INTERNAL COMBUSTION

ENGINES
Introduction
A heat engine is a device which transforms the chemical
energy of a fuel into thermal energy and uses this
thermal energy to produce mechanical work.

Heat engines are classified as

(i) External combustion engines (EC Engines).
(ii) Internal combustion engines (IC Engines).
In an External combustion engine the combustion
takes place outside the engine.
In steam engine, the working fluid (high pressure
steam) is generated outside the cylinder by the
combustion of fuel.
The steam is then passed to a reciprocating
engine or turbine for useful work.
In an Internal combustion engine the combustion
takes place inside the cylinder
Chemical energy is released
when the fuel-air mixture is burnt
in the combustion chamber.

I.C engines directly convert
chemical energy of the fuel into
useful mechanical work.

The gas produced in this
reaction rapidly expands forcing
the piston down the cylinder on
the power stroke.
The basic components of I.C engines are
cylinder block
Cylinder
Piston
piston rings
inlet and exhaust valves
connecting rod
Flywheel
Crankshaft
gudgeon pin
Camshaft
cams
Cylinder
Cylinder is made up of cast iron or an aluminium alloy.
Inside the cylinder, piston is fitted which makes the
reciprocating motion.
This reciprocating motion is converted to rotary motion
through a mechanism consisting of a connecting rod
and crank shaft (slider crank mechanism).
Piston
It is cylindrical in
shape fitted tightly
inside the cylinder.
It moves up and
down inside the
cylinder bore and
transmits the force
exerted by the
combustion of fuel to
the crankshaft.
Piston rings
Piston rings provide a sliding seal between the external cylindrical
surface of the piston and the inner surface of the cylinder.
The rings serve two purposes:
They prevent the fuel/air mixture and exhaust in the combustion
chamber from leaking into the sump during compression and
combustion.
They keep oil in the sump from leaking into the combustion area,
where it would be burnt and lost.
Intake and exhaust valve
The intake and exhaust valves open at the proper time
to let in air and fuel and to let out the products of burnt
fuel (exhaust)
During compression and combustion both the valves
are closed
Spark plug
Used to generate the spark which ignites the
compressed fuel and air mixture in the spark ignition
engine.
To generate the spark a high voltage of around 20, 000
Volts is applied.
Connecting rod


The connecting rod connects the piston to the
crankshaft.
It can rotate at both ends so that its inclination angle
can change as the piston moves up and down and the
crankshaft rotates.
Crankshaft

The crankshaft converts up and down motion of the piston into
circular motion.
Flywheel

It is mounted on the crankshaft which stores
excess energy during the power stroke and
returns that energy during the other strokes and
hence reduces the fluctuation in speed.
Gudgeon pin

It is the pin which links the connecting rod
with the piston
Camshaft

It is used to operate the inlet and exhaust valves through
cams, cam followers, push rods and rocker arms.
Cams
Used to operate the valves.

Designed in a way to open the valves in correct
time and to keep open for necessary duration
Sump
Sump surrounds the crankshaft

Contains some amount of oil, which collects in
the bottom of the sump (the oil pan)
Terminology in I.C engines


Bore
The inside diameter of the cylinder is known as bore.

Stroke
Maximum distance travelled by the piston inside the cylinder in
one direction is known as stroke.
Equals twice the radius of the crank.

Top Dead Centre (TDC)
Extreme position of piston at the top of the cylinder.

Bottom Dead Centre (BDC)
Extreme position of piston at the bottom of the cylinder




Terminology in I.C engines
Clearance Volume
The volume contained in the cylinder above the top of the piston when it is
at TDC and is denoted Vc.

Piston Displacement or Swept Volume (Vs)
Volume swept by the piston when travelling from one dead centre to the
other is called piston displacement.
Expressed as cubic centimetre (cc)

Vs = A x L = (/4) d
2
L

Compression Ratio (r)
Ratio of the total volume of the cylinder above the piston when it is at
BDC to the volume when the piston is at TDC is called compression
ratio.Denoted as r

r = (Vc+Vs)/Vc
4 - Stroke SI engine working principle

Movement of the piston up or down the cylinder makes up one
stroke.
It is the distance between TDC and BDC and is equal to twice the
radius of the crank.
In the four stroke engine cycle there are four strokes namely,
Suction or Intake stroke,
Compression stroke,
Expansion stroke or power stroke,
exhaust stroke.
One cycle completes when piston moves for four strokes or two
revolutions of the crankshaft.
(i) Suction or Intake stroke.

In the suction stoke piston moves from top dead centre to
bottom dead centre.

Inlet valve opens at this time and the exhaust valve is
closed.

The fuel air mixture is sucked into the cylinder during the
intake stroke.

The suction is shown in the Ideal PV diagram (path 0-1)
(ii) Compression stroke

Piston starts moving from bottom to top (path 1-2)
compressing the air-fuel mixture.

Both inlet and exhaust valves are closed during this stroke.

At the end of the compression stroke the fuel-air mixture is
ignited with the spark plug leads to increase in pressure and
temperature which is around 2000C (path 2-3).

The heat addition takes place at constant volume process.
(iii) Expansion or Power stroke.
Piston is pushed to BDC (path 3-4) with high force due to
high pressure released by burnt gases.

During expansion the pressure and temperature decreases
(path 4-5).

This is known as power or expansion stoke.

Both inlet and outlet value are in closed position during the
power stroke.
(iv) Exhaust stroke.
The piston which is in BDC starts moving to TDC (path
5-0).

During this stroke the exhaust valve opens and the
inlet valve remains closed.

The burnt gases are pushed out to the atmosphere by
the piston.

The exhaust valve closes when the piston reaches
TDC.

Thus one cycle completes.

During a cycle the crank shaft turns by two revolutions.

Ideal PV diagram of a four stroke SI engine (Otto cycle)
Working of 4 stroke 4 cylinder diesel engine
WORKING OF 4 STROKE 4
CYLINDER PETROL ENGINE
2 Stroke engine working principle
In the 2 stroke cycle the working cycle completes in two
strokes of the piston movement or one revolution of the crank
shaft.
The valves are replaced by ports.
There are three ports in two stroke engine namely inlet port,
transfer port and the exhaust port.
The ports are opened and closed by the movement of
piston, here cams are not used for operating to open and
close the ports.
Exhaust port is located slightly above the inlet port and the
transfer port is located in between the exhaust port and inlet
port.

When the piston is at TDC and about to move downwards,
only the inlet port is kept opened and other two ports are
closed.

The air and fuel (petrol) mixture is drawn into the crankcase
due to vacuum produced by the upward movement of the
piston.

It is to be noted that top surface of the piston controls the
opening and closing of the exhaust port and transfer port
whereas the bottom surface of the piston controls the opening
and closing of the inlet port.
CONTD...
During the movement of piston from BDC to TDC the
mixture inside the cylinder gets compressed.
As the piston reaches TDC the spark is produced by the
spark plug.
As the pressure and temperature of the burnt gases
increase the gases push the piston towards downward
direction.
When the exhaust port open during the movement of piston
from TDC to BDC the burnt gases leave the cylinder
through exhaust port.
CONTD..
When the piston moves down, the inlet port also closes due to
which the air fuel mixture trapped in the crankcase will get
compressed.
As the piston moves still towards BDC the transfer port is
opened due to which the mixture from the crank case enters
the cylinder.

CONTD...
The piston crown is specially made in a shape such that the fresh
mixture hits the piston crown and gets deflected up and is
prevented from going out directly to the atmosphere through the
exhaust port.
The deflected fresh mixture pushes the burnt gases out.
This action of sweeping out the exhaust gases with the help of
fresh charge is known as Scavenging.
During the downward movement of piston the power, exhaust
and suction process takes place.

CONTD...
When the piston moves from BDC to TDC first
transfer port closes, then exhaust port closes finally
the inlet port will open.
After closing the exhaust port the air-fuel mixture
gets compressed and the cycle is repeated.
The inlet port is opened and closed by the bottom portion
of the piston.
WORKING OF 2 STROKE SI
ENGINE
Two stroke SI engine with Inlet valve.
Nowadays in the two stroke SI engine instead of inlet
port, spring loaded inlet valves are used for suction of
fuel air mixture.

2 Stroke Diesel engine
Working principle of two stroke diesel engine is
similar to two stroke petrol engine.
During suction stroke, only air is sucked instead
air-fuel mixture.
The fuel is injected using fuel injector during the
power stroke;
here there is no spark plug.
Comparison between Four stroke and Two
stroke engine
Comparison between SI and CI engine


Cooling System
To maintain the temperature of I.C engine in an
optimum value, cooling of engine is essential.

If cooling is not provided the temperature of I.C engine
rises and the expansion of piston and burning out of
lubricating oil occurs which leads to seizure of piston.

Also the strength of the materials used for various
engine parts usually decreases with the increase in
temperature.
Two types of cooling are adopted
(i) Air cooling
(ii) Water cooling
Air cooling

Air cooling is used for low power engines like the ones
used for motor cycles and also for aero engines to
reduce the weight.
Cooling fins are provided in the cylinder head and the
outer surface of the cylinder as shown in the figure.
The amount of heat dissipated depends upon the surface
area of the fins, amount of air circulated, the velocity of
air and the temperature difference between the engine
block and the surrounding.
In large size engine the circulation of air is enhanced by a
fan.
Water cooling
Water cooling is commonly used in cars, buses, heavy trucks
and in stationary engines.
Water passage is provided between the walls of cylinder and the
cylinder heads for the flow of water, these passages are known as
water jackets.
Water is circulated along the cylinder by a pump driven by the
crankshaft.
The water from the over flow tank flows to the engine via
radiator.
The heat will be carried away by the water passing over the
engine.
The hot water will be cooled when it passes over the radiator.
The water in the radiator is cooled by the air circulated by the
cooling fan as shown in the figure.
Water cooling
Lubrication

Friction, Wear and Lubrication are three important
terms in mechanical engineering. In fact the study
of these three items is called Tribology.

Lubrication is the activity of providing a lubricant
(a substance) between solid surfaces in contact
having relative motion to reduce friction.
Functions of lubrication
Reduce the friction between the rubbing
parts
Reduce the wear and tear.
Reduce the power loss
Form good seal between piston rings and
cylinder walls.
Keep the rubbing parts clean

SAE (Society of automobile engineers) has allocated
numbers for specifying the viscosity of Engine Oils.

The SAE grades 0W through 25W, where W stands for
Winter, have a maximum viscosity specified at low
temperatures (-5C to -35C), to ensure easy starting
under low temperature conditions.

The SAE grades 20 through 60 only have limits set at
100C as these grades are not intended for use under
low temperature conditions.
CONTD...
Automotive oils are normally formulated with Viscosity
Index Improvers (VI Improvers) to provide multigrade
performance.

The use of these special polymers makes it possible to
meet both the low temperature viscosity requirements of
the W grades as well as the high temperature
requirements of the non-W grades.

SAE 20W40 has the low temperature viscosity value of a
SAE 20W oil at low temperatures and the high
temperature viscosity of a SAE 40 oil at the higher
temperature.
The parts required lubrication in I.C engines are

Piston,
cylinder,
crankshaft,
cam shaft
connecting rod.

Normally the lubrication is applied to these parts by splash
lubrication system where oil is placed on the oil sump.

In two stroke SI engines the lubricating oil will be directly
mixed with petrol for lubrication.
Types of Lubricants

Solid lubricants Graphite

Liquid lubricants Mineral oils, Vegetable oils

Semi solid lubricants - Grease
Requirements of lubricating oil
A good lubricant should possess the following requirements

Sufficient viscosity to work under high and low temperature.

Normally high viscosity index is preferred for engine
lubrication.

Should not react with the surfaces being lubricated

Should be noncorrosive and should provide protection against
corrosion.

Must have good detergent quality to keep the rubbing parts
clean

Must be Non toxic and non-flammable
Applications of I.C engines

For transport on land, sea and air

Industrial power and prime movers for electric
generators. plants

For Irrigation purpose

Earth moving equipment
Classification of Ic engines
Questions
Give four applications of I.C engines

Give the difference between
(a) Petrol and diesel engines
(b) Two stroke and four stroke engine

Explain the construction of a four stroke single cylinder
I.C engine.

Explain the working principle of
(a) Four stroke petrol engine
(b) Four stroke diesel engine
(c) Two stroke petrol engine with intake port.

Contd..
With a PV diagram explain the process in
Otto cycle.

With a neat sketch explain the water cooling
system used in cars

Give a comparison between water cooling
and air cooling.

Explain the need for lubrication in I.C engine