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YANBU TECHNICAL INSTITUTE

Mechanical Skills Department


Program: Diploma Certificate Instructor: Muhammad Rafique
Subject: MET 4402: Industrial Equipment Basics I Contact: rafiquem@rcyci.edu.sa
Handout Module 8: Internal Combustion Engines Office : C2 B5 F3

HEAT ENGINE

It is a Thermo-Mechanical Machine that enables conversion of chemical energy


of fuel into useful shaft power.

Another look:

Air Fuel

Thermal
Energy
Combustion Mechanical Mechanical
Chamber Mechanism Work

IC Engine Waste Energy


TYPES OF HEAT ENGINE

Heat engines are classified on the bases of location of combustion process.

Heat Engine

Internal External
Combustion Combustion

Rotory Reciprocating Reciprocating Rotary

Open Cycle Open Cycle


Petrol Engine Steam Engine
Gas Turbine Gas Turbine

Wankel Engine Diesel Engine Striling Engine Steam Turbine

1. Internal Combustion Engine: If the conversion of chemical energy (CE) into


heat energy (HE) and then the heat energy into mechanical energy (ME) in the
same machine, it is called Internal Combustion Engine.

Air
Power

CE HE ME

Fuel

2. External Combustion Engine: If the conversion of chemical energy (CE) into


heat energy (HE) and then the heat energy into mechanical energy (ME) in
different machines, it is called External Combustion Engine.

Air Power

CE HE HE ME

Fuel Boiler Steam Engine

IC ENGINE MECHANISMS

The different mechanisms enabling the energy conversion are as follows:

1. Combustion Chamber: It perform combustion where the chemical energy


of fuel is converted into heat energy as a result of chemical reaction of fuel
with air oxygen and then
2. Cylinder Piston Mechanism: It converts heat energy into mechanical
energy
3. Crank Mechanism: It converts the mechanical energy into shaft power

Chemical
Energy
Combustion
Chamber

Thermal
Energy
Cylinder
Piston
Mechanism
Mechanical
Energy

Crank Shaft
Mechanism
Shaft
Power

Mechanism Energy Transformation


1 Combustion Chamber Chemical Energy into thermal energy
2 Cylinder-Piston Mechanism Thermalenergy into Mechanical Energy
3 Crank Shaft Mechanism Mechanical Energy into Shaft Power
TYPES OF INTERNAL COMBUSTION ENGINES

The Internal Combustion Engines are classified on various bases. The very common
bases are

1. Type of Ignition
2. Mechanical Cycle
3. Type of Fuel
4. Method of Cooling
5. Number of Cylinders
6. Arrangement of Cylinders

INTERNAL
COMBUSTION

IGNITION MECHANICAL COOLING NUMBER OF ARRANGEMENT


FUEL
METHOD CYCLE METHOD CYLINDERS OF CYLINDERS

COMPRESSION
TWO STROKE DIESEL AIR BASIC
IGNITION

MULTI-
SPARK IGNITION FOUR STROKE PETROL WATER
CYLINDER

No Character Detail
1 Ignition Method Spark, Compression
2 Mechanical Cycle 2 Stroke, 4 Stroke
3 Fuel used Petrol, Diesel
4 Cooling Method Air, Water
5 Number of Cylinders 1, 2, 3, 4, 5, 6, 7, 8, .
6 Arrangement of cylinders Horizontal, vertical. V, W,
Opposed, Radial etc
According to Type of Ignition

1. If the combustion process is started by the spark of fire, it is called Spark Ignition
Engine.
2. If the combustion process is started by the heat generated by compression of air,
it is called Compression Ignition Engine.

According to Mechanical Cycle

1. If the thermal cycle is completed in two strokes of the engine, it is called two
stroke engine.
2. If the thermal cycle is completed in four strokes of the engine, it is called four
stroke engine.

According to Type of Fuel

1. If the engine is using Diesel as fuel, it is called Diesel Engine.


2. If the engine is using Petrol as fuel, it is called Petrol Engine.

According to Cooling Method

1. If the engine is cooled by air flowing over and around the cylinder, it is called Air
Cooled Engine, e.g. motorcycles e.t.c.
2. If the engine is cooled by circulating water in jackets around the cylinder, it is
called Water Cooled Engine.

According to Number of Cylinders

1. If the engine consists of one cylinder, it is called Single Cylinder Engine.


2. If the engine consists of more than one cylinders, it is called Multi Cylinder
Engine.
According to Arrangement of Cylinders

The engine may have various arrangements, as shown.

Single Cylinder Inline or Straight Radial

V Engine

W Engine

Opposite Engine
Opposed Piston
IC ENGINE NOMENCLATURE

ENGINE BASIC TERMS

1. BORE (D):
It is diameter of cylinder.
2. DEAD CENTERS:
These are locations on cylinder where piston reverses motion in cylinder at top
and bottom.
3. STROKE or STROKE LENGTH ( ):
It is distance between TDC and BDC
4. CLEARANCE LENGTH ( ):
It is distance between TDC and top of
cylinder
5. DISPLACEMENT VOLUME ( ):
It is volume of cylinder from TDC to BDC.

2
=
4
6. CLEARANCE VOLUME ( ):
It is volume of space between TDC and top of cylinder

= 2
4

7. CYLINDER VOLUME: = +

8. COMPRESSION RATIO (CR): =

9. CAPACITY:
It is volume of air taken in by the engine in its one cycle.
= =
BASE IC ENGINE

A base engine consists of single cylinder.

Two Stroke Basic Diesel Engine

There are several types of two stroke engines. A common example is the uniflow type
where ports are used to introduce air into the cylinder and a valve is used for the
exhaust.
Four Stroke Basic Diesel Engine

The basic engine


components have
been identified in the
following diagram,
together with a
description and
explanation of each
component.
BASIC STRUCTURE OF ENGINE
An engine has many components which are essential for its operation.
These components of the engine can be described in the following groups:

Classification of Engine Parts

The engine parts are grouped in two classes:

Engine Block, Cylinder Head, Crank


Stationary Case, Cylinder Liners, Manifolds, Ports,
Parts Tappet Cover, Bearings, Oil Sump,
Daskets, Mufflers etc

Engine
Parts
ROTATING PARTS:
Crank Shaft, Fly Wheel, Camshaft,
Timing Gear, Valves,Crankshaft Gear
etc

Moving
Parts
RECIPROCATING PARTS:
Piston. Connecting rods, Gidgeon Pin,
Piston Rings,Valve tappets
Engine Block Components:
Roughly the parts are grouped as attached to Top, Bottom, Front and Rear on
engine block.

1. Timing belt cover 17. Oil pressure switch 35. Dipstick tube
2. Timing belt cover back 18. Oil pump 36. Oil filler tube
plate 19. Oil pump plug 37. Oil filler cap
3. Thermostat outlet 20. Plug and O ring 38. Sump plug
4. Camshaft cover 21. Oil pressure relief valve 39. Oil sump
5. Coolant thermistor spring 40. Oil sump gasket
6. Thermostat 22. Oil pressure relief valve 41. Front main bearing cap
7. Thermostat housing plunger 42. Main bearing shells
8. Cylinder head 23. Oil filter cartridge 43. Intermediate main
9. Dowel 24. Timing belt tensioner bearing cap
10. Cylinder head stud 25. Water pump pulley 44. Centre main bearing
long 26. Deflector cap
11. Cylinder head bolt 27. Water pump 45. Thrust washers
12. Cylinder head stud 28. Cylinder block 46. Intermediate main
short 29. Cylinder head gasket bearing cap
13. Spark plug 30. Knock sensor 47. Rear main bearing cap
14. Alternator/water pump 31. Crankshaft rear oil seal 48. Dowel
belt 32. Gearbox adapter plate 49. Oil separator
15. Crankshaft pulley 33. Crankshaft sensor 50. Oil strainer and O ring
16. Oil seal 34. Dipstick
Internal Engine Components:
1 Cam Shaft Assembly Cam shaft, Valve-Follower Assembly, Timing Belt Assembly
2 Crank Shaft Assembly Crankshaft, Piston-Connecting Rod Assy, Crankshaft Gear &
Pulley Assy.

1. Timing belt tensioner 15. Connecting rod and 28. Connecting rod RH
2. Timing belt piston LH 29. Big-end bearing shell
3. Camshaft gear 16. Gudgeon pin 30. Pulley bolt
4. Camshaft front oil seal 17. Compression rings 31. Washer
5. Camshaft 18. Oil control ring 32. Crankshaft pulley
6. Camshaft rear oil seal 19. Piston 33. Gear flange
7. Tappet 20. Exhaust valve seat 34. Crankshaft gear
8. Shim insert 35. Gear flange
9. Cotters 21. Inlet valve seat insert 36. Pulley and gear key
10. Cup 22. Valve guide 37. Oil pump key
11. Spring 23. Exhaust valve 38. Crankshaft
12. Valve stem seal 24. Inlet valve 39. Flywheel dowel
13. Seat 25. Crankshaft washers 40. Connecting rod nut
14. Deflector 26. Main bearing shell 41. Connecting rod cap
27. Connecting rod bolt
WORKING OF IC ENGINE
Four Stroke Petrol Engine

1: Suction Stroke 2: Compression Stroke

3: Working Stroke 4: Exhaust Stroke


Four Stroke Diesel Engine

1: Suction Stroke 2: Compression Stroke

3: Working Stroke 4: Exhaust Stroke


Two Stroke Petrol Engine

STROKE 1: BDC to TDC

1-1: Transfer & Exhaust 1-2: Compression & Suction

STROKE 2: TDC to BDC


EXERCISE

1. Define heat engine and describe its types.


2. Classify Internal Combustion Engine.
3. During the expansion stroke of an IC Engine, the combustion gases in the
cylinder push the piston with an acceleration of 50 m/s2. If equivalent
inertia of piston is 10kg and bore diameter is 150 mm, determine the
pressure acting on piston.

4. For the basic diesel engine,

Bore (D) = 8 cm

Stroke Length ( ) = 7 cm

Clearance Length ( ) = 0.5 cm

Calculate the following,

Parameter Formula Calculation

1 2
Stroke Volume [cm3] =
4
2 Clearance Volume [cm3]
2
=
4
3 Total Volume [cm3]
= +
4 Compression

=
Ratio

5 Capacity [cm3]
=
5. Identify the parts as identified on the
diagram.

Crankshaft
Piston
Big- End Bearing
Fuel Injector
Piston Rings
Valve
Connecting Rod (Con-rod)
Gudgeon Pin

6. Identify five major parts and describe their function on the Base Engine.

7. Sketch shows internal side of engine, identify three major assemblies and
describe three parts in each assembly.

Assembly name Parts Names


1
2
3
8. Sketch shows external side of engine, identify five major assemblies and
describe three parts in each assembly.

Top
Front

Rear
Bottom

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