ELEMENTS OF

MECHANICAL
ENGINEERING
B.E -First Year
SUBJECT CODE:-2110006

Contact info: Puneet Mathur

puneet_mathur87@rediff.com
Assistant Professor
puneet.mathur@marwadieducation.edu.in
M.Tech (Machine Design)
MEFGI, Rajkot
 Reference Books
1. Basic Mechanical Engineering by Pravin Kumar,
Pearson
2. Thermal Science and Engineering by Dr. D.S. Kumar,
S.K. Kataria & sons, Publication New Delhi
3. Fundamental of Mechanical Engineering by G.S.
Sawhney, PHI Publication New Delhi
4. Elements of Mechanical Engineering by Sadhu Singh,
S. Chand Publication
5. Introduction to Engineering Materials by B.K. Agrawal,
Tata McgraHill Publication, New Delhi
6. Applied Thermodynamics by Omkar Singh, New Age
Publication
UNIT- I (Internal Combustion
Engine)
 Internal Combustion Engines

 Introduction and Classification,

 Engine details,

 four-stroke/ two-stroke cycle

 Petrol/Diesel engines,

 Indicated power, Brake Power, Efficiencies

 Course Outcome:
After learning the course the students should be able
to
 To understand the fundamentals of mechanical
systems
 To understand and appreciate significance of
 Introduction
 “Engine refers to a device which transforms one form of
energy into the other form”.
 “Heat engine is a modified form of engine used for
transforming chemical energy of fuel into thermal energy
and subsequently for producing work”. Based on the
mechanism used for adding thermal energy they can be
classified into the following:
(a) External combustion engine
(b) Internal combustion engine.
 External combustion engine have combustion occurring
outside engine and adding heat to the working fluid used in
the engine.
 Thus, in external combustion engines heat released during
combustion is indirectly utilized by the working fluid in
external combustion engine.
 Internal combustion engines have combustion occurring in
engine itself and heat released during combustion is
directly utilized for getting shaft work
 Internal Combustion Engines (IC-engines) produce
mechanical power from the chemical energy contained
in the fuel, as a result of the combustion process
occurring inside the engine.
 IC engine converts chemical energy of the fuel into
mechanical energy, usually made available on a
rotating output shaft.
 Chemical energy of the fuel is first converted to
thermal energy by means of combustion or oxidation
with air inside the engine, raising the T and p of the
gases within the combustion chamber.
 The high-pressure gas then expands and by
mechanical mechanisms rotates the crankshaft, which
is the output of the engine.
 Crankshaft is connected to a transmission/power-train
Advantages of I.C. Engine over E.C.
Engine
Internal combustion engines have numerous
advantages over external combustion engines
 such as lower weight to power output ratio,
 simplicity,
 smaller initial cost,
 higher efficiency etc.
Applications
Internal combustion engines are exhaustively used
in
 automobiles,
 gas turbine etc. And
External combustion engines are used in
 steam turbine,
 steam engine,
 nuclear power plant etc.
CLASSIFICATION OF IC
ENGINES
 Based on number of strokes

 Based on thermodynamic cycle

 Based on mechanism of ignition

 Based on type of fuel used

 Based on fuel admission

 Based on type of cooling

 Based on type of motion

 CLASSIFICATION OF IC
ENGINES
Internal combustion engines can be classified on the following
basis.
(a) BASED ON NUMBER OF STROKES : Number of strokes
involved in a cycle of IC engine can be two strokes or four
strokes. Such engine can be;
(i) Two stroke engines
(ii) Four stroke engines

(b) BASED ON THERMODYNAMIC CYCLE : Depending upon

thermodynamic cycle used in the internal combustion engines
these can be classified as:
(i) Engines based on Otto cycle (‘Spark-Ignition engine’)
(ii) Engines based on Diesel or Dual cycle (‘Compression-Ignition
engine’)

(c) BASED ON MECHANISM OF IGNITION: Internal combustion

engines have combustion as the basic process.
(i) Spark ignition engines (S.I. Engines)
(ii) Compression ignition engines. (C.I. Engines)
(d) BASED ON TYPE OF FUEL USED: IC engines may be
classified depending upon the type of fuel being used.
These can be:
(i) Petrol engines (petrol being used as fuel)
(ii) Gas engines (gaseous fuel being used)
(iii) Diesel engines (diesel being used as fuel)
(iv) Multi-fuel engines (more than one fuel being used)

(e) BASED ON FUEL ADMISSION: IC engines can be of

different types depending upon arrangement used for fuel
admission:
(i) Carburettor type engines (use carburettor fuel metering)
(ii) Injection type engines (use fuel injector and injection
system)

(f) BASED ON TYPE OF COOLING: IC engines have

inherent requirement of continuous cooling of engine. Based
 (g) BASED ON TYPE OF MOTION: IC engines may
have reciprocating motion of piston or it may also have
rotary motion. Such engines can be:
(i) Reciprocating engines
(ii) Rotary engines

Reciprocating engines may have different cylinder

arrangements such as:
(i) Opposed cylinder engines
(ii) Inclined cylinder engines
(iii) V-shaped cylinder arrangement.

Rotary engines may be further classified as single rotor

engines or multi rotor engines i.e.
(i) Single rotor engine
(ii) Multi rotor engine
Single cylinder, 4-stroke engine 4- cylinder, 4-stroke
engine
IN-Line Engiine
Opposed Piston Engine
V-Engine
Rotary Engine
Engine Details
1. Cylinder: It is a cylindrical block having cylindrical space inside for piston
to make reciprocating motion. Upper portion of cylinder which covers it from
the top is called cylinder head. This is manufactured by casting process and
materials used are cast iron or alloy steel.

2. Piston and Piston rings: Piston is a cylindrical part which reciprocates

inside the cylinder and is used for doing work and getting work. Piston has piston
rings tightly fitted in groove around piston and provide a tight seal so as to prevent
leakage across piston and cylinder wall during piston‟s reciprocating motion. Pistons
are manufactured by casting or forging process. Pistons are made of cast iron,
aluminum alloy. Piston rings are made of silicon, cast iron, steel alloy by casting
process.

3. Combustion space: It is the space available between the cylinder head and
top of piston when piston is at farthest position from crankshaft (TDC).

4. Intake manifold: It is the passage/duct connecting intake system to the inlet

valve upon cylinder. Through intake manifold the air/air-fuel mixture goes into
cylinder.

5. Exhaust manifold: It is the passage/duct connecting exhaust system to the

exhaust valve upon cylinder. Through exhaust manifold burnt gases go out of
7. Spark plug: It is the external ignitor used for initiating combustion
process. Spark plug is activated by electrical energy fed by electrical system with
engine. It delivers spark with suitable energy to initiate combustion at appropriate
time for suitable duration.

8. Bearing: Bearings are required to support crank shaft. Bearings are made
of white metal leaded bronze.

9. Connecting rod: It is the member connecting piston and crankshaft. It has

generally I section and is made of steel by forging process.

10. Crank: It is the rigid member connecting the crankshaft and connecting
rod. Crank is mounted on crankshaft. Crank transfers motion from connecting rod
to crankshaft as it is linked to connecting rod through crank pin.

11. Crankshaft: It is the shaft at which useful positive work is available from
the piston-cylinder arrangement. Reciprocating motion of piston gets converted
into rotary motion of crankshaft. Crankshaft are manufactured by forging process
from alloy steel.

12. Crankcase: Crankcase actually acts like a sump housing crank,

crankshaft, connecting rod and is attached to cylinder. These are made of
aluminium alloy, steel, cast iron etc. by casting process.
14. Cams and Camshafts: Cams are mounted upon camshaft for opening and
closing the valves at right timings and for correct duration. Camshaft gets motion
from crankshaft through timing gears.

15. Carburettor: Carburettor is device to prepare the air fuel mixture in right
proportion and supply at right time.

I.C. Engine Terminology

1. Bore: It is nominal inner diameter of the cylinder.

2. Piston area: It is the area of a circle of diameter equal to bore.

3. Stroke: It is the nominal distance travelled by the piston between two

extreme positions in the cylinder. It is denoted by L.

4. Dead centre: It refers to the extreme end positions inside the cylinder at
which piston reverses it‟s motion. Thus, there are two dead centres in cylinder,
called as „top dead centre‟ or „inner dead centre‟ and „bottom dead centre‟ or
„outer dead centre‟. Top dead centre (TDC) is the farthest position of piston from
crankshaft. It is also called inner dead centre (IDC). Bottom dead centre (BDC)
refers to the closed position of piston from crankshaft. It is also called outer dead
center (ODC).
5. Swept volume : It is the volume swept by piston while travelling from one
dead centre to the other. It may also be called stroke volume or displacement
volume.
Mathematically, Swept volume = Piston area × Stroke

6. Clearance volume: It is the volume space above the piston inside cylinder,
when piston is at top dead centre. It is provided for cushioning considerations and
depends, largely upon compression ratio.

7. Compression ratio: It is the ratio of the total cylinder volume when piston is
at BDC to the clearance volume.
Compression ratio (r)= Total cylinder Volume/Clearance
volume
For Petrol engine r varies from 6 to 10
For diesel engine r varies from 14 to 20

8. Piston Speed: It is the average speed of the piston

Vp=2LN/60 m/s
4- Stroke Petrol Engine- Working
4- Stroke Petrol Cycle or Otto
Cycle
4- Stroke Diesel Engine- Working
4- Stroke Diesel Cycle or Diesel
Cycle
Two Stroke Petrol Engine
 It is a modified form of 4-stroke
petrol engine.
 All the four processes required for
completion of one cycle of SI engine
get completed in two strokes.
 Thus, obviously in each stroke two
processes get completed.
 Here all four processes occur during
two strokes and one revolution of
crank shaft.
 Thermodynamic cycle followed by 2-
stroke SI engine is Otto cycle.
 Scooter engines are generally two
stroke engines.
 2-stroke SI engines are used for
smaller applications.
 Performance Evaluation
 Internal combustion engines have combustion taking
place inside and power is available at crankshaft.
 The shaft work available is less than the total energy
released inside the cylinder due to frictional and other
losses.
 For performance evaluation of internal combustion engine
one is interested in following different powers.
(a) INDICATED POWER (I.P):
 It refers to the power available inside the cylinder
i.e. the power provided to piston.
 It is the power actually developed by the engine
cylinder.
 It is measured from the indicator diagram which is
 Mathematically,

A = cross-sectional area of cylinder. A = π /4D2, where D is bore.

L = length of stroke.
N = Speed of the engine in rpm
N=N (For 2-stroke cycle)
N=N/2 (For 4-stroke Cycle)
k = no. of cylinders.
Pm = Mean effective pressure= as/l

b) Friction power: It refers to the power lost due to friction and other
reasons. It is quantified by the difference between indicated power and
brake power.

Friction power = Indicated power – Brake power

(C) BRAKE POWER: It refers to the power available at
crankshaft i.e. it is the useful shaft work.
 It is usually measured by means of brake mechanism
(Prony brake or rope brake)
Brake power is usually measured by absorption or
transmission type dynamometers. It can be given as:

Let, W= Net load acting on the brake drum, N

R=Radius of the brake drum, m
N= R.P.M. of crank shaft
T= resisting torque N-m
Efficiencies
(i) Indicated thermal efficiency:
Indicated Power
=
Heat supplied by fuel
I.P.
∴ ƞit=
mf∗C.V.
Where, mf = mass of fuel supplied, kg/sec,
C.V. = Calorific value of fuel, J/kg

(ii) Brake thermal efficiency

Brake Power
=
Heat supplied by fuel

B.P.
∴ ƞbt =
mf∗C.V.

Also ƞbt= ƞmechx ƞit

(3) Relative efficiency:
It is the ratio of indicated thermal efficiency of an engine to
air standard cycle efficiency
ƞ
∴ ƞrel= it
ƞair
(4) Air Standard efficiency: It is the efficiency of
thermodynamic cycle of engine.

1
for petrol engine, ƞair= 1 -
r (γ−1)
ργ−1
1
for diesel engine, ƞair= 1 - γ ρ−𝟏
r (γ−1)

where, r = compression ratio,

ρ = Cut-off ratio, V3/V2
and γ= Adiabatic index, cp/cv
(5) Volumetric efficiency: It is the ratio of the volume of charge/air actually
sucked at atmospheric condition to swept volume of engine.
It indicates breathing capacity of the engine.

charge
Actual volume of air
sucked at atm.condition
Ƞvol= swept volume
(6) Specific output : The specific output of the engine is defined as the power
output per unit piston area.
𝐁.𝐏.
specific output = 𝐀
(7) Specific fuel consumption: Specific fuel consumption (SFC) is defined as
the amount of fuel consumed by and engine for one unit of power production.

m
SFC = B.P.f kg/kWh
Where mf= mass of fuel consumed in kg/hr,
B.P. = Power produced in kW
Difference between SI and CI engine
Comparison of 2-stroke with 4-stroke
engine
Q1. A four cylinder diesel engine of 4-stroke type has
stroke to bore ratio as 1.2 and the cylinder diameter is
12 cm. Estimate indicated power of the engine using the
indicator diagram arrangement. Indicator card shows
the diagram having area of 30 cm2 and length as half of
stroke. Indicator spring constant is 20 × 103 kN/m3 and
engine is running at 2000 rpm. Also find out mechanical
efficiency of engine if 10% of power is lost in friction and
other losses.
Q2. A four cylinder two stroke cycle petrol engine
develops 23.5 KW brake power at 2500r.p.m. The mean
effective pressure on each piston is 8.5 bar and the
mechanical efficiency is 85%. Calculate the diameter
and stroke of each cylinder, assuming the length of
stroke equal to 1.5 times the diameter of cylinder.
Q3. A four stroke single cylinder petrol engine has a bore
of 150 mm and stroke of 250mm. At 500 r.p.m and full
load, the net load on friction brake is 435N and torque
Q4. During trial of four stroke single cylinder engine the
load on dynamometer is found 20 kg at radius of 50 cm.
The speed of rotation is 3000 rpm. The bore and stroke
are 20 cm and 30 respectively. Fuel is supplied at the rate
of 0.15 kg/min. The calorific value of fuel may be taken as
43 MJ/kg. After some time the fuel supply is cut and the
engine is rotated with motor which required 5 kW to
maintain the same speed of rotation of engine. Determine
the brake power, indicated power, mechanical efficiency,
brake thermal efficiency, indicated thermal efficiency,
brake mean effective pressure, indicated mean effective
pressure.
Q5. Determine the power required to drive a double acting
reciprocating pump having indicator diagram with area 40
cm2 and length 8 cm. Bore and stroke of the pump are 15
cm and 20 cm. The pump motor runs at 100 rpm.