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An
INDUSTRIAL TRAINING REPORT
On
"Cylinder Head"
SUBMITTED TO:
SUBMITTED BY:
B.Tech (Mechanical)
SRMCEM, LUCKNOW
ACKNOWLEDGEMENT
2.DIESEL
LOCOMOTIVE
SHED
CHARBAGH,
LUCKNOW
SAND BOX
RADIATOR
RADIATOR FAN
TURBO SUPERCHARGER
BOGIE(2 SETS)(3AXLE OR 2 AXLE)
FUEL TANK
AIR RESERVOIERS
POWER PACK
DYNAMO WITH ALTRNATOR
BATTERIES
DRIVER CABIN
WHEEL ASSEMBLY
DISC
BLOWER
TRACTON MOTER
TRUCK
GEAR AND PENION ASSSEMBLY
CYLINDER HEAD
CROSS HEAD
FUEL INJECTION PUMP
BATTERIES (8 OF 8.68 VOLTS)
FUEL TANK
AFTER COOLING CORE
JUNCTION BOX
4.CYLINDER HEAD
(PROJECT STUDY)
4.1 INTRODUCTION
In an internal combustion engine, the cylinder head (often informally abbreviated
to just head) sits above the cylinders on top of the cylinder block. It closes in the
top of the cylinder, forming the combustion chamber. This joint is sealed by a head
gasket. In most engines, the head also provides space for the passages that feed air
and fuel to the cylinder, and that allow the exhaust to escape. The head can also be
a place to mount the valves, spark plugs, and fuel injectors.
Key features of Cylinder Head:
It is subjected to high shocks, stresses and combustion temperature.
Cooling passages are cored for heat rejection.
It also provides passages for inlet air, exhaust gases, fuel injection nozzles,
valve guide, valve seats etc.
Part No.
DESCRIPTION
22200215
2231129
AIR VALVE
2231129
EXHAUST VALVE
2461082-1
2231231
SPRING SEAT
2231152
22200115
2221082
2221092-1
2221093-1
2221094-1
2461083
2241024-1
2221081-2
2151119
54021A
21514279-3
21516311
2151313-1
LOCKWASHER,1/2
2151429-5
21516310
2241294-1
2153403
25000286
25000288
DESCRIPTION
Valve Guide
Lock
P.L. NO.
10124639
10210477
Description
Exhaust Gas Valve
Inlet Valve
Lock
Valve Seat Insert 30
Spring
P.L. No.
10244334
10245807
10210477
10249254
10160115
Hydraulic test
A hydrostatic test is a way by which cylinder heads, pressure vessels
such as pipelines, plumbing, boilers and fuel tanks can be tested for
strength and leaks. The test involves filling the vessel or pipe system
with a liquid, usually water, which may be dyed to aid in visual leak
detection, and pressurization of the vessel to the specified test pressure.
Pressure tightness can be tested by shutting off the supply valve and
observing whether there is a pressure loss. The location of a leak can be
visually identified more easily if the water contains a colorant. Strength
is usually tested by measuring permanent deformation of the container.
Steps:
o Run the engine to attain normal operating temperature(650C)
o Stop running the engine after attaining its operating temperature
o Bring the piston into its compression state
o Fit the hydraulic gadget into the cylinder head close all the openings
o Flow the water into the combustion chamber
o Cut off water supply at 70 psi. Through stop cock and record the time
when it comes to zero. 7 to 10 seconds are ok.
Blow-by Test
Blow-by refers to the leakage of gas past the piston of an engine at
maximum pressure.
Cause: oversized bore, bad ring profile, dent on piston rings, more
gaps in piston ring, late opening and closing of exhaust valves, etc.
Effect: Generally, a new engine has high blow-by which reduces
considerably with running as the high points of bore honing wears away
and thus improving piston rings sealing. But if it is due to any
manufacturing defects or excessive worn parts, then it will surely reduce
engine performance. In worst case it will increase lubricating oil
consumption causing high smoke and particulate emission.
Blow-by Test: It is conducted to check the sealing
efficiency of the combustion chamber on a running
engine, as per the following procedure:
Run the engine to attain normal operating temperature
(65C)
Stop running after attaining normal operating temperature.
Bring the piston of the corresponding cylinder at TDC in
compression stroke.
The procedure for grinding valve seat inserts and reconditioning valves are
as follows:
1. Remove glaze on valve seat by using piece of sand paper under
grinding stone and then spin it.
2. Grind the seat and use dial indicator to check the trueness.
3. Check out valve seat run out. The valve guide bore must be within
tolerance limit.
4. Check the surface of the valve seat insert for cracks.
5. If valves showing crack should be scrapped.
6. Valves should be properly faced (exhaust gas valve at 45 o, air inlet
valve at 30o).
7. To check valve with seat blue valve insert is used. Fine line must
show around entire circumference on large diameter of seat
contracting area.
COMPRESSION SEAL
Since the cylinder head liner joint is metal to metal the seating area must be
in good condition. These surfaces should be checked and if necessary, lapped
using a lapping ring. Seating surfaces must be smooth and in one plane. Using
bluing, a continuous blue mark not less than 1/16 inch wide must show
throughout the circumference.
NOZZLE HOLE SLEEVE
A sleeve is applied with Tite seal in the nozzle hole of each cylinder head to
provide a water jacket for nozzle cooling and to furnish a seat for the nozzle.
TURBO SUPERCHARGER
by
burning of
burning of
proper ratio
is a prerequisite.
compressor
correct pressure, at correct quantity and correctly atomized. The system injects
into the cylinder correctly metered amount of fuel in highly atomized form.
High pressure of fuel is required to lift the nozzle valve and for better
penetration of fuel into the combustion chamber. High pressure also helps in
proper atomization so that the small droplets come in better contact with the
compressed air in the combustion chamber, resulting in better combustion.
Metering of fuel quantity is important because the locomotive engine is a
variable speed and variable load engine with variable requirement of fuel. Time
of fuel injection is also important for better combustion.
5.3 BOGIE
The work of power pack section is to do the overhauling and repairing work. They
take out the head from the engine and assembles it after necessary repair. In the
power pack section the assembly of piston and connecting rod is done. The
thorough checking of piston is done in this section. The piston is send for zyglo test
then it is checked for all the clearances. It is checked whether the piston is seizing
or not.
There are two types of piston used, modified and unmodified. In modified piston,
piston head is made up of steel, the piston skirt is made up of aluminum.
Unmodified piston is totally made up of steel only. The weight of the assembly is
of 90kg. There are generally 5 rings used in the cylinder, first 3 are compression
ring next 2 are oil rings. The first one is made up of steel and has square face. The
second one is also of steel and has tapered face. The third one is of C.I. and is fuel
efficient taper face. The fourth and fifth are also of C.I. and are called oil scrapper
rings.
PARTS OF THE POWER PACK
EXHAUST MANIFOLD
WATER CHANNEL
PGEV GOVERNOR
CRANK CASE MOTOR
CYLINDER (MAX. 16 CYLINDER)
PISTON
FUEL OIL INJECTOR
ROCKER ARM
YOKE
LUBE OIL HEADER PIPE
CAM SHAFT
CRANK SHAFT
CROSS HEAD
FUEL INJECTION PUMP
CROSS PIPE
FIP COVER
6. REFERENCE
Internal combustion Engine Fundamentals, Heywood, Tata McGraw Hills.
Internal combustion Engine, V Ganeshan, Tata McGraw Hills.
Internet sources like:
o www.wikipedia.com
o www.railwaylocoengine.com
o www.rdso.indianrailways.gov.in
Contents
1.
2.
3.
4.
CYLINDER HEAD................................................................................................... 8
5.
6.
4.1
INTRODUCTION.............................................................................................. 8
4.2
4.3
4.4
Critical parts................................................................................................ 10
4.5
4.6
4.7
TURBO SUPERCHARGER...............................................................................18
5.2
5.3
BOGIE........................................................................................................... 19
5.4
GENERATOR................................................................................................. 20
5.5
Power Pack................................................................................................... 20
REFERENCE........................................................................................................ 23