School of Mechanical and Manufacturing Engineering
(SMME)
Internal Combustion Engines
Course Code ME-448
INTRO to ICE
Lec 1
Engr Mohammad Ikhlaq Khattak
ikhlaq@[Link].pk1
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Introduction:
– History of ICEs
– Cycles
– Engine classification
– Fundamentals of ICEs
– Slider-crank mechanism
– Torque, power,
performance
– Efficiency
– Exhaust products
Page 2
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Engine:
Device to convert fuel energy to mechanical energy
Fuel energy to thermal energy by combustion
Thermal energy to mechanical energy by expansion
• Internal combustion: combustion takes place in working
fluid
• External combustion: combustion occurs externally;
energy coupled to working fluid by heat transfer device
• Open cycle: working fluid discharged to atmosphere; e.g.
all ICE
• Close cycle: working fluid recycled through engine; e.g.
steam engine with condenser Page 3
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Classification of Internal Combustion Engines
Size: displacement volume 1cc to 1m3 per cylinder; it is difficult to build engine outside this
range. Power: 10 W to 108 W per cylinder
Classification:
• by application: Car, Truck, Marine, Rail, Stationary generation,
• by basic engine design: reciprocating, rotary, in-line block, V-block, radial, oppose piston,
pre-/open chamber
Page 4
• by working cycle: 2-stroke, 4-stroke, naturally aspirated , turbo-charged,
super-charged, turbo-compound
• by fuel: gasoline, diesel, alcohol, natural gas, …
• by mixture preparation: carbureted, fuel injection
• by ignition: spark ignited, compression ignited
Page 5
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• What is a motor / engine?
• What are its different kinds?
Page 6
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• What is a motor / engine?
We wish to produce mechanical work. This necessitates
the conversion of energy initially in another form to
mechanical power
• Historically
Animal, water Wheel and Wind Mills,: all using natural ,
re newable, and Soler energy sources
Page 7
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Combustion machines
Use chemical energy stored in fuel which may come
from fossil (oil, gas, coal etc.) or biological (vegetable or
animal) sources
Page 8
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Electric machines
Use electrical energy, which has to be produced generally via
the conversion of mechanical energy. This mechanical energy
itself may come from a renewable or non-renewable energy
source (hydraulic, heat engine, nuclear reactor, wind…)
Page 9
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Combustion engines
– A fluid is made to follow a certain cycle of operations
under the influence of thermodynamic principles. The
cycle thus obtained is known as a thermodynamic
heat engine cycle
– If the combustion takes place in the working fluid that
is undergoing the thermodynamic cycle, the engine is
known as an Internal Combustion Engine
(reciprocating engines, gas turbines, rotary engines
etc.)
Page 10
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Combustion engines
– If the combustion takes place outside of the working
fluid of the thermodynamic engine cycle, the engine is
known as an External Combustion Engine. A few
examples are engines running on the Stirling, Ericsson,
Rankine and Hirn cycles.
Page 11
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Combustion engines
Page 12
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Idealised cycles
– Otto cycle
– Diesel cycle
– Dual combustion cycle
Page 13
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Otto cycle
Otto cycle, also known as the Beau de Rochas (France).
Alphonse Eugène Beau de Rochas was awarded the
patent for a practical four stroke cycle sixteen years
before Nikolaus Otto made a practical working engine
based on this cycle.
Page 14
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Diesel cycle
The Diesel cycle (named
after Dr. Rudolf Diesel) –
similar to Beau de Rochas
– except that the
combustion is at constant
pressure
Page 15
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Dual combustion /mixed cycle:
Based on the Beau de Rochas cycle with a limited
combustion pressure. The heat addition happens at
constant volume and then at constant pressure
Page 16
Thermodynamic Cycles for CI engines
• In early CI engines the fuel was injected when the piston reached
TC and thus combustion lasted well into the expansion stroke.
• In modern engines the fuel is injected before TC (about 20o)
Fuel injection starts
Fuel injection starts
Early CI engine Modern CI engine
• The combustion process in the early CI engines is best approximated
by a constant pressure heat addition process Diesel Cycle
• The combustion process in the modern CI engines is best approximated
by a combination of constant volume & constant pressure Dual Cycle
Modern CI Engine Cycle vs Dual Cycle
Fuel injected
A at 20o bTC
I
R
Air Combustion
Products
Actual
Cycle
Intake Compression Power Exhaust
Stroke Stroke Stroke Stroke
Qin Qin Qout
Air
Dual TC
Cycle
BC
Compression Const volume Const pressure Expansion Const volume
Process heat addition heat addition Process heat rejection
Process Process Process
Dual Cycle
Process 1 2 Isentropic compression
Process 2 X Constant volume heat addition
Process X 3 Constant pressure heat addition
Process 3 4 Isentropic expansion
Process 4 1 Constant volume heat rejection
X 3 Qin
3
2 Qin
X
4
4 2
1
1 Qout
Thermal Efficiency
Qout m u4 u1
Dual 1 1
cycle Qin m (u X u2 ) ( h3 hX )
For cold air-standard the above reduces to:
1 rck 1
Diesel 1 k 1
const cV r ( 1) k rc 1
where rc= v3/vX and a = P3/P2
Note, the Otto cycle (rc =1) and the Diesel cycle (a=1)
are special cases:
1 1 1
Diesel 1 k 1
r k
c 1
Otto 1 k 1
r const c V
r k rc
1
The use of the Dual cycle requires information about either the fractions
of constant volume and constant pressure heat addition (common
assumption is to equally split the heat addition), or the maximum
pressure P3.
Transformation of rc and a into more natural variables yields
k 1 Qin 1 1 1 P3
rc 1
k P1V1 r k 1 k 1 r k P1
For the same inlet conditions P1, V1 and the same compression ratio:
Otto Dual Diesel
For the same inlet conditions P1, V1 and the same peak pressure
(actual design limitation in engines):
Diesel Dual otto
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Engine classification
– Spark ignition
• Combustion initiated via a spark. Generally run on light
easily vaporizing fuels (petrol, alcohols, gas)
• Air / Fuel mixture may be made outside (Carburetor,
TBI or MPFI) or inside (GDI, FSI, IDE)
– Compression ignition
• Combustion initiated by compression of air charge.
Generally run on heavier grades of oils
• Air / Fuel mixture is made inside the cylinder.
Page 22
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Fundamentals of ICEs
– Principal moving parts of an ICE
– Functioning of these parts
– Different technological solutions
Page 23
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Principal moving parts of an ICE
• The variation in volume for the working
fluid is brought about by the
reciprocating action of the piston inside
the cylinder
• The crank transforms this alternating
movement into a rotational movement
• The intake and exhaust events take
place via the intake and exhaust valves.
These valves are opened / closed at the
right moment by the camshaft(s).
Page 24
Introduction
Internal Combustion Engines – SI & CI
Forced Induction
Exhaust Emissions and their control
Alternative Engine Design Concepts
• Pistons, rings and connecting rods (conrods)
• Pistons are generally made of aluminium. They may be
forged or cast. They may also have special coatings for
heat protection (head) and reduction in friction (skirt)
Page 25
• Pistons, rings and connecting rods (conrods)
• Cast pistons – lower cost, tighter tolerances, low
start-up noise, low oil consumption
• Forged pistons – higher cost, greater strength,
greater resistance to knock Page 26
• Pistons, rings and connecting rods (conrods)
• A gas-tight seal between the piston and the cylinder is assured
by piston rings. These are almost exclusively made of steel.
They may be chrome plated for high wear-resistance.
Page 27
• Pistons, rings and connecting rods (conrods)
• The connecting rods are in most engines made of steel. They can
be cast or forged. In some production engines, they may be of
titanium. Aluminium is also used in case of high-power, short
duration applications – drag racing, tractor pulling etc.
Page 28
• Crankshaft
• Presently, crankshafts are made of nodular cast iron.
Forged steel is used in case of some diesel engines and
mostly for high performance applications. They are usually
in one piece.
Page 29
• Crankshaft journals
• Crankshafts are supported in the engine block on journal
bearings which are split in two shells. These bearing shells
are made of steel with various metals plated in layers. They
support both radial and axial loads (clutch).
Page 30
• Rotating assembly
• Pistons, connecting rods and crankshaft constitute a
rotating assembly. It may or may not be internally
balanced. Page 31
• Cylinder head
• The cylinder head, situated on top of the engine block, serves as one
half of the combustion chamber. It incorporates the ignition / fuel
source and valvetrain in all modern four stroke engines.
• The intake and exhaust headers are also bolted to the head.
Page 32
• Head gasket
• The headgasket serves to seal the cylinder against the cylinder head to
produce a combustion chamber. They incorporate holes for the cylinder,
coolant, oil, valevtrain passages and location dowels.
• Most OEM gaskets are steel and fibrous material, high performance
ones are full metal and may incorporate lock rings to seal the cylinder
against the head.
Page 33
• Engine block and cylinders
• The engine block is usually made of aluminium or cast iron.
• The cylinders may be directly bored into the cylinder block,
or may be pressed-in in the form of liners
Page 34
• Engine block and cylinders
• The liners may be of the dry or wet type
• The block is the main structural part of the engine. It
maintains the parallelism of the crankshaft, balance shafts,
camshafts and pistons
Page 35
• Cylinder / piston arrangement
• Most of the engines in vehicles have multiple cylinders, the cycles of which are all distributed. This
is to produce work in a smooth and continuous manner
• The arrangement varies according to certain constraints of which space is a major factor.
• The arrangement of the pistons and the firing order of the engine have a very big influence on the
balance and smoothness of the engine.
Page 36
• Engine balance
• Crank with counterweights
(may be internally balanced)
• Crank with split crankpins
(VR6)
Page 37
• Engine balance
• Balance shafts
Page 38
• Engine balance
• W8 engine (VAG)
• Crank with split crankpins and two balance shafts
Page 39
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Thank you
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