ME 463: AUTOMOBILE ENGINEERING

CIJIL B. JOHN
Asst. Professor
Dept. of Mechanical Engineering
Jyothi Engineering College
 MODULE 1 - Syllabus
• Piston: - material for piston, clearances, piston rings, types, need for
two compression rings, oil control ring, piston pin, Piston for IC engine,
piston rings, piston pin, connecting rod, crank shaft, crank pin, cam
shaft, valves, fly wheel, fluctuation of energy and size of fly wheel, hub
and arms, stress in a fly wheel rim, simple problems.
• Petrol fuel injection systems: - comparison petrol injection and
carbureted fuel supply systems- comparison –multiport fuel injection
(MPFI) and common rail direct injection (CRDI) systems.
• Super charging systems: fundamentals, naturally aspirated engines and
supercharged engines– Turbo charger, turbo lag.
• Hybrid cars, safety overview -Formula-I engine technology: overview,
electrical technology, brakes, transmission technology.
 What is an ‘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)
 Classification Of Automobiles

1. Based on Purpose
1. Passenger Vehicles – Car, Bus, Motorcycle
2. Goods Vehicles – Lorry, truck, Pick up

2. Based on Capacity
1. Heavy Motor Vehicle (HMV) – large trucks, Buses, Tractor
2. Light Motor Vehicle (LMV) – Cars, Jeep, Motor cycles
3. Medium Vehicle – Small trucks, Minibus, Tempo
 Classification Of Automobiles
3. Based on Fuel Source
1. Petrol Engine 2. Diesel Engine
3. Gas Vehicles 4. Solar Vehicles
5. Hydrogen Vehicles 6. Electric Vehicles
7. Steam Engine vehicles
8. Hybrid Vehicles
9. Hybrid Electric Vehicles
4. Based on Type of Transmission
1. Automatic transmission vehicles – mostly American
2. Conventional transmission vehicles – Most Indian Vehicles
3. Semi - Automatic transmission vehicles – mostly British
 Classification Of Automobiles

5. Based on Make
1. MARUTI SUZUKI 2. HINDUSTAN MOTORS

3. TATA MOTORS 4. MAHINDRA & MAHINDRA

5. TVS MOTORS 6. HERO MOTOCORP

7. ASHOK LEYLAND 8. EICHER MOTORS

9. FORCE MOTORS 10. BAJAJ AUTO LTD

11. ROYAL ENFIELD

12.VOLVO, VOLKSWAGEN, MERC BENZ, BMW,

CATERPILLAR, BENTLEY, AUDI etc.
 Classification Of Automobiles

6. With respect to the drive

1. Left Hand Drive 2. Right Hand Drive
3. Fluid Drive 4. Front Wheel Drive
5. Rear Wheel Drive 6. All Wheel Drive (AWD or 4WD)

7. With respect to the Suspension

1. Conventional – Leaf Spring
2. Independent – Coil, Torsion bar, MacPherson Strut
 Classification Of Automobiles

8. With respect to the Type of Engine

1. Reciprocating – Piston Engines
2. Rotary – Wankel Engine, Gas turbine

9. With respect to the body & doors

1. Sedan
2. Hatchback
3. Station Wagon
4. Convertible
5. Sports utility vehicle
6. Multi Utility Vehicle (MUV or MPV)
7. Delivery Vans etc
 Classification Of Automobiles

10. Based on no. of wheels

1. Two wheeler
2. Three wheeler
3. Four
4. Six
 COMPONENTS OF AN AUTOMOBILE

1. The Basic structure

2. The Engine

3. The Transmission system

4. The Auxiliaries

5. The Controls

6. The Superstructure
 COMPONENTS OF AN AUTOMOBILE

1. The Basic Structure:

It consists of the frame, the suspension system, axles, wheels

and tyres.

2. The Engine:

It provides the motive power for all various functions which

the vehicle or any part of it, may be required to perform. The
engine for automotive use is IC type.
ENGINE
 COMPONENTS OF AN AUTOMOBILE

3. The Transmission System:

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 gear box
to the rear axle and a differential gear to distribute the final
torque equally between the driving wheels.
Transmission System
 COMPONENTS OF AN AUTOMOBILE

4. The Auxiliaries:

The Electrical systems.

5. The Controls:

They consists of steering systems and brakes

6. The Super Structure:

In those cases where frameless construction is not

adopted there must be super structure i.e, the body.
 Automobile Chassis
• The power unit is connected with the transmission.

• The structural frame fitted to the axles through the suspension

system carries the power train.

• For an automobile to propel safely on the road, the engine, the

transmission system, suspension, steering & brakes are included to
the basic frame. These units combined together – Chassis.

• The body or Cabin is jointed to the cabin by means of bolts & nuts
or by welding.
 Automobile Chassis
• Chassis – French term used to denote the main structure of a vehicle

• It’s the backbone of the vehicle – made of steel.

• All moving parts are fitted to it.

• To give it extra strength it is provided with bolted, riveted or welded

cross pieces.

• All major units required to propel the vehicle, direct its motion,
stop it as well as permit to run smoothly over varying road surface
is known as chassis.
Automobile Engines
Engine & Engine components
 Basic Engine Terminology
1. Bore: The inside diameter of the cylinder is called bore
2. Stroke: The linear distance along the cylinder axis between two
limiting position s is called stroke.
3. Top Dead Center ( T.D.C.) : The top most position of the piston
towards cover end side of the cylinder is called T.D.C.
4. Bottom dead Center ( B.D.C.) : The lowest position of the piston
towards the crank end side of the cylinder is called B.D.C.
5. Clearance Volume : The volume contained in the cylinder above
the top of the piston , when the piston is at top dead center , is
called the clearance volume.
6. Swept Volume: The volume swept through by the piston in moving
between T.D.C. and B.D.C, is called swept volume or piston
displacement.
 Basic Engine Terminology
7. Compression Ratio: It is the ratio of Total cylinder volume to
clearance volume
Comp. Ratio
6:1 to 10:1 for Petrol engines
15:1 to 25:1 for Diesel engines
Comp. Temp.
250*C for S.I.
600*C for C.I.
Comp. Pressure
1 MPa for S.I.
3.5 MPa for C.I.
 Engine & Engine components
1. Cylinder Block 2. Cylinder head
3. Crankcase 4. piston
5. Piston rings 6. Piston pin
7. Connecting rod 8. Crank shaft
9. Flywheel
10. Valves and valves mechanism
11. Rocker arm 12. Camshaft
13. Accessories: Air cleaner, oil filter, automatic chokes,
automatic heat controls.
other parts: Spark plug, ignition devices, carburetor
 Engine components
1. Cylinder block
It consists of three parts.
 The cylinder in which the pistons slide up and down.
 The passages for the flow of cooling water.
 The bottom of the block supports the crankshaft, oil sump and
camshaft.
• Various engine accessories & clutch housing are bolted to it.
The Cylinder block is usually made from grey cast iron.
Sometimes its made with addition of nickel or chromium, Aluminium
and Compacted Graphite Iron(CGI) – heavy duty alloy.
 Engine components : 1.Cylinder block
Cylinder block and crankcase form a single casting
(monoblock). It gives a rigid structure and extra strength.
The Cylinder block may also have a separate crankcase
for the crankshaft.(Individual block)
Advantages of Monoblock
No water leakage, more rigid
Size is reduced, easy water circulation
Advantages of Individual block
Easy for repairing, less replacement cost
Cylinder Block (Monoblock)
2. Cylinder Head
 The top of the cylinder is covered by a separate cast piece known as
the cylinder head. It is bolted to the cylinder block.
 It is usually made of grey iron or Aluminium alloy. Aluminium has
the advantage of light in weight and high heat conductivity.
 A flat piece of gasket is placed between the cylinder head and block
to retain compression in the cylinder and to provide a gas and water
tight seal.
 Gasket is made of Copper-asbestos-Copper.
• Camshafts, rockers & valves may be carried on the cylinder head.
• Water passages may also be provided to cool the valves, the head
and the spark plugs.
3.Piston
Piston helps to convert the chemical energy obtained by
the combustion of fuel into useful mechanical power.
The purpose of the piston is to provide a means of
conveying the expansion of the gases to the crankshaft through
the connecting rod.
It is provided with piston rings to provide a good seal
between the cylinder wall and piston. It has to withstand very
high temperatures of combustion.
 Piston

Materials Used

Aluminium alloys, Cast steel,

Cast Iron or Chrome Nickel
 Engine components : Piston
Head or Crown: top of the piston
Ring grooves
Skirt: parts below the ring grooves
Lands: the portion that separates the grooves.
The piston must posses the following qualities
 Rigidity to withstand high pressure.
 Lightness to reduce weight and inertial forces.
 Good heat conductivity to reduce the risk of detonation
 Silence in operation
4.Piston rings
Fine grained alloy cast iron used for the piston rings.
 Cast Iron plated with Chromium, Cadmium or Tin.
Functions:
 Prevent the escape of burnt gases from the combustion
chamber past the piston (Crank case blow by).
 Prevent the leakage of oil into the combustion space.
 Heat from the piston is transmitted to the cylinder via piston
rings.
Piston Rings
 4.Piston rings

a. Compression rings:
o Prevents the blow by or escape of burnt gases to the crank case.

o 2 or 3 compression rings are fitted into the top grooves.

o A gap is formed in the ring to impart the property of radial

expansion and compression.

o This gap is necessary for assembly and renewal of ring

o Made from Cast Iron plated with Chromium, Cadmium and Tin.
Compression Ring
 4.Piston rings
b. Oil Control rings:
o These rings scrap off excessive oil from the cylinder wall and
return it to the oil sump.
o The oil control ring is fitted into the lower groove of the
piston.
o Oil control grooves has a series of slots. These slots transfer
the excess oil through the holes in the piston groove to the
inside of the piston and to the sump
o Made from steel, outer edges of the rings chromium plated
5.Connecting rod
 The connecting rod usually has I-beam cross-section.

 Small end is connected to the piston pin and big end to the crank
pin

 The function of the connecting rod is to convert linear motion of the

piston into rotary motion of the crankshaft.

 The connecting rod carries the power thrust from piston to the
crank pin. So it must be strong, rigid and as light as possible.

 Always made from steel forgings, in few cases Aluminium alloy is

used.
 5. Connecting rod

• Cross section is an “H” or “I”

• Types include :

a) Plain Rod

b) Fork and blade rod

c) Master and articulated

 a) Plain Rod

o Used on inline and opposed engines

o Small bushing at piston pin end is pressed in place and reamed to

final dimensions

o Large end of rod includes a cap, bolts, nuts, and plain bearing
inserts

o Rods are numbered as to cylinder and for cap-to-rod alignment

 b) Fork and Blade Connecting Rod

• Used on “V” type engines

• One rod inside another allows cylinders to be aligned and to

share a common location on the crankshaft
Fork and Blade Type C Rod
 c) Master and Articulating Rod

o Used on radial engines

o Uses “knuckle pins” to retain articulated rods to master

6. Crank shaft

 It is the 1st part in the power transmission.

 The reciprocating motion of the piston is converted into rotary
motion of the crankshaft with the help of connecting rod.
 It consists of crankpins, webs, balancing weights and main
journals.
 Big end of connecting rod is connected to the crankpin of the
crankshaft.
 The crank shaft is supported by the main bearings on the
main journals.
 Made of Casting or forging of heat treated alloy steel.
Crankshaft
Engine components : 6.Crank shaft
 Valve Actuating Mechanisms
 To admit the air-fuel mixture in the engine cylinder and to force the
exhaust gases out at correct timings, some control system is
necessary, which is provided by the valves.

 The engine valves may be broadly divided into 3 main categories:

1. Poppet valve

2. Sleeve valve

3. Rotary valve

A most common type of valve used at present is poppet valve.

 Valves
• Usually made of Austenitic Stainless Steel which is a corrosion &
heat resisting material.

• Race engines use Beryllium-Copper alloy seats with Titanium

valves (21-4N) – 40% lighter than Steel.
 Poppet Valve
• The valves are operated by cams mounted on a camshaft.

• According to the location of the valves,

the valve mechanisms are

a. Straight poppet valve mechanism

b. Overhead poppet valve mechanism

c. Overhead camshaft mechanism

 a. Straight (or side) poppet valve
. mechanism

• The valve mechanism to operate

the valve when it is in the
engine block(as in L,T and F-
head).
b. Overhead poppet valve mechanism
c • The valve mechanism to operate the
valve when it is in the cylinder head( as in
I and F head design).

• It requires two additional moving parts-

the push rod and the rocker arm. As the
cam rotates, it lifts the valve tappet.

• It actuates the push rod and thereby the

rocker arm end pushes the valve stem to
open the valve.
Overhead Poppet Valve Mechanism
 c. Overhead camshaft mechanism
• In this type, the camshaft is
c
mounted above the valve in the
cylinder head.
• The cam on the cam shaft operates
the valve directly. A small clearance
is provided in between the cam and
valve cap.
• The clearance is adjusted by
providing small shims in the bottom
of the cap.
SOHC & DOHC
Variable Valve Timing (VVT)