AUTOMOBILE

ENGINEERING

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 COURSE OBJECTIVES (CO’s)

1.Understand the construction, function, and types of frames used on

wheeled vehicles

2.Understand power transmission of the vehicle.

3.Extend the knowledge of the lubrication in Automobile.

4.Compare the lubrication system in the automobiles and propose.

5.Maintain the automobile in conditioned manner with the proper service

system learnt by the topics.

6.Understand the electrical and mechanical configuration in automobiles.

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 COURSE OUTCOMES (PO’s)

At the end of the course, student will be able to:

•Identify the automobile components and individual parts functions.

•Learn about economical control and pollution control in lubrication oil

selection.

•Provide alternate lubrication systems.

•Awareness about pollution standards, noise control systems.

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 Definition

An automobile (or automotive) is a vehicle that is capable of propelling itself.

(OR)

Automobile is a vehicle driven by an internal combustion engine and it is used for

transportation of passengers and goods on the ground.

Examples : Car, jeep, bus, truck, scooter, etc.

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 Components of four wheeler of an automobile.

Chassis and body

Power unit
UNIT -I Power transmission

Rear wheel drive, front wheel drive, 4 wheel drive

Types of automobile engines

Engine construction

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 Engine lubrication, splash and Pressure lubrication systems.

Oil filters, Oil pumps

UNIT – I Crank case ventilation
Cont… Engine service

Reboring , decarbonisation,

Nitriding of crank shaft.

Pollution standards Pollution Control – Techniques

Noise Pollution & control

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 COMPONENTS OF FOUR WHEEL AUTOMOBILE

The Basic Structure

The Power Plant (engine)
The Transmission System AUTOMOBILE CHASIS

The Auxiliaries
The Controls
The Super Structure

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 Suspension
Frame Axles Wheels
system

THE BASIC STRUCTURE AUTOMOBILE

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 THE BASIC STRUCTURE
The Basic structure of an automobile is the unit on which all the other
automobiles units like Engine, transmission system etc are attached.
1. Frame construction:

Frame
construction

Conventional Frameless

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Conventional frame: Conventional pressed steel frame to which all the
mechanical units are attached and on which the body is superimposed.

The frame less construction, In which the body structure is designed as to

combine the functions of the body frame, the units normally attached to the
frame then being attached directly to the body.
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 Advantage of Frameless
construction
Reduced weight and consequent
saving in fuel consumption.
Lower manufacturing cost.
Safety to the passengers when the
accidental situation.
Disadvantage of Frameless
construction
Economical only if frameless
construction is adopted in mass
production.
Reduction of durability.
Difficult to design.
Repair cost is high.
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 Axles

It is the weight carrying portion of the body with considering as beams supported at
the ends. Several loads acting on the axles those are:

1. The vertical load at the spring centres due to the weight of the vehicle.

2.The torque reactions due to driver or brakes.

A side thrust at the radius of the tyre due to centrifugal force when rounding a curve.
Axles

Live Axle Dead Axle

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 Axle Contd..

Live axle transmits the Torque received from the engine, to the driving
wheels.

Dead axle just connects the wheel to the frame but does not transmit any
power.

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 THE BASIC STRUCTURE Contd..
Suspension System and Its Functions:

To prevent the road shocks from being transmitted to the vehicle
components.
To safeguard the passengers from road shocks.
 Preserving the stability of the vehicle in pitching and rolling while motion.
Suspension
system

Conventional Independent

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 Suspension System Contd.. and Considerations

Conventional system road springs are attached to a rigid beam Axle.

In independent system each wheel is free to move vertically without affecting other
wheels.

Vertical Loading, Rolling (C.G), Brake Dip, Side thrust, Unsprung weight.

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 The Power Plant

The Power plant (engine) provides the motive power for all the various functions which
the vehicle or any part of it.

IC Engines / Electric motors / Hybrid ( IC & Electric) , Solar.

I

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 Transmission system

Functions of Transmission System:

To disconnect the engine from the road wheels when desired.

To connect the engine to the driving wheels without shock.

To make provision such that the driving wheels may rotate at different speeds while taking turns.

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 The Auxiliaries

1. Supply system – Battery and generator

2.The stator

3.The ignition system – battery and magneto ignition.

4. Ancillary devices.

a) Driving lights- Head lights, side lights, etc.

b) signaling – horn, direction indicators

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 The Controls

The controls consist of :

1. 1. Steering System

2. 2. Brakes

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 THE BASIC STRUCTURE
Wheels:
Wheels are three types.
1. Disc Wheel

2. Wire wheel

3. Alloy wheel
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SUMMERY OF THE BASIC STRUCTURE

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 CHASIS CONSTRUCTION
Chassis frame represented as longitudinal members, cross members joined
with help of bolts and rivets.
Diagonal cross bracing gives torsional rigidity to the frame.

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 CHASIS CONSTION...
Automobile Chassis are classified as:

Semi -forward control chassis

Full -forward control chassis

Conventional control chassis

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 CHASIS CONSTION Contd...

Functions of Chassis Frame:

1. 1. Supporting the chassis components and body.

2. 2. Bear the static load, dynamic loads with out deflections or distortion.

Loads on chassis frame:

Load due to weight of passengers and chassis components., automobile

hits a bump, side wind and road camber, vehicle taking turn, collision ,
inertia load due to acceleration or braking.

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 Front Wheel Drive (FWD)

Advantages: Compact Engine Disadvantages: Loss of Grip

Driving wheels have more weight Uneven tire wear

Example : Verna, Alto, Honda City

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 Rear Wheel Drive (RWD)

Advantages: Better Weight distribution. Disadvantages: Loss of Grip.

Weight transfer according to acceleration. Uneven tire wear.

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 Four Wheel Drive

1. Torque at the front wheel and rear wheels will be equal.

2. Tractive effort is less due to equal load distribution on front and rear axle.

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Types of Engines

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 Engine Construction

Cylinder bore

Piston area

Stroke

Dead center

Displacement / Swept volume

Clearance volume

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 ENGINE LUBRICATION

When a film of some lubricating oil is interpose between two surfaces so

that the two are not in actual physical contact with each other, the only
resistance to motion remains the resistance of the oil itself. This type of friction
is called viscous or fluid friction. This state, from lubrication point of view, is
called hydrodynamic lubrication.

Objectives of Lubrication:

Primary objectives- To reduce friction between moving parts to its minimum

value so that power loss is minimized.

To reduce wear of the moving parts as far as possible.

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 ENGINE LUBRICATION

Secondary objectives:

To Provide the cooling effect for the crank case by absorbing the
surrounding air., after dissipate heat easily.

To provide the cushioning effect to the bearings while engine running and
lubricant absorbs the sudden pressure rise in the cylinder and the shocks.

To provide cleaning action during its circulation it dissolves many impurities.,
e.g., carbon particles.

To provide a sealing action between piston rings and cylinder.

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 AUTOMOBILE ENGINE LUBRICATION

The main parts of an automobile engine which require lubrication are:

1.Main crankcase bearings.
2.Big end Bearings
3. Gudgeon pin bearings.
4.Piston rings and cylinder walls
5.Timing gears

6. Cam shafts and camshafts bearings

7. Valve mechanism 32
 SYSTEMS OF ENGINE LUBRICATION

 Various systems adopted for the lubrication of automobile engine are.

Petroil system

Splash

Pressure system

Dry-sump
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 AUTOMOBILE ENGINE LUBRICATION

Splash System: It consists of a scoop fitted at the lower end of the

connecting rod as shown in fig.
As the engine runs scoops splashes the oil from through by centrifugal force
to all engine parts.

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 AUTOMOBILE ENGINE LUBRICATION

Pressure System:

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 OIL FILTERS

To remove the impurities and to avoid permanent damage running parts oil
filters are required.
Most of the damaging impurity particles of 5 – 15 microns diameter.

Modern engines, the minimum working oil film thickness can be as small as 1
to 2 microns which causes rapid wear at the bearing to avoid this there are
different types of filtration systems are available.
Oil filtration
systems

Bypass Full flow

system system
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 OIL FILTERS

Oil starvation will be controlled by using of By-Pass valve.

Activated pressure 40 – 100kPa

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 OIL FILTERS
Oil filter characteristics:
1. High filtration efficiency.

2. Less pressure loss.

3. Long life.
Oil filters basically Two types.
1. Primary ( surface filter) 2. Secondary.
Primary filters are uses inlet side of the oil pump
Secondary filter is installed on the outlet side of the oil pump.

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 OIL FILTERS

Primary filter is more commonly known as strainer and is formed from wire
guage of 40-50µm.
 Secondary filter are used in automobile engines are of various kinds and
important are.

1. Cartridge type.
2. Edge type
3. Centrifugal type.

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Cartridge type oil filter 1.Cartridge filter can filter size down to
within the region 5 microns.

2.Replacing intervals of 10,000km

3.Commonly using materials are wire

gauge, cotton, felt, paper, plastic
impregnated paper.

4.New filter element to resist offered

by oil is 0.3 to 0.5 bar.

5.Due to clogging of the filter we can

give pressure max 2 bars.
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Edge type /Stack oil filter Centrifugal type oil filter

Rotor speed -
2000 and 7000
rpm

Cleaned
intervals about
70,000 km

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Performance curves

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 OIL PUMPS

The oil pump is responsible for circulating oil throughout the entire lubrication
system.
• Different types of pumps used for lubrication are:
1. Gear pump
2. Crescent pump
3. Rotor Pump
4. Plunger pump
5. Vane pump

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 OIL PUMPS
1. Gear pump: These are the commonly used gear pump with meshing of
two helical gears.

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 OIL PUMPS
Crescent type gear pump: An internal gear is in mesh with a driving
external gear which is mounted eccentrically with respect to the ring gear.
Due to this eccentrically, there is a space in between the two gears where a
crescent shaped spacer is placed.

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 OIL PUMPS
Rotor pump: Widely used in automobiles and works as similar to the gear
pump.
1. A is the external rotor having the number of lobes one more than on the
internal rotor B.
2. This is 25% more efficient and compact than the gear pump

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 OIL PUMPS
Vane pump

Plunger type

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 Leakage of the gas from the combustion
CRANKCASE chamber to crankcase leads to damage of
the complete engine.
VENTILATION Gases contain the partially burnt
Developed crankcase ventilation systems are hydrocarbons, water vapour,
mainly CO,CO2,sulpher.
1.Road draft system
2.Manifold suction system The effects of piston blow-by are:

1.Due to partial unburnt hydrocarbons

deterioration of performance of the engine
lubricating oil and also produce sludge
particle.

2.Rich mixture leads to explosion.

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3. Corrosion due to Sulphur content.
Manifold Suction system
 REBORING OF CYLINDER
The cylinder get worn with time and tend to become oval shaped.
 Reboring process
When the bore diameter over size by 0.01mm
reboring needs to be done by checking the
suitable piston rings.

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 Honing Process
When the bore diameter less than
0.01 including actual bore dia
honing needs to be done by replace
with new piston rings.

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 DeCarburization
Reasons for carbon deposition in cylinder:

1. Due to rich mixture.

2. Use of wrong grade oil.

3. Poor fitted piston rings , etc.

Above reasons create knocking , valve blockings, greater fuel consumption.

Methods to for decarburizing:

1. Scrapping method.

2. Oxygen decarburizing method ( without removing the cylinder head) with O2 gas film.

3. Chemical method of decarburizing.

 Nitriding of crankshaft
Nitriding is a chemical hardening process in which the part is heated in a furnace, the oxygen is
vacuumed out, and nitrogen is introduced which penetrates the entire surface.

The depth of hardness is dependent upon the time the crankshaft is exposed to the gas.

Typically, a nitrided crankshaft will have a hardness depth of about .010 - .030.
 Pollution Standards
International Emission Standard for Vehicular Emission fall into three categories:

1. European Emission system (EURO SYSTEM).

2. Japanese Emission system.

3. American Emission system

Pollution Standards
 Pollution Standards Contd..
European Norms for regulating vehicular emissions:

Norms are expressed in terms of the weight of the pollutants such as carbon monoxide (CO),
hydro-carbons (HC), oxides of nitrogen (Nox) and particulate matters (PM) emitted per kilometer
of vehicular run.
EURO -I EURO -I EURO -II EURO -II

Pollutant Petrol Diesel Petrol Diesel

CO (g/km) 2.72 2.72 2.2 1.0
HC + NoX (g/Km) 0.97 0.97 0.57 0.70
Particulate - 0.14 - -
matters (PM)
 Pollution Standards Contd..
Enforcement of Emission Norms in India:

Bharat Stage II: Its same as Euro II and its enforce from April 1 , 2005.

Bharat Stage III: Its same as Euro III and its enforce from April 1 , 2010.

Bharat Stage IV: Its same as Euro IV and its enforced partially in India.
Sl.No Vehicle type ( In use S.I Vehicle emission norms) CO (%) HC ( %)

1 2 & 3 wheelers (2/4 stroke ) – vehicles manufactured before 31.3.2000 4.5 9000

2 2 & 3 wheelers (2 stroke ) – vehicles manufactured after 31.3.2000 3.5 6000

3 2 & 3 wheelers (4 stroke ) – vehicles manufactured after 31.3.2000 3.5 4500

4 Bharat stage –II complaint 4 wheelers 0.5 750

5 4 wheelers other than Bharat Stage – II complaint 3.0 1500

Emission certificate :

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 Pollution Control Techniques
Major pollutants emits from the automobile parts are:

1.Fuel tank

2.The Carburetor

3.The Crankcase

4. The exhaust system

 Functions of a Transmission system
Transmission System are:

To Disconnect the engine from the road

wheels when desired.

To connect the engine to the driving

wheels without shock.

To vary the leverage between the engine

and the driving wheels.

To turn the drive through a right angle.

To make provision for the flexing of the

road springs which causes a relative
movement between the engine and the
driving wheels.
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