are two dead centres in the engine.

1.Top Dead Centre(TDC) and

2.Bottom Dead Centre(BDC)

The piston reciprocates in the cylinder between two fixed positions. The uppermost position i.e. position nearest to the cylinder
cover is termed as Top Dead Centre(TDC) while the lowermost position(nearer to the crankshaft) is Bottom Dead Centre(BDC).
4.Swept Volume:

The volume displaced by the piston, when travelling from one dead Centre to the other Dead center is called as swept volume.

Vs = (π/4)d2L

5.Clearance Volume:

The space between the cylinder head and the Piston face at the Top Dead Centre(TDC) is known as the clearance volume.

6.Compression ratio:

It is the ratio of the total cylinder volume when the piston is at the bottom dead centre(VT) to the clearance volume.

Compression ratio,r = (VT/VC)

= (Vc + Vs)/Vc

= 1+(Vs/Vc)
 Classification of IC Engines:

The classification of IC Engines are as follows.

1. Basic Engine Design

2. A cycle of Operation(Working Cycle)
3. Number of Strokes
4. Type of Ignition
5. Method of Cooling
6. Method of Charging
7. No. of Cylinders
8. Cylinder Arrangement or Type of cylinder
9. Fuel used
10. Method of Fuel Supply
11. Engine Speed
1.Basic Engine Design:

a. Reciprocating Engines
b. Rotary Engines (Wankel Engine)

2.Cycle of Operation(Working Cycle):

c. Engines working on OTTO Cycle (SI Engines)

d. Engines working on DIESEL Cycle (CI Engines)

3.Number of Strokes:

e. Four Stroke Engines

f. Two Stroke Engines

4.Based On Type of Ignition

g. Spark Ignition Engines

h. Compression Ignition Engines
5.Method of Cooling

a. Air-cooled Engine
b. Water Cooled Engine

6.Classification Based On Method of Charging

a.Naturally Aspirated Engines

Admission of Fuel-air Mixture at Near Atmospheric Pressure

b.Super-charged Engines

Admission of Fuel- Air Mixture Under Pressure (Above Atmospheric)

7.No. of Cylinders:

● Single Cylinder
● Multi Cylinder
8.Type Of Cylinder Arrangements

● V- Engine
● Opposed Cylinder Engine
● Opposed Piston Engine
● Radial Engine
● X-type Engine
● H-type Engine

9.Fuel used :

a. Gasoline or Petrol Engines

b. Compressed Natural Gas (CNG) Engines
c. Diesel Engines

10.Fuel Supply:

7. Carbureted type- Fuel supplied through Carburetor

8. Injection type- Fuel supplied through injector
11.Classification Based On Engine Speed

● Low Speed – up to 500 rpm

● Medium Speed – 500 to 1000 rpm
● High Speed – above 1000 rpm

12.Classification Based On Applications:

● Motor cycle engine

● Automobiles
● Earth Movers
● Locomotive engine
● Marine engine
● Aero engine
● Prime movers for Electric Generators
 Supercharging and TurboCharging
Supercharging:
A supercharger is an air compressor used for forced induction of air into an internal combustion engine.The process of
forcing more charge into the engine cylinder than can be drawn by naturally aspirated piston action to get more power
is called as Supercharger.

It is fitted before the Intake valve of the cylinder so that air can be compressed in the supercharger and allowed it to be
forced into the cylinder via the Intake valve.It is used to increase engine power, efficiency, torque by compressing the
air in multistages for increasing quantity of air, pressure and temperature.

The greater mass flow-rate provides more oxygen to support combustion in the cylinder compared to the naturally
aspirated engine.

Supercharger allows more fuel to be burned and more work to be done per cycle, increasing the power output of the
engine.

The Power to the supercharger comes mechanically from the engine's crankshaft via a belt, gear, shaft, or chain.
SuperCharger increases the pressure of the A/F mixture and supplies at higher pressure
than atm pressure.

Supercharged engine produces higher power up to 40% to that of the normal engine.

It also increases torque by 40%.

At higher altitudes it helps by increasing the density of the air fed to the engine.

https://www.youtube.com/watch?v=w5Eica5vCL4
 Types of Superchargers

According to the method of compression, there are two main types of superchargers.

i. Positive displacement (ex. Twin-screw, roots)

ii. Dynamic compressors (ex. Centrifugal)

A Positive Displacement Pump has an expanding cavity on the suction side and a decreasing cavity on the discharge
side.
Centrifugal Type Supercharger

A/F mixture enters the impeller at the centre and passes through
the impeller and diffuser vanes.

Finally it enters volute casing and the mixture goes to the

engine from the casing.

● Pressure is increased by 30%

● Impeller speed → 80000 rev /min
● Impellers are made of duralumin/alloy steels to withstand
high steels.
Root’s Supercharger
Two rotors of epicycloids shape, each rotor keyed to its shaft.

• One rotor is connected to other by means of gears.

• Gears are of equal size and two rotors rotate with same speed.

• Operates like a gear pump.

• Mixture at the outlet of the supercharger is at high pressure.

Turbocharger

A turbocharger is a centrifugal compressor powered by a turbine that is driven by an

engine's exhaust gases.

To improve an engine's volumetric efficiency by increasing the intake density.

The turbine converts the engine exhaust pressure energy and kinetic energy into rotational
power, which is in turn used to drive the compressor.

https://www.youtube.com/watch?v=DqWKNuTppmU
For more info, visit
https://mechanicalstudents.com/difference-between
-supercharger-and-turbocharger-pdf-supercharger
-vs-turbocharger/
Engine Lubrication System:
By the use of Lubrication, the heat produced between the mating parts will be reduced and
no heat will be dissipated into the component.
Lubrication is the admittance of oil having relative motion between two surfaces.

The purpose of lubrication maybe one or more of the following.

● Reduce wear and friction between the parts having relative motion.
● Cool the surfaces by carrying away heat due to friction.
● Seal a space adjoining the surfaces such as Piston rings and cylinder liner.
● Absorb shock between bearings and other parts and consequently reduce noise.
● Cleaning the surfaces by carrying away the carbon and metal particles caused by wear.

https://www.youtube.com/watch?v=mmmcj53TNic
Types of Lubrication systems
1. Dry sump lubrication
2. Mist lubrication
3. Wet sump lubrication
● Splash
● Semi pressure system or Pressure Fed or Force Feed.
● Full pressure system or Combination Pressure Fed and Splash.

1.Splash Lubrication system

2.Pressure Lubrication system

1.Splash Lubrication system
Splash lubrication System:

Splash lubrication is commonly used in early motorcycles engines.

More specifically, this technique is used in lawn mower and outboard boat engines or motors that have
sufficient amounts of oil in the trough to fully lubricate the machine.

Firstly oil is filled in the Crankcase.Oil strainer will remove any impurities present in the oil.The oil pump
will supply it to all the parts including oil troughs.

In the splash lubrication system, oil is splashed up from the oil trough or oil trays in the lower part of the
crankcase with each revolution of the crankshaft to produce the oil splash.
The oil is thrown upward as droplets or fine mist and provides adequate lubrication to valve mechanisms,
piston pins, cylinder walls, and piston rings.

Oil flows through the holes drilled inside the crankshaft and main bearing to lubricate them.

This system is too uncertain for automotive applications. One reason is that the level of oil in the
crankcase will vary greatly the amount of lubrication received by the engine.

A high level results in excess lubrication and oil consumption and a slightly low level results in inadequate
lubrication and failure of the engine.
Pressure Lubrication system
The Pressure Lubrication system is universally used in modern car engines.

The Pressure Lubrication system has came into picture because the Splash Lubrication
system is not suitable for automobile engines due to the absence of positive lubrication.

In this system, Oil is taken from the wet sump through the strainer by the pump and
delivers it at a pressure of 200 to 400 Kpa to the main oil gallery.

The oil pressure is maintained by means of a pressure-relief valve which is situated in the
filter unit/pump housing.

An oil pressure regulator ensures that the oil pressure level is maintained properly.

For inline engines,one main gallery is used whereas for V-Engines one/two main galleries
and two valve tappet galleries are used.

https://www.youtube.com/watch?v=mmmcj53TNic&t=96s
The oil filter removes all the dust particles present in the oil and supplies clean oil to all
the oil lines.

The pressurised oil flows through the oil lines and galleries so as to lubricate the moving
engine parts.

Oil from the main gallery flows through the holes drilled inside the crankshaft and main
bearing to lubricate them.

The oil sprout connected with the gallery forces the oil upwards to lubricate the piston and
all the parts of it from inside.

Oil flows through the oil rings to lubricate and form a thin film around the cylinder walls.
After all the parts are lubricated in first gallery, the oil will be pumped to the second
gallery which can lubricate all the parts connected with camshaft.

The sprouts connected to the gallery helps in lubricating camshaft,valves and valve
springs.

After lubricating the engine parts, oil begins to flow downwards through a seperate
passage to the sump.

A pressure gauge calculates the oil pressure in the system and displays it on the dial
For more info, Visit
https://mechanicalstudents.com/types-of-lubricatio
n-systems-pdf-splash-lubrication-system-pressure-l
ubrication-system/
Oil Pumps
After strainer, the next component is the pump which is used to
suck the oil from the sump and supplies it to all the galleries of the
engine.

In an internal combustion engine, the oil pump circulates engine

oil under pressure to the sliding pistons,rotating bearings, and the
camshaft of the engine.
Types of Oil Pumps

1.Gear Pump

2.Plunger Pump

3.Vane pump
1.Gear Pump:

● A Gear pump uses the meshing of gears to pump fluid by displacement.

● Gear pumps are fixed displacement, meaning they pump a constant amount of fluid
for each revolution.
● They are one of the most common types of pumps for hydraulic fluid power
applications.
● Gear pumps however are also widely used in chemical installations to pump fluid
with a certain viscosity.
● There are two main variations; external gear pumps which use two external spur gear
and internal gear pumps which use an external and an internal spur gear.
2.Plunger Pump:

● The plunger pump is the oldest type in common use.

● Piston or plunger pumps consist of a cylinder in which a piston or plunger moves
back and forth i.e. reciprocating motion.
The plunger reciprocates in the cylinder to take the oil from the crankcase and supply it to
the various parts of the engine.

As the plunger reciprocates towards the front, the pressure is created towards the inlet and
exhaust valves.

The flow is created over there and that hits both the valves. The inlet valve closes and the
oil is passed away from the outlet valve.

Similarly, when the piston/plunger moves towards the top of the engine, the inlet valve
opens and outlet valve closes.The piston hits the oil by the reciprocating motion makes the
outlet valve open and inlet valve close.

In this way, the plunger pump works to supply the oil to various parts of the engine.
3.Vane Pump:

Vane pump includes a rotating cylinder containing equally spaced radial pistons arranged
radially around the cylinder central line.

The spring pushes the pistons against the inner surface of an encircling stationary ring mounted
eccentric to the cylinder.

The pistons draw the fluid during half the revolution and drive the fluid out by the other half
revolution.

The greater the ring eccentricity is, the longer the piston stroke and more fluid they transfer.
Oil Filters

An oil filter is used to remove the dust particles/contaminants from the oil before it is
feeding to all the parts of the engine.

They are three types of Oil filters.

1.Renewable Cartridge type oil filter

2.Edge type oil filter

3.Centrifugal type oil filter

1.Renewable Cartridge type oil filter

For content on Types of Oil filters, visit the below link

https://mechanicalstudents.com/types-of-oil-filters-pdf-cartrid
ge-type-oil-filter-edge-type-oil-filter-centrifugal-type-oil-filte
r/
2.Edge type oil filter
3.Centrifugal type oil filter
For content on Types of Oil filters, visit the below link

https://mechanicalstudents.com/types-of-oil-filters-pdf-cartridge-type-oil-filter-edge-type-oil-filter-centrifugal-type-
oil-filter/
Crankcase Ventilation
Methods of Crankcase Ventilation are

1.Road Draft system

2. Manifold Suction system (Positive Crankcase Ventilation)

1.Road Draft system
2.Positive Crankcase Ventilation

The content will be updated...

 Engine Service
The servicing procedure for the following engine parts for Engine service is as follows

1. Engine Removal
2. Cylinder Head
● Removing Cylinder head
● Cleaning and Inspection
● Refitting the Cylinder head

3.Valves and Valve Mechanism

● Valve Removal
● Camshaft
4.Piston-Connecting rod assembly

● Dismantling the assembly

● Pistons
● Piston Rings
● Connecting rod
● Piston pin
● Reassembly

5.Cylinder block

6.Reinstalling the assembly in the cylinder

7.Crankshaft and main bearings

8.Engine Reassembly
 Reboring
You maybe aware that the piston has rings to both lubricate the cylinder wall and to create a tight sealing to prevent the gases
from entering the crankcase.

Over time, due to wear, both the cylinder wall and the rings wear out. When this happens, the first level of maintenance is to
replace the rings. Rings come in slightly different sizes.

Reboring is required when the piston, piston rings and cylinder are damaged, either after wear or tear or excessive usage
(continuous high speed use, or usage without proper lubrication).

When the cylinder wall is damaged, it can be rebored to a larger size and larger size pistons are used. The next step after
reboring (after several rebores) is sleeving. That is to put a sleeve inside the cylinder and use smaller or standard size pistons.

Reboring is however, not the only solution.

The best solution, though more expensive than reboring, is to replace the piston and cylinder kit with a new one.
Reboring an engine is necessary when the cylinder is:

● Check for deep scratches, marks, etc

● Un-round, or oval: This can be caused by
overheating
● Flat spots in the cylinder wall
● Out of specification in Diameter