Ae Unit 1

DEPT & SEM : ME & I SEM
SUBJECT NAME AUTOMOBILE ENGINEERING

:
AE
COURSE CODE
: I
UNIT : B SAROJ KUMAR
PREPARED BY :
COURSE: DM UNIT: 3 Pg. 1

SYLLABUS

SYLLABUS

OUTLINE
• Introduction
• Components of four wheeler automobile
• Chassis and body
• Power unit and Power transmission
• Rear wheel drive
• Front wheel drive
• Four wheel drive
• Types of automobile engines
• Engine construction
• Turbo charging and super charging
• Oil filters, oil pumps
• Crank case ventilation

INTRODUCTION
Automobile
A vehicle producing power within itself for its propulsion is known as a Self propelled
vehicle.
Eg. Moped, Scooter, motorcycle, Car, jeep, truck, tractor, ships, aircrafts, rocket etc.
A self propelled vehicle used for transportation of goods & passengers on the ground
is called an Automobile.
Different from Aeronautical vehicles (planes, helicopters, rockets) & marine vehicles
(ships, boats, submarines)

COMPONENTS OF AUTOMOBILE
 The automobile can be considered to consist of five basic components
1. The engine or power plant: It is source of power.
2. The frame and chassis: It supports the engine, wheels, body, braking system,
steering, etc.
3. The transmission: Which transmits power from the engine to the car wheels. It
consists of clutch, transmission, shaft, axles and differential.
4. The body and controls.
5. Accessories: Including light, air conditioner/ hearer, stereo, wiper, etc.

CHASSIS AND BODY
CHASSIS
 When engine , transmission system , steering & wheels are fitted on the frame , the
assembly known as the “chassis”.
 It is the backbone of the vehicle.
 It is the vehicle without body.
 It contains all the major units necessary to propel the vehicle.
 Vehicle can be driven after placing the driver seat on the chassis.

SIMPLE CONSTRUCTION OF TRUCK CHASSIS

COMPONENTS OF CHASSIS
Chassis consist of following components:

 Engine
 Wheels
 Radiator
 Brakes
 Fuel tank
 Steering system
 Suspension system
 Transmission system (clutch , propeller shaft , differential , rear axle)

BODY
Body
 It is a super structure of the vehicle.
 Chassis & body makes the complete vehicle.
 For small & light car body & chassis are made as a single unit but in large
 Vehicles both are made as a single unit.
 Generally it is made from metal or fibre.
 Main purpose of car body is to provide comfort & protection to the passenger
& also the good look.

TYPES OF BODY FOR CAR

CHASSIS

CHASSIS
Main Supporting Structure of

vehicle consist of almost all major
parts except automobile body

FRAME
Frame
Frame have different types:

1. Conventional frame
2. Integral or Unit construction or Frameless chassis
Functions of frames:
 To support chassis components and body
 Withstand the static and dynamic load of different components of chassis
 To withstand load of the body
 To carry load
 To withstand stresses caused due to uneven road conditions
 To withstand force caused due to turning of the vehicles and sudden braking or
acceleration

CONVENTIONAL FRAME
 It is used in most of the heavy

vehicles.
 Construction of frame varies
according to the type of vehicle.
 Generally made from the steel
sections.
 This type of frame has “ 2 long
side members” & “5 to 6 cross
members” joined together with
the help of rivets or bolts.
 Cross members are used to
increase the strength of the
frame.
 They are inswept (Narrow) at the
front & are upswept (Broad) at
the rear.

 The frame is narrowed down at the front (inswept) to have a better steering lock
which provides space for pivoting & swinging of the front wheels.
 Upswept at the rear provided to give room for the vertical movement of the rear
axle as it travels over road bumps & other road inequalities.
 Body brackets are provided to support the body of the vehicle.
 Spring brackets are provided for mounting the body of the vehicle.
 Extension of chassis frame ahead of the front axle known as front overhung.
 Extension of chassis beyond the rear axle known as rear overhung.
 Different sections are used for long & cross members. Generally channel section &
box section are used for long side members & other sections like I section , hat
section , tubular section are used for cross members.

INTEGRATED FRAME CHASSIS OR FRAMELESS CHASSIS
 Need of the heavy side members

are eliminated ,which is used in
conventional frame &the floor is
strengthened by cross members
& body , all welded together.
 In some cases sub-frames are
also used on which various
chassis components are
mounted. This sub-frames are
supported by main frame.
 The main purpose of sub-frame
are to provide isolation ,
flexibility & simplified
production.
 This type of construction gives
more strength & rigidity.

WHAT IS TRANSMISSION
 The mechanism that transmits the power developed by the engine of automobile
to the engine to the driving wheels(rear wheels) is called the Transmission and the
system is called Transmission system.
 It is used to transmit engine torque to the driving wheels to drive the vehicle on
the road.
Provide means of connection and disconnection of engine with rest of power train
without shock and smoothly.
Enable power transmission at varied angles and varied lengths.
Provide means to drive the driving wheels at different speeds when required.
Provide a varied leverage between the engine and the drive wheels
.
.
PARTS OF TRANSMISSION SYSTEM
 Engine
 Flywheel
 Clutch
 GEAR BOX (Or) TRANSMISSION BOX
 Universal Joint
 Propeller Shaft Or Drive Shaft
 Differential
 Rear Wheel Axle
 Rear Wheels

ENGINE
Engine is a mechanical device

which converts the chemical
energy of a fuel into heat or
thermal energy and then converts
the heat energy into mechanical
energy and makes the vehicle to
run at different loads.
Engines are again classified into IC
or EC Engines and are used for
different purposes.
So the main purpose of engine is
to transfer mechanical energy to
different parts of the transmission
system by the crankshaft.

FLYWHEEL
A FLYWHEEL is connected to the
crankshaft of the engine which is
a rotating device.
FLYWHEEL is a body having large
mass and it act as a reservoir for
energy store coming from the
engine.
It stores energy from engine
when it is more and releases the
energy when it is more than
requirement.
In IC engines power
produced in one stroke and the
remaining three strokes are idle.
So in that case a Flywheel
supplies energy to all the
rotating parts and makes the
crankshaft to run at uniform
speeds.
CLUTCH
The purpose of clutch is to engage

and disengage the transmission
system from the engine when a
vehicle is being driven away from a
standstill and when the gearbox gear
change is necessary. The gradual
increase in the transfer of engine
torque to the transmissions roust be
smooth.
When the clutch is in the coupling
(normal running) position, power
flows through it from the engine to
the transmission. If the transmission
is in gear, then power flows on
through to the propelling wheels of
the vehicle.
The clutch contains a friction disc,
spring arrangement and pressure
plate for pressing this disc tightly
against the smooth rear face of the
flywheel.
GEAR BOX
This Gear box is considered as

the heart of the transmission
system.
It is located between Clutch and
Propeller shaft .
Gear box varies the
leverage (speed ratio &
hence torque ratio)
between the engine
&driving wheels.
It is provided
with either 4 speed or 5 speed
ratios or more depending on
design.
To change the gears to travel at
different speeds.

UNIVERSAL JOINT
A universal joint is used to

transmit power from gear box to
propeller shaft. and then from
propeller shaft to diffrential.
So to maintain uniform speed and
motion, two universal joints are
used, one b/w gear box and drive
shaft and another b/w drive shaft
and differential and the coupling is
called universal coupling.
They are designed to eliminate
torque and speed fluctions(for
constant velocity)
If only one universal joint is used,
speed fluctuations will not be
neutralized

PROPELLER SHAFT
Front engine rear wheel drive

Reduction in car height.
It propels the vehicle forward,
so called propeller shaft.
A Propeller Shaft connects a
gearbox to a Differential.
It is used to transmit the drive
force generated by the engine
to the axles.
It is provided with two U-
joints to maintain constant
velocity and positioning of
differential at different plane.
It is provided with a slip joint
to take care of the change in
length.
It is strong enough to handle
maximum low gear torque. COURSE: DM UNIT: 3 Pg. 25
DIFFERENTIAL
To transfer the engine power to

the rear wheels.
To act as the final gear
reduction in the vehicle.
To make the wheels to rotate at
different speeds neglecting the
turn.
It is provided with different gears
to transmit power to rear wheels.

REAR WHEELS AXLES
Transmits rotary motion

and torque from the
engine-transmission- driveshaft
to the wheels.
Provides speed reduction and
torque multiplication.
Finally provide power from
engine to road wheels (rear
wheels) through many different
steps.

PROCESS OF TRANSMISSION

FRONT ENGINE – REAR WHEEL DRIVE
 In this chassis layout ,the

engine is fitted at the
front.
 The engine, clutch and
gear box are fitted at
front while drive to the
rear axle is given with the
help of propeller shaft
 This chassis layout is one
of the oldest and still
remain popular for heavy
commercial vehicle.

ADVANTAGE OF FRONT ENGINE –REAR WHEEL DRIVE
• The weight distribution is reasonably balanced between the front and rear wheels,
which gives good handling characteristics.
• Due to engine and radiator are at front , the forward facing radiator takes full benefit of
the natural air stream , created by vehicles movement .hence reduce the power losses for
a large fan.
• The weight of vehicle is shifted to rear driving wheels during acceleration and on
steeps resulting in better road grip hence,there are less chances of wheel slipping .
• Since the front wheel are used only to steer the vehicle, hence steering mechanism
become simple in design and easy to operate.
• Accessibility to various components like engine , gear box and rear axle is better
in comparison to outer layout
• The control linkages accelerator ,clutch, choke and gear box are shot and simple.
• Large luggage space is available at back of vehicle which providing increased carrying
capacity as well as space for easy body extension .

DISADVANT AGE
• During the breaking ,weight of vehicle is fitted to front wheels and weight on
rear wheels decreased , results in decreased breaking effort developed
• It required long propeller shaft and differential at rear
,therefore height of floor area is increased. Also, due to long propeller shaft
transmission problems and weight are increased.
• Due to less weight on driving rear wheels , there is less adhesion on road and
result in less holding capacity. Therefore there is less chance of skidding on
slippery surface.

FRONT ENGINE –FRONT WHEEL DRIVE
 In this type of chassis layout the

engine is fitted at front and
drive is also given to the front
wheel .No propeller shaft is
used in this layout and
differential are included in the
same assembly.
 This layout provides optimum
body luggage space and flat
floor line .However , due to all
assemblies at front ,it make
very difficult to accommodate
the steering mechanism.

ADVANTAGE OF FRONT- WHEEL DRIVE
• Due to more weight placed on driving front wheel, the vehicle has more adhesion
on road. Hence good road holding capacity even on the curves and slippery
roads .
• This layout provides low floor, since no propeller shaft and the differential placed
at front instead of rear.
• The clutch,gearbox, and final drive usually made as one unit thereby coast of
vehicle is reduce.
• The wheel do not take to sharply turn into the curve due to tendency of
understeering . The understeer condition generally preferred by many drivers are
promoted by this type of chassis.
• Either a transverse or longitudinal engine position can be used .In case of
transverse mounted engine , as the engine crankshaft and wheels already rotate in
the parallel planes ,therefore, they do not require their drive to be turned through
90degree as in case of conventional longitudinally mounted engines.

DISADVANTAGE FRONT- WHEEL DRIVE
• The weight on the driving front wheels is reduced during acceleration and
climbing of steep gradient due to weight of the vehicle shifting to the rear wheels.
Hence,result in decreased tractive effort.
• This dis advantage become more serious on slippery gradient.
• The steering mechanism become more complicated due to accommodation
of engine, clutch ,gearbox & final drive all at front of vehicle.

REAR ENGINE-REAR WHEEL DRIVE
 In this chassis layout engine is

fitted at the back and drive is also
given to rear wheel
 This arrangement eliminate the necessity

for a propeller shaft because engine is
mounted near the driven wheel.
 The passenger are kept away

from inconveniences like noise,
heat and fumes because engine
at back of vehicle

DISADVANTAGES
• Efficient cooling becomes very difficult to obtain due to air passes through side
part of the body
• Long linkages are required to connect the control panel and engine , gear
box, accelerator and clutch.
• The wheel get turned too sharply into the curve due to tendency of
oversteering

4 WHEEL DRIVE
• 4X2 = 4 Wheel vehicle and 2 Wheels can receive torque.
• 4X4 = 4 Wheel vehicle and all 4 Wheels can receive torque.
• E.g. are Jeeps, SUVs(Sports Utility Vehicle), etc.
• Games derived it’s name from 4WD only.
• Used mostly in defense services or where graveled or slick roads are present.

WHY 4 WHEEL DRIVE ARE USED?
 To get enough “TRACTION”

between wheels and road
surfaces.
 To move vehicle on slick surfaces,
dirt, slippery roads, sand roads
and snowy, muddy roads etc.

PART TIME 4 WHEEL DRIVE
 Manual Shift.
 Equipped with Switching
mechanism.
 Select 2WD under normal
condition and 4WD on off
road situation.

ADVANTAGES
• Increased Traction is obtained in slippery surfaces.

• More balanced axle load distribution.
• Even tire wear.

DISADVANTAGES
 Weight of vehicle is increased.
 Cost vehicle is increased.
 Maximum speed of vehicle is reduced.
 Less fuel economy than 2WD.

WHAT IS AN ENGINE?
 An engine is an device which is use to convert chemical energy into mechanical

energy or work.
Types of engine
On the basis where combustion takes place, there are two types of engine
1. External combustion engine (E.C. engine)
2. Internal combustion engine (I.C. engine)

EXTERNAL COMBUSTION ENGINE
In external combustion
engine the fuel is burn
outside from the engine
cylinder and the heat
generated then transferred
to the main working fluid to
vaporizes it, and a high
pressure is generated which
helps to move the piston.
Example - steam engine

INTERNAL COMBUSTION ENGINE
In internal combustion engine

working fluid burns inside the
cylinder and the heat generated
due to burning is then help to move
the piston
Ex: Petrol engine, Diesel engine

ENGINE'S MAIN PARTS
1.Cylinder block
2.Cylinder
3.Piston
4.Combustion chamber
5.Inlet manifold
6.Exhaust manifold
7.Inlet valve
8.Exhaust valve
9.Spark plug
10.Connecting rod
11.Crank shaft

IMPORTANT TERMS USED IN ENGINE
1.Cylinder bore (D) - it is the nominal inner diameter of the working cylinder.
2.Piston area (A) -It is the area of the circle of diameter equal to cylinder bore.
3.Stroke length (L) - The nominal distance through which a working piston moves
between two successive reversals of its direction of motion.
4.Dead centre - the position of the working piston and the moving parts which are
mechanically connected to it at the moment when the direction of the piston
motion is reversed (at either end point of the stroke).
Top dead centre - when the piston held at its top position in the cylinder then this
top position is called top dead centre. Bottom dead centre - when the piston
position occurs at the lowest position of the motion then this lowest position is
called bottom dead centre.
5.Swept volume (Vs) - The volume swept by piston while moving from top dead
centre to bottom dead centre is called "swept volume".
6.Clearance volume ( Vc) - The volume of the cylinder from its top most surface to
top dead centre (T.D.C.) is called "clearance volume".
7.Compression ratio (r) - It is the ratio of total volume of the cylinder to the
clearance volume. COURSE: DM UNIT: 3 Pg. 46
4-STROKE SPARK IGNITION ENGINE
1.Suction stroke - In this stroke the fresh charge come into the cylinder and the
piston moves from top to bottom dead centre.
2.Compression stroke - in this stroke the movement of the piston from bottom
dead centre to the top dead centre and thus the fresh charge get compressed. Both
valves remain closed during this stroke.
3.Expansion or power stroke – In this stroke both valves remains closed and
ignition of compressed charge takes place and power for wheels and for completion
of rest of three stroke takes place. Piston moves from bottom to top dead centre.
4.Exhaust stroke - In this stroke the piston moves from bottom dead centre to top
dead centre.
Thus the burnt charge sweeps out from cylinder to atmosphere.

FOUR STROKE COMPRESSION IGNITION ENGINE
1.Suction stroke - In this stroke the fresh charge (air) come into the cylinder and the
piston movement takes place from top to bottom dead centre. Only inlet valve
opened in this stroke.
2.Compression stroke - In this stroke the movement of the piston from bottom
dead centre to the top dead centre and thus the air get compressed. Both valve
remains closed during this stroke.
3.Expansion or power stroke – In this stroke at the end of compression stroke the
injector inject diesel into the cylinder and thus ignition of the diesel takes place and
power is obtained. Both valve remain closed in this stroke.
4. Exhaust stroke - In this stroke the piston moves from bottom dead centre to top
dead centre. Thus the burnt charge sweeps out from cylinder to atmosphere. Only
outlet valve opened in this stroke.

2-STROKE ENGINE
In two stroke engine suction and

compression stroke occurs
together and expansion and
exhaust strokes occurs together.
when the piston is at its bottom
dead centre then fuel comes in
the cylinder through the port,
when piston moves upward the
fuel get compressed and thus we
obtain high pressure and
temperature. After the ignition of
the fuel a high pressure will
occurs on the piston head and
piston moves downward, this
stroke is known as power stroke.
With this stroke the exhaust
stroke also occurs.

TURBO CHARGING
A turbocharger, or turbo is a turbine- driven forced induction device that increases

an internal combustion engine's efficiency and power output by forcing extra air into
the combustion chamber.
The turbocharger was invented by Swiss engineer Alfred Büchi (1879-1959), the
head of Diesel engine research at Gebrüder Sulzer engine manufacturing company
in Winterthur, who received a patent in 1905 for using a compressor driven by
exhaust gases to force air into an internal combustion engine to increase power
output, but it took another 20 years for the idea to come to fruition.
This results in a greater mass of air entering the cylinders on each intake stroke.
The power needed to spin the centrifugal compressor is derived from the kinetic
energy of the engine's exhaust gases. A turbocharger may also be used to increase
fuel efficiency without increasing power.
Turbochargers are widely used in car and commercial vehicles because they allow
smaller-capacity engines to have improved fuel economy, reduced emissions, higher
power and considerably higher torque.

WORKING OF TURBO CHARGER
In order to achieve this boost, the

turbocharger uses the exhaust
flow from the engine to spin a
turbine, which in turn spins an air
pump.
The turbine in the turbocharger
spins at speeds of up to 150,000
rotations per minute (rpm) that's
about 30 times faster than most
car engines can go. And since it is
hooked up to the exhaust, the
temperatures in the turbine are
also very high.

SUPERCHARGER, THE ENGINE BOOSTER
A supercharger is an equipment that

compresses the air being delivered to an
engine, allowing the combustion chamber to
be the space.
The higher concentration of oxygen

provided by a super charger is matched with
a larger amount of fuel from the fuel
injectors thus boosting the power of the
engine

WHY SUPERCHARGER ?
 Increases the power of an engine.

 Increases the torque produced.
 An efficiently working supercharger can achieve the same speed in one third
time.
 Necessary in aero-planes as they have less oxygen at high altitudes.
 Ensures complete combustion of the fuel.
 Reduces pollution to some extent.

CLASSIFICATION OF SUPERCHARGERS
Based on method of compression, Superchargers can be classified as:-
1.Positive-displacement - which deliver a nearly fixed volume of air per revolution

at all speeds and a fairly constant level of boost regardless of engine speed.
2.Dynamic compressors -rely on accelerating the air to high speed and then
exchanging that velocity for pressure by diffusing or slowing it down & deliver
increasing boost with increasing engine speed.

COMMONLY USED SUPERCHARGERS

ROOTS SUPERCHARGER
Working:-
As the meshing lobes spin, air trapped in the pockets between the lobes is carried
between the fill side and the discharge side & Large quantities of air move into the
intake manifold and "stack up" to create positive pressure.
• Roots superchargers are usually large and sit on top of the engine.
•Roots superchargers are the least efficient supercharger for two reasons:-
1)They add more weight to the vehicle.
2)They provide air in discrete bursts instead of

providing in a smooth and continuous manner.

A STANDARD ENGINE WITH THE ADDITION OF A SUPERCHARGER

TWIN-SCREW SUPERCHARGER
A twin-screw supercharger
operates by pulling air through a
pair of meshing lobes that
resemble a set of worm gears.
A twin-screw supercharger
compresses the air inside the
rotor housing (That's because
the rotors have a conical taper,
which means the air
pockets decrease in size as air
moves from the fill side to the
discharge side).
As the air pockets shrink, the

air is squeezed into a smaller
space.

Thus twin-screw superchargers are
more efficient compared to roots
supercharger.
 They cost more because the

screw-type rotors require more
precision in the
manufacturing process.
 They also make a lot of noise.
 The compressed air exiting the discharge

outlet creates a whine or whistle that
must be checked with noise suppression
techniques.
OIL PUMP
Forces oil out of the pan, through the filter and galleries, and to the engine
bearings
Oil pump drives:
Shaft-driven
Belt-driven
Gear-driven
Crankshaft-driven

PRESSURE RELIEF VALVE
Limits maximum oil pressure
Spring-loaded bypass valve in the

oil pump, engine block or filter
housing
Under normal pressure conditions,

a spring holds the valve closed
Under high oil pressure conditions,

the valve opens, allowing some oil
to pour back into the oil pan.

OIL FILTERS
Removes small metal particles, carbon, rust and dirt from oil
Filter element
 Paper or cotton filtering substance
Filter bypass valve
 Protects the engine from oil starvation
 Valve opens if too much pressure is formed in the filter
 Allows unfiltered oil to the bearings

OIL FILTER TYPES
Spin-on filter
 Sealed unit
 Filter is screwed into place
Cartridge oil filter

 Separate element and housing
 To service, housing is removed
 New element is installed inside the existing housing

SPIN-ON OIL FILTER

FILTER OIL FLOW

OIL FILTER HOUSING
Mounting place for the oil filter

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DEPT & SEM : ME & I SEM

SUBJECT NAME AUTOMOBILE ENGINEERING

UNIT : B SAROJ KUMAR

COURSE: DM UNIT: 3 Pg. 1

COURSE: DM UNIT: 3 Pg. 2

COURSE: DM UNIT: 3 Pg. 3

COURSE: DM UNIT: 3 Pg. 4

COURSE: DM UNIT: 3 Pg. 5

 The automobile can be considered to consist of five basic components

1. The engine or power plant: It is source of power.

4. The body and controls.

5. Accessories: Including light, air conditioner/ hearer, stereo, wiper, etc.

COURSE: DM UNIT: 3 Pg. 6

COURSE: DM UNIT: 3 Pg. 7

COURSE: DM UNIT: 3 Pg. 8

Chassis consist of following components:

COURSE: DM UNIT: 3 Pg. 9

 It is a super structure of the vehicle.

 Chassis & body makes the complete vehicle.

 Vehicles both are made as a single unit.

 Generally it is made from metal or fibre.

& also the good look.

COURSE: DM UNIT: 3 Pg. 10

COURSE: DM UNIT: 3 Pg. 11

COURSE: DM UNIT: 3 Pg. 12

Main Supporting Structure of

COURSE: DM UNIT: 3 Pg. 13

Frame have different types:

COURSE: DM UNIT: 3 Pg. 14

 It is used in most of the heavy

COURSE: DM UNIT: 3 Pg. 15

COURSE: DM UNIT: 3 Pg. 16

 Need of the heavy side members

COURSE: DM UNIT: 3 Pg. 17

 GEAR BOX (Or) TRANSMISSION BOX

 Propeller Shaft Or Drive Shaft

 Rear Wheel Axle

COURSE: DM UNIT: 3 Pg. 19

Engine is a mechanical device

COURSE: DM UNIT: 3 Pg. 20

The purpose of clutch is to engage

This Gear box is considered as

COURSE: DM UNIT: 3 Pg. 23

A universal joint is used to

COURSE: DM UNIT: 3 Pg. 24

Front engine rear wheel drive

To transfer the engine power to

COURSE: DM UNIT: 3 Pg. 26

Transmits rotary motion

COURSE: DM UNIT: 3 Pg. 27

COURSE: DM UNIT: 3 Pg. 28

 In this chassis layout ,the

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COURSE: DM UNIT: 3 Pg. 30

COURSE: DM UNIT: 3 Pg. 31

 In this type of chassis layout the

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 In this chassis layout engine is

 This arrangement eliminate the necessity

 The passenger are kept away

COURSE: DM UNIT: 3 Pg. 35