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Internal combustion engine is the engine designed to derive its power from fuel, burn within
cylinder. Fuel is mixed with the air and burned in gas turbine plant as shown in figure. The hot
gasses are passed through the turbine to generate the power and then the gasses are exhausted. In
this case, the same working fluid (air) cannot be used again in the cycle. During the next cycle,
again, the fresh air is taken and mixed with the fuel for heating. It uses the expansive force of
gasses produced by burning the fuel within the cylinder. The motion of the piston rotates a
crankshaft with the help of a connecting rod. The heat that supplies the energy for working
substance is generated within cylinder. Hence, the name is given as Internal Combustion Engine
where suction, compression, combustion and expansion are carried out in different components.
1. Engine component and their function
The arrangements of different engine parts for 4-stroke spark ignition engine (petrol engine) and
4-stroke compression ignition engine (Diesel engine) are shown in Figs. 3 and 8.The purpose of
each part is described in short as follows:
a. Cylinder.
The cylinder of an I.C. engine is considered as the main body o f the engine in which piston
reciprocates to develop power. It is a part of the engine which confines the expanding gases and
forms the combustion space. It provides space in which piston operates to suck the air or air-fuel
mixture. The piston compresses the charge and the gas is allowed to expand in the cylinder,
transmitting power for useful work. It has to withstand very high pressures (about 70 bars) and
temperatures (about 2200 ° C) because there is direct combustion inside the cylinder. Therefore,
its material should be such that it can retain strength at high temperatures, should be good
conductor of heat and should resist to rapid wear and tear due to reciprocating parts. Generally
ordinary cast iron is used, but in case of heavy duty engines, alloy steels are used. Sometimes,
when engine blocks are heavy and for easy maintenance, sleeves or liners are inserted into the
cylinders which can be replaced when worn out. Liners are generally made o f Nickel chrome
iron.
b. Cylinder head.
The cylinder head closes one end of the cylinder. It houses the inlet and exhaust valves through
which the charge is taken inside the cylinder and burned gases are exhausted to the atmosphere from the
cylinder.Cylinder head is usually east as one piece and bolted to the top of the cylinder, A cupper asbestos
gaskets are provided between the cylinder and cylinder-head to obtain a gas-tight joint. The material used
for the cylinder-head is also cast iron.
c. Piston and Piston Rings.
It is a cylindrical part closed at one end which maintains a close sliding fit in the engine cylinder.
It is connected to the connecting rod by a piston pin. The functions of the piston are to compress
the charge during compression stroke and to transmit the gas force to the connecting rod and then
to the crank during power stroke. The force of the expanding gases against the closed end of the
piston, forces the piston down in the cylinder. This causes the connecting rod to rotate the
crankshaft. The pistons of I.C. engines are usually made of cast iron, cast steel and aluminum
alloy. The aluminum alloy has the advantage of higher thermal conductivity and lower specific
gravity. Piston is the heart of the engine. The piston rings are housed in the circumferential
grooves provided on the outer surface of the piston. It gives gastight fitting between the piston
and the cylinder and prevents the leakage of high pressure gases. These are made of special
grade cast iron or pressed steel alloy. This material retains its elastic property at very high
temperature. The upper piston rings are called the compression rings and the lower piston rings
are called the oiling or oil control rings. The functions of the ring are as follows:
It forms a gas tight combustion chamber for all positions of piston.
It reduces contact area between cylinder wall and piston wall for preventing friction
losses and excessive wear.
It controls the cylinder lubrication and transmits heat away from the piston to cylinder
walls.
d. Connecting Rod.
It is special type of rod, one end of which is attached to the piston and the other end to the
crankshaft. It transmits the power of combustion to the crankshaft and makes it rotate
continuously. It is usually a steel forging of circular, rectangular, I, T, or H section and is highly
polished for increased endurance strength. Its small end forms a hinge and pin joint with the
piston and its big end is connected to the crank by crank pin. It has a passage for the transfer of
lubricating oil from the big end bearing to small end bearing (gudgeon pin).
e. Crank and Crankshaft.
Crankshaft is the main shaft of an engine which converts the reciprocating motion of the piston
into rotary motion of flywheel. Both are steel forged and machined to a smooth finish. The two
are held together by means of a key. Crankshaft is supported in main bearings and has a heavy
wheel as counter weights throughout its length to have counter balance of the unit, called
flywheel, to even out the fluctuations of torque. The power required for any useful purpose is
taken from crankshaft only. The crankshaft is the back bone of the engine. Crankshaft is
subjected to bending as well as twisting from the connecting rod end.
f. Piston Pin or Wrist Pin: It is also called Gudgeon pin. The piston pin provides the bearing
for the oscillating small end of the connecting rod. Piston pin is used to join the connecting
rod to the piston. It provides a flexible or hinge like connection between the piston and the
connecting rod. It is usually made of case hardened alloy steel.
g. Valve Spring: The valves are kept closed by the valve springs.
h. Cam-shaft:
It is a shaft which raises and lowers the inlet and exhaust valves at proper time. Camshaft is
driven by crankshaft by means of gears, chains or sprockets. The speed of the camshaft is exactly
half the speed of the crankshaft in four stroke engine. The function of the cam shaft is to operate
the intake and exhaust valves through the cams, cam followers, push rods and rocker arms. The
cam shaft is driven positively from the crankshaft at half the speed of the crankshaft.
i. Cam and Cam-follower: It is made of a required profile to give desired motion to the valve
through the follower.
j. Timing gear:
Timing gear is a combination of gears, one gear of which is mounted at one end of the camshaft
and the other gear on the end of the crankshaft. Camshaft gear is bigger in size than that of the
crankshaft gear and it has twice as many teeth as that of the crankshaft gear. For this reason, this
gear is commonly called Half time gear. Timing gear controls the timing of ignition, timing of
opening and closing of valves as well as fuel injection timing.
k. Push-rod and Rocker Arm: The motion of the cam is transmitted to the valve through the
push rod and rocker arm. These links together are also known as valve gear.
Figure 9: Theoretical and actual p-v diagrams for 4-stroke petrol engine
If all these modifications are taken into account, then the cycle can be represented on p-v
diagrams as shown in Fig.9 (b).
The area 4'-5-l-4' representing negative work is called negative loop or pumping loop. This work
is required for admitting the fresh charge and for exhausting the burnt gases. This loss of work is
known as pumping loss and power consumed for this is known as pumping horse-power.
Figure 11: Theoretical and actual p-v diagrams for 4-stroke diesel engine