01 Introduction To Recip Engine (Ignition)

Malaysian Institute of Aviation Technology
FOR TRAINING PURPOSE ONLY
RECIP. ENGINE OVERHAUL
TYPES OF ENGINE
1. INTERNAL COMBUSTION ENGINE combustion occurs inside the engines (cylinders) e.g; piston engine, turbine engine, rotary engine and stirling engine EXTERNAL COMBUSTION ENGINE. combustion occurs outside the engine e.g: old locomotives and ships to run the
2.
propeller.
GENERAL DESIGN AND CONSTRUCTION
Internal combustion engine or heat engine, convert heat energy to mechanical energy to drive a propeller from the expansion of gas (as result of combustion of fuel and air). Reciprocating engines derive their name from the backand-forth, or reciprocating movement of their pistons.
TYPE OF RECIPROCATING ENGINE

1.
CLASSIFICATION a. b. Cylinder arrangement with respect to the crankshaft Method of cooling (liquid cooled or air cooled)
a.
Cylinder arrangement
1. 2. 3. 4. Radial engines. In-line engines. V-type engines. Opposed type engines.
1. RADIAL ENGINE. a. Rotary type b. Static type 1a. Rotary type radial engine Cylinder mounted around the crankcase Cylinder and propeller rotate together and crankshaft stationary. Most popular rotating engine was the Bently, Gnome and LeRhone
1a.
Disadvantage of the rotary radial engine The torque effect produced by the large rotating mass of the propeller and cylinders made aircraft difficult to control. Coupled with carburetor, lubrication and exhaust problem. Large frontal area Have some cooling problem
1b.
Static type radial engine. Engine is stationary and bolted to the airframe. Crankshaft rotates and turns the propeller. No. of cylinders from 3 to 28 cylinders. Consist of a single row and multiple rows, max of 4 rows with 7 cylinders in a row. And total of 28 cylinders. Produce higher horsepower and high power to weight ratio, mostly used on military and civilian transport
aircraft. - Most radial engine is a single row and has an odd number of the cylinder and connected to the single crankshaft. - In multiple row radial engine, cylinder is staggered behind the space between the frontal cylinders to increase the amount airflow past each cylinder for cooling
2. IN-LINE ENGINE Cylinder are aligned in single row parallel with crankshaft. engine either liquid or air-cooled Piston either located upright or inverted. Inverted engine is generally employed. Number of cylinders limited to six only to facilitate cooling and prevent engine overheating Cylinder are generally even number to provide proper balance. Advantages of in-line engine Small frontal area, less drag, greater propeller clearance as for inverted engine. Shorter main landing gear and provide better visibility Disadvantages of in-line engine Relatively low power to weight ratio, the rearmost cylinder receives less cooling air Low and medium horsepower output to engine fitted to light aircraft only.
3. V-TYPE ENGINE Two type : a. Inverted V-type engine b. Upright V-type engine. Cylinders are arranged in two rows (bank) forming letter V Angle between banks 45, 60 or 90 deg. Cylinders are always even number in each row The two banks are opposite each other Most V-type engine has 8 or 12 cylinders Either air cooled or liquid cooled Still employed typically found on racing aircraft.
Advantages of V-type engine Producing higher horsepower than in-line engine Small frontal area with higher power to weight ratio Better pilot visibility as shorter/lower main landing gear.
iv.
OPPOSED TYPE ENGINE Most popular recip. engine used on light aircraft. Engine as little as 36 hp. and as much as 400 hp. Cylinder are always even numbers and opposes each other. Some engines are liquid cooled, mostly air cooled Horizontally installed on fixed wing aircraft. When installed on helicopter it is mounted vertically. Recent development engine employs dual electronic ignition system.
Advantages - High power to weight ratio because of small and light weight crankcase. - Small frontal areas, more streamline and less drag - Less vibration because the power impulses tend to cancel each other.
MAJOR ENGINE COMPONENTS

1. Basic part of reciprocating engine include: a. Crankcase b. Crankshaft c. Connecting rod d. Piston e. Cylinders f. Valves g. Valve operating mechanism
2. Valves, pistons and plugs are located in the cylinder
a.
CRANKCASE i. It is foundation of the reciprocating engine. Type of crankcase : Opposed and radial ii. Crankcase provides mounting surface for cylinder and external accessories. iii. It also houses valves operating mechanism, crankshaft and connecting rods. iv. Tight enclosure for lubricating oil as well as a means of attaching a complete engine to an airframe. v. Extremely rigid and strong capable of absorbing internal combustion forces and maintain its integrity. vi. Consist at least two pieces and up to five pieces case assemblies
Opposed Engine Crankcase Consist of two halves of cast aluminum alloy. Halves split vertically, held together by bolts and nuts Manufactured either by sand casting or mold (permold). Thinner wall, strong, denser (mold) and fewer tendencies to crack due to fatigue. Cylindrical in shape with smooth are machined to serve as cylinder pad Cylinder pad place to mount cylinder to crankcase. To allow a crankcase to support a crankshaft, a series of transverse webs are cast directly into a crankcase. Webs integral parts of the structure and houses that bearings support the crankshaft and strengthen the crankcase.
Radial Engine Crankcase
Radial engine crankcase separates into 4 section a. Nose section b. Power section c. Supercharger d. Accessories section
a. Nose section Front of the crankcase, bolted to the power section Made of aluminum alloy, one piece with domed/convex shape. Houses and support prop. governor drive shaft,prop. shaft, cam ring and reduction gear. Additional mounting for magneto and others engine accessories.
b.
Power section - Section of the crankcase where the reciprocating motion of the piston is converted to the rotary motion of the crankshaft. - One or three pieces, made of aluminum or magnesium bolted together. - Contain machined bosses that rigidly support the crankshaft bearing and the crankshaft. - Cylinder are attached around the perimeter - Inner circumference of a cylinder pad is chamfered or tapered to permit the installation of O-ring on the cylinder skirt that seal the joint between the cylinder and cylinder pad
c. Diffuser or Supercharger section Houses the gear train, bevel and spur gear to drive various engine components. Spur gear drive heavy load on accessories.
d. Accessories section Provide mounting for accessories such as magneto, carb., pump, starter and generator.
b.
CRANKSHAFT - Purpose to transform the reciprocating motion of the piston and connecting rod into rotary motion to turn the propeller. - The crankshaft may have one or more throws. Two crank cheek and crankpin is one throw - Can withstand high stress, made of forged alloy such as chromium-nikel molybdenum steel.
b.
CRANKSHAFT cond a. b. Main part of crankshaft Main bearing journal (Main journal) - Represent centerline of a crankshaft and support the crankshaft as it rotates in the main bearings Crankpin - Attachment points for the connecting rod. - Forged directly into a crankshaft and offset from the main bearing journal. Crank cheeks or crank arms - Connect the crankpin to the crankshaft Counterweight and dampers help to balance the shaft dynamically
c. d.
b.
CRANKSHAFT cond - Types of crankshaft depend on number and arrangement of cylinder - The common types single, two, four and six throws - Single throw crankshaft is used on single row radial engine.
Bearing - To support and reduce friction between moving part:

a. b. c. d. Plain bearing Ball bearing Roller bearing Tapped - radial load only - high radial load - radial load - radial and thrust load.
CRANKSHAFT BALANCE
TO REDUCE ENGINE VIBRATION WHICH CAN CAUSE FATIQUE AND FAIL AND WEAR EXCESSIVELY EXCESSSIVE VIBRATION IS CAUSE BY UNBALANCE CRANKSHAFT
TYPE OF BALANCE
1.
2.
STATICALLY BALANCE DYNAMIC BALANCE
STATICALLY BALANCE
WHEN ENTIRE CRANKSHAFT IS BALANCE AROUND ITS AXIS OF ROTATION CAN BE ACHIEVED BY PLACING IT IN KNIFE EDGE BALANCING BLOCK
DYNAMIC BALANCE
BALANCING THE CENTRIFUGAL FORCE CREATE BY THE ROTATING CRANKSHAFT AND THE IMPACT FORCE CREATE BY ENGINE POWER IMPULSE CORRECTED THROUGH USING OF DYNAMIC DAMPERS
c. CONNECTING ROD Purpose a. To transmit exerted forces on a piston to a crankshaft. b. To convert reciprocating motion of piston to a rotary motion of crankshaft. Small end is connected to the piston and big end connected to the crankshaft. Types a. Plain types b. Master and articulated type c. Fork and blade type
a.
PLAIN CONNECTING ROD
USED ON INLINE AND OPPOSED ENGINE BRONZE BUSHING ARE PRESSED AT THE PISTON PIN END CRANNKPIN END USUALLY FITTED WITH TWO PIECES
BEARING AND CAP WHICH IS HELD BY BOLT AND STUD TO PROVIDE PROPER FIT AND BALANCE CONNECTING ROD ARE MATCH WITH THE PISTON STAMP WITH NUMBERS TO IDENTIFY CYLINDER AND PISTON ASSEMBLY
b.
MASTER AND ARTICULATED ROD
USED ON RADIAL TYPE OF PISTON ENGINE ONE PISTON IN EACH ROW OF CYLINDER IS CONNECTED TO CRANKSHAFT BY A MASTER ROD THE REMAINING PISTON IS CONNECTED TO A MASTER ROD THROUGH A LINK OR ARTICULATED RODS MASTER ROD ARE MANUFACTURED FROM A STEEL ALLOY FORGING WHILE LINK ARE MANUFACTURED FROM FORGED STEEL ALLOW LINK ROD IS EITHER I OR H CROSS SECTIONAL PROFILE MASTER ROD IS THE ONLY BETWEEN THE PISTON AND THE CRANKPIN LINK ROD IS ATTACHED TO MASTER THROUGH KNUCKLE PIN SOME KNUCKLE PIN DO NOT IN THE FLANGE HOLE BUT SOME FULL FLOATING
FORK AND BLADE TYPE

- Used primarily on V-type engine.
- Consists of fork-connecting rod and blade
connecting rod
d. PISTON Two primary functions: a. Draw fuel and air into a cylinder and compress the gases b. To transmit the force produced by combustion to the crankshaft The ring grooves are cut at outside surface of piston to hold set of piston rings. As many as six ring grooves. The lower/base of the piston are called piston skirt. Piston are often classified according to their head design. Type of heads : a. Flat head b. Flat head with valve recessed c. Cupped head d. Domed head e. Truncated cone Flat head type is commonly used in modern aircraft All piston expend as they heat up. Cam ground piston compensate for uneven expansion of the piston.
d. PISTON cont Piston rings Perform three functions a. To prevent gas leakage from combustion chamber b. Reduce oil leakage into combustion chamber. c. To transfer heat from the piston to cylinder wall Piston ring gap a. Butt joint b. Angle joint c. Step joint Types of piston ring a. Compression ring prevent gas escape past the piston during engine operation. placed in the ring groove below the piston head. no. of ring used on piston determined by the type of engine and design.
d. PISTON cont b. Oil ring control amount of oil that applied to the cylinder wall as well as prevent oil from entering the combustion chamber. - 2 types of oil ring 1. Oil control ring - to regulate the thickness of oil film on the cyl. wall. - placed below compression ring 2. Oil scraper ring (oil wiper ring) - to regulate amount of oil that passes between the piston skirt and cylinder wall. - usually beveled face and installed below of the piston skirt.
d. PISTON cont Ring gap must be staggered/offset to prevent gas leak or known as blow-by ring gaps are staggered at 120 apart for three piston rings. Cross section of piston ring a. Rectangular b. Tapered c. Wedge
Piston pin Is to joint the piston to the connecting rod. Types of piston pin a. Stationary (rigid) pin held tightly in place by screw that prevents movement. b. Semi-floating retained stationary in the connecting rod. c. Full-floating free to rotate.
d. PISTON cont A piston pin must be held in place laterally to prevent it from rubbing and scoring the cylinder walls. Three devices that are used to hold a piston pin in place are 1. circlets, 2. spring rings, and 3. metal plugs. A circlet is similar to a snap ring that fits into a groove cut into each end of the piston boss. A spring ring also fits into grooves cut into the ends of a piston boss but consists of a single circular spring-steel coil. Both circlets and spring rings are used primarily on earlier piston engines. More current practice is to install a plug of relatively soft aluminum called a piston-pin plug. These plugs are inserted into the open ends of the piston pins and provide a good bearing surface against the cylinder walls.
e. CYLINDER Provide a combustion chamber where the burning and expansion of gases takes place to produce power. Houses of piston and connecting rod assembly as well as the valves and spark plugs. Cylinder must be strong, lightweight and good heat-conducting properties. Air cooled cyl. consist of : i. Barrel ii. Cylinder heads iii. Mounting flange iv. Skirt v. Cooling fins vi. Valve assembly.
e. CYLINDER cond Cylinder barrels - Construction for cylinder barrel must be as light as possible. - Material used chromium molybdenum steel - nickel chromium molybdenum steel - Cylinder barrels are machined with a skirt that project into the crankcase and mounting flange, used to attach the cylinder to the crankcase. - Exterior cylinder barrel consist of several thin cooling fins. - Threaded at the top part of the barrel so cylinder head can be screwed into it. - Cylinder bore choke bore cylinder- smaller at the top for expansions cause by operating temperature. - The amount of choke is between .003 and .005 inches. - Internal surface of the barrel is treated with chrome plating/electroplating and nitriding to form of case hardening on the surface.
e.
CYLINDER cond - Identification for nitrided cylinder by applying blue band around cyl. base or cooling fin, and orange paint for the electroplating cylinders. - chromium is too smooth that it could not retain enough oil to lubricate the piston ring - overcome through process called chrome channeling - chrome channeling is a process where by a reverse current is through a cylinder for controlled period of time after chromium is applied - microscopic crack will occur on the surface that help holding lubricating oil - Advantages over nitrided cylinder 1less susceptible to rust and corrosion 2once it wear beyond its usable limit it may be chrome plated back to original size
Cylinder heads cond Provide an enclosed chamber for combustion Heads contain intake and exhaust ports, spark plug, valve actuating mechanism and also conduct heat away from cylinder barrels. Made of forged or die-cast aluminum alloy because of good heat conductor, lightweight and durable Inner surface maybe flat, semi-spherical or peaked. The semi-spherical type proved to be the most satisfactory and stronger and provide more rapid and thorough scavenging of exhaust gas.
e. CYLINDER cond Cylinder Numbering Left or right of an engine always viewing form the rear. The crankshaft rotation is also referenced from the rear of the engine is specified as either clockwise or counterclockwise. All cylinders are numbered, odd numbered are on the right and even numbered on the left. Continental engine start its cylinder numbering with the most rearward cylinder. Lycoming engine start with the most forward Radial engine cylinders are numbered consecutively starting from the top cylinder and progressing clockwise as viewed from the rear of the engine. Double row radial engine, all odd numbered cylinders are in the rear row and the even numbered cylinders are in the front row
f. VALVES 1. Purpose is to regulate flow of gases into and out of cylinder by opening and closing valves port at predetermine times. 2. Types of valve: i. Intake valve (chromium, nickel or tungsten steel) ii. Exhaust valve exhaust valve stems are hollowed and partially filled with metallic sodium. (inconel, siliconchromium or cobalt-chromium alloys) 3. Classified by shape of head i. Flat head ii. Semi tulip iii. Tulip iv. Mushroom 4. Valve springs are hold valve face against valve seat 5. Valve springs are held in place by spring retainer and split key
g.
VALVE OPERATING MECHANISM
To open and close each valve at correct time Consist of : i. Camshaft or cam rings ii. Valve lifter or tapped iii. Pushrod iv. Rocker arm Camshaft is used in opposed engine while cam ring is used in radial engine
HYDRAULIC LIFTERS
1.
2.
MOST OPPOSED ENGINE USED HYDRAULIC LIFTERS USED OIL PRESSURE TO CUSHION THE IMPACT OF THE CAMLOBES STRIKING THE LIFTER AND REMOVES ANY PLAY WITHIN THE VALVES OPERATING MECHENISM
OPPOSED ENGINE VALVE OPERATING MECHANISM

1. 2. 3.
4.
5. 6.
Valve operation begins with the camshaft Consists of round shaft with a series of cams or lobes. To transform a circular motion of the crankshaft to a linear motion needed to actuate valve. The shape of the cam lobes determines valve left (distance a valve lifted off its seat and valve duration) Each valve must open and close for every two rotations of the crankshaft. (speed of camshaft is one-half that of the crankshaft. OPERATION : camshaft rotates, the lobe raise the valve lifter (tappet), transmits the lifting force of the cam to the push rod
PUSH ROD
Transmit lifter action to the rocker arm
Hole on each end to allow oil flow from lifter to valve
component Enclose by thin metal shroud that run from cylinder head to crankcase These provide return path for oil that is pump up to cylinder head
ROCKER ARM
PURPOSE Change lifting movement of the pushrod into downward motion needed to open the valve
RADIAL ENGINE VALVE OPERATING MECHANISM

1. 2.
3.
4. 5.
VALVE OPERATING MECHANISM ON RADIAL USED ONE OR TWO DEPENDING ON THE NO. OF ROWS THE CAMRING IS A CIRCULAR PIECE OF STEEL WITH A SERIES OF CAM LOBES. THE SMOOTH AREA BETWEEN THE LOBES IS CALLED CAM TRACK CAM RING IS DRIVEN BY CRANKSHAFT THROUGH A SERIES OF GEAR. THE SPEED OF THE CAMRING IS CAN BE DETERMINED BY USING THE FORMULA 1 2 X NUMBER OF LOBES
VALVE CLEARANCE
SPACE OR CLEARANCE BETWEEN VALVE TIP AND ROCKER ARM FACE
VALVE CLEARANCE
VALVE CLEARANCE
1. 2. 3.
4.
To maintain engine running smoothly To set up the valve clearances, refer engine MM specifies either cold or hot valve clearance. During normal engine operating temperature, the cylinder assemblies expand and force the cylinder along with it valve operating component further away from the crankcase. Due to mass the push rod expand less than the cylinder resulting increases in valve clearance.
PROPELLER REDUCTION GEAR

-
Purpose of the reduction gear, permits a propeller to turn slower than the engine speed. Mostly used by the high powered engine. Utilize spur gears, planetary gears or a combination of two. Whenever reduction gear is used that does not aligned with the crankshaft, vibration will be created to the engine. To minimize the vibration a quill shaft and planetary reduction gear is used Type of propeller shaft 1Tapered propeller shaft 2Splined propeller shaft 3Flanged propeller shaft
ENGINE IDENTIFICATION
-
Almost recip. engine are identified by a series of letters and numbers. Most manufacturers use the same identification code consists of letter or series of letters followed by number and model designation. - O horizontally opposed engine R radial engine I inline engine V v-type engine T turbocharged I fuel injected S supercharged G geared nose section L LH rotation for multi engine H horizontal mounting for helicopters V vertical mounting for helicopter A modified for aerobatics
ENGINE IDENTIFICATION cond

1- e.g ; O-320 indicate horizontally opposed engine with a displacement of 320 cubic inch. 2- e.g ; LIO-360-C indicate left-hand rotation, fuel injected, horizontally opposed engine, displacement of 320 cubic inch and C model. 3- e.g : GTSIO-520-F indicate engine is geared, turbocharged engine, fuel injected, horizontally opposed engine, displaces 520 cubic inch and F model
FINISH FOR THE DESIGN AND CONSTRUCTION OF RECIP ENGINE
RECIPROCATING ENGINE OPERATING PRINCIPLES
ENERGY TRANSFORMATION
- AN ENGINE IS A DEVICE THAT CONVERT CHEMICAL ENERGY OF THE FUEL INTO HEAT ENERGY - ONCE CONVERTED, THE HEAT CUASES AN INCREASE OF GAS PRESSURE IN THE CYLINDER THAT CONVERT IT INTO MECHANICAL ENERGY
BASIC OPERATING PRINCIPLES cond

TERM : 1. Type of operating cycle : a. Four stroke b. Two stroke Those operating cycles are developed by August Otto, sometimes referred as OTTO CYCLE. 2. Stroke is a total distance travel of piston most outward and inward. 3. Most outward travel is called top dead center (TDC) 4. Most inward travel is called bottom dead center (BDC)

FOUR STROKE CYCLE 1. The four stroke cycles consists of : a. Intake stroke b. Compression stroke c. Power stroke d. Exhaust stroke 2. To complete four stroke cycle requires two revolutions of the crankshaft. 3. Ignition takes place during compression stroke. Therefore in one complete cycle there are four stroke and five events.
OPERATING PRINCIPLES
1. The sequences of events of reciprocating engine are : i. Intake ii. Compression iii. Ignition iv. Power v. Exhaust i. Intake - Piston travels from top dead center to bottom dead center. - Intake valve opens and exhaust valve closes. - Fuel and air mixture drawn into cylinder Compression - Piston travels from top dead center to bottom dead center. - Both valves are closed - Mixture fuel and air compressed
ii.

iii.. Ignition - Compressed mixture is ignited by spark plug. - Both valves are still closed - Piston near top/top dead center Power - Expanded burning gases forces piston downward - Crankshaft rotates to produces work. - Both valves are still closed Exhaust - Exhaust valve opens and intake valve still close. - Piston travels from bottom to top dead center. - Burned gases scavenged out of cylinder.
iv.
v.
2. All five events are considered one cycle.
VALVE TIMING OR MODIFIED OTTO CYCLE
TERM USED TO DESCRIBES THE POINT AT WHICH THE INTAKE AND EXHAUST BEGIN TO OPEN AND CLOSED DURING THE FOUR STROKE CYCLE
VALVE TIMING
- To increase engine performance and more efficient. - The no. of crankshaft degrees that the intake valve opens early before the piston reaches TDC (valve lead). - To ensure sufficient charge (mixture) enter the cylinder. - The no. of degrees the exhaust valve remain open after TDC. (valve lag). - To ensure fully scavenge of hot gases from the cylinder. - Combination of the valve lead and valve lag is called VALVE OVERLAP.
VALVE TIMING
- Purpose of valve overlap is to allow the charge (mixture) to
enter the cylinder as early as possible to increase engine performance and aid in cylinder cooling and also to ensure fully scavenge of hot gases from the cylinder. degrees to reach TBC, 180 degrees to reach BDC then 45 degrees past BC and the total of 240 degrees of rotation. (duration of intake valve open).
- Therefore, e.g. if the amount of intake valve open, will be 15
FIRING ORDER
Define as the sequence in which ignition occurs in different cylinder Each engine is designed with a specific firing order to maintain balance and reduce vibration. Example continental 0-200a= 1324 lycoming 0-320-E3D = same order but cylinder are numbered differently
FIRING ORDER ON RADIAL ENGINE

THE ODD CYLINDER FIRE FIRST FOLLOWED BY THE EVEN NO CYLINDER. 14 CYLINDER = +9 -5, MEANS IF NO 1 IS FIRING THE NEXT CYLINDER TO FIRE IS 1 + 9 = 10 CYLINDER, THE NEXT CLINDER TO FIRE IS 10 5 = 5 AND SO O N 18 CYLINDER +11 7, IF NO 1 CYLINDER IS FIRING THE NEXT CYLINDER TO FIRE IS 1 + 11= 12 NEXT WILL BE 12 7 = 5

TWO STROKE CYCLE 1. 2. 3. 4.
5. 6.
Has the same five events and only two piston strokes rather than four strokes in only one crankshaft revolution to complete the cycle. Each stroke two events take place. When piston moves up induction and compression takes place. Ignition occurs when piston moves up a few degrees before top dead center. When piston moves down power and exhaust occur During downward movement of piston compression also takes place in crankcase not in cylinder.
WORK-POWER CONSIDERATIONS
ALL AIRCRAFT ENGINE ARE TESTED AND RATED ACCORDING TO THEIR ABILITY TO DO WORK AND PRODUCE POWER. ENGINE DESIGNS AND CONSTRUCTION DETERMINES HOW EFFECTIVE IN CONVERTING FUELS CHEMICAL ENERGY TO WORK AND POWER
DEFINATION OF WORK
If force applied to an object and the object moves,
work is done. Amount of work done is directly proportional to the force applied and distance the object moves. If force is applied to an object and the does not moves , work is not done. Work produced by the engine is used to turn the propeller work (w) = force (f) x distance (d) = ______ ft/lbs
DEFINATION OF WORK
English system, work is typically measured in foot-pounds. One footpound is equal to one pound of force applied to an object through the distance of one foot In the metric system, the unit of work is the joule. One joule is the work done by a force of one newton acting through a distance of one meter. One pound is equal to 4.448 newtons.
The work produced by an engine is used to turn a propeller which is produces thrust to move an aircraft.
POWER
When determining the amount of work done, time required to do the work is not considered, Power, on the other hand, does take time into consideration. Define as time rate of doing work. FORMULA FORCE X DISTANCE = ___________ft/lbs/sec TIME
When rating engines, power is a primary consideration because it represents how quickly an engine-propeller combination can respond to power demands. Power is a critical factor when determining whether or not an engine can deliver the force needed to produce a specific amount of work in a given time. E.g., a large airplane needs more power to take off in the same distance as a small airplane because more force is needed to accelerate a heavier object the same distance in the same amount of time.
HORSE POWER
Another unit of measure for power is the horse-power. The amount of power required to do 33,000 ft/lbs work in 1 min
or 550 foot-pounds of work in one second.
HORSEPOWER = FORCE X DISTANCE
33000 X TIME
INDICATED HORSE POWER

(IHP) is the total power actually developed in an engines
cylinders without reference to friction losses within the engine. To calculate indicated horsepower, the average effective pressure within the cylinders must be known. One way to determine the effective pressure is to attach a mechanical indicating device to the engine cylinder that records the actual pressure existing in the cylinder during a complete operating cycle. This average pressure is referred to as indicated mean effective pressure and is included in the indicated horsepower calculation with other engine specifications.
INDICATED HORSE POWER

FORMULA
PLANK 33,000 = IMEP inside the during a power stroke = length of stroke = area of piston head = number of power stroke per min for one cylinder. On a four-stroke engine, this is found by dividing the rpm by two. = number of cylinder
P L A N
FRICTION HORSEPOWER
Not all of the horsepower developed by engine goes to
driving the propeller, all the moving part inside the engine will creating friction. Engine lubrication is crucial in limiting friction and wear, but cannot completely eliminated. The power required to overcome the friction and energy losses
BRAKE HORSEPOWER
The actual power delivered to the propeller shaft IHP - FHP = BHP
Devices that are capable to measuring torque, including
the dynamometer and torquemeter. Early powerplant design engineers measured brake horsepower using a Prony brake dynamometer ,on most modern engines is measured with an electric or hydraulic dynamometer.
PISTON DISPLACEMENT
Volume of air displace by a piston as it moves from
BDC to TDC FORMULA - A X L X N A = area of piston head ( r ) L = length of stroke in inches N = number cylinders piston displacement always in cubic inches
ENGINE EFFICIENCY
To determine how efficient an engine is,
several factors must be examined, including an engines thermal, volumetric, and mechanical efficiency.
THERMAL EFFICIENCY
- A ratio of the amount of energy converted to useful work to
the amount of heat energy contained in the fuel used to support combustion
E.g - two engine that produce the same amount hp but consume different amount of fuel the engine that consume less amount of fuel has higher thermal efficiency
VOLUMETERIC EFFICIENCY
Ratio of volume of fuel and air takes into the cylinder to the
total piston displacement If engine draws in volume of fuel/air that is exactly equal to the total piston displacement, VE would be 100% Varies with change of atmospheric condition VE in normally aspirated engine is less than 100 % VE on turbo charge engine can exceed than 100 % Anything that decreases the density, or volume of air entering a cylinder decreases volumetric efficiency.
MECHANICAL EFFICIENCY
Is the ratio of brake horsepower to indicated horsepower
and represents the percentage of power developed in the cylinders that reaches the propeller shaft. E.g an engine develops 160 brake horsepower and 180 indicated horsepower, the ratio of brake horsepower to indicated horsepower is 160:180, which represents a mechanical efficiency of 89 percent.
The factor that has the greatest effect on mechanical
efficiency is the friction within the engine itself.
FACTORS THAT EFFECT VOLUMETRIC EFFICIENCY OF A NON-TURBOCHARGED ENGINE

1. 2. 3. 4. 5. 6.
7.
PART THROTTLE OPERATION LONG, SMALLER DIAMETER INTAKE PIPES INDUCTION SYSTEM SHARP BEND HIGH CARBURETOR AIR TEMPERATURE INCOMPLETE SCAVENGING IMPROPER VALVE TIMING INCREASE IN ALTITUDE
FACTORS AFFECTING POWER OF THE ENGINE

1. 2. 3. 4. 5. 6. 7. 8.
MANIFOLD PRESSURE DETONATION AND PRE IGNITION COMPRESSION RATIO IGNITION TIMING ENGINE SPEED SPECIFIC FUEL CONSUMPTION ALTITUDE FUEL / AIR RATIO
MANIFOLD PRESSURE
CHANGE OF MANIFOLD PRESSURE AFFECT THE
AMOUNT OF POWER AN ENGINE CAN PRODUCE CONTINUE SUPPLY OF HIGH MANIFOLD PRESSURE CAN DAMAGE THE ENGINE
DETONATION AND PRE-IGNITION

DETONATION IS UNCONTROL EXPLOSIVE IGNITION IN THE

CYLINDER PROMOTES TO HIGH CYLINDER TEMPERATURE CAN BE DETECT THROUGH KNOCKING IN THE ENGINE PRE-IGNITION FUEL/AIR MIXTURE IGNITES TOO SOON CAUSE BY HOT SPOT DUE TO OVERHEATED VALVE EDGE, SILICA DEPOSIT ON SPARK PLUG, OR RED HOT SPARK PLUG ELECTRODE DETONATION AND PREIGNITION CAN OCCUR SIMULTANEOUSLY
COMPRESSION RATIO
A RATIO OF CYLINDER WHEN THE PISTON IS AT BDC TO WHEN THE PISTON IS AT TDC
DETERMINE THE AMOUNT OF HEAT ENERGY THAT IS CONVERT TO
USEFUL WORK HIGH CR ALLOWS THE FUEL/AIR MIXTURE TO RELEASE ENERGY RAPIDLY AND PRODUCE MAXIMUM PRESSURE INSIDE THE CYLINDER JUST AS THE PISTON BEGIN THE POWER STROKE ONLY CAN BE INCREASED OR DECREASED BY ALTERING THE ENGINE DESIGN CHARACTERISTIC OF AVAILABLE FUEL DETERMINE THE PRACTICAL OF COMPRESSON RATIO THAT CAN BE USED IN ENGINE DESIGN IF TURBO CHARGE ENGINE DEGREE OF TURBOCHARGING LIMIT THE COMPRESSION RATIO
IGNITION TIMING
CHANGE IN IN ENGINE IGNITION WILL ALSO EFFECT THE ENGINE
POWER TO ENSURE COMPLETE COMBUSTION THE ENGINE MUST BE TIME PROPERLY EARLY IGNITION LOST POWER DUE TO MAXIMUM PRESSURE IN THE CYLINDER BUILT TOO EARLY , AND EXPANDING GAS OPPOSED THE ROTATIONAL INERTIA BECAUSE THE PISTON IS STILL MOVING UPWARD GAS PRESSURE ON PISTON HEAD DOES NOT BUILD UP TO EXPECTED LEVEL LATE IGNITION DOES NOT ALLOW ENOUGH TIME FOR COMPLETE COMBUSTION CAN LEAD TO DETONATION
SPECIFIC FUEL CONSUMPTION
A NUMBER OF POUND OF FUEL BURN PER HR TO PRODUCE 1 HORSEPOWER IF AN ENGINE BURN 12 GALLON WHILE PRODUCING 180 BHP THEREFORE BSFC IS .4 CALCULATION 7 X 12 = 84 84 DEVIDE BY 180 = .46666666666 FACTORS EFFECTING ENGINE FUEL CONSUMPTION ENGINE SPEED DESIGN VOLUMETRIC EFFICIENCY FRICTION LOSSES THE BEST FUEL CONSUMPTION IS APPROXIMATELY AT 75% POWER ( CRUISING )
ALTITUDE
ANY TIME ENGINE IS OPERATED ABOVE SEA LEVAL LESS
AIR IS DRAWN INTO THE ENGINE THUS RESULTING IN DECREASE ENGINE POWER OUTPUT DENSITY IS A TERM GIVEN TO DESCRIBE THE DENSITY OF AIR AT GIVEN ALTITUTE EVENTHOUGH THE ACTUAL ALTITUTE DOES NOT CHANGE DENSITY ALTITUTE CAN CHANGE CONSTANTLY DUE TO CHANGE AIR TEMPERATURE CAN BE OVERCOME BY THE USED TURBOCHARGER
FUEL/AIR RATIO
STOICHIOMETRIC MIXTURE IS A PERFECTLY BALANCE FUEL/AIR MIXTURE RICH MIXTURE MORE FUEL LESS AIR E.G 14: 1. COMBUSTIBLE FUEL AIR RATIO IS RANGE BETWEEN 8:1 TO 18:1 CONTROL MIXTURE ALLOW ADJUSTMENT OF THE FUEL/AIR RATIO FROM IDLE CUT-OFF TO FULL RICH MIXTURE. LEANING MIXTURE CAN RAISE ENGINE OPERATING TEMPERATURE LEANING MIXTURE IS NECESSARY AS ALTITUTE INCREASE BECAUSE FUEL WILL BECOME RICHER DUE TO LESS AIR AT ALTITUTE BEST POWER MIXTURE USED DURING TAKE OFF

END

01 Introduction To Recip Engine (Ignition)

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01 Introduction To Recip Engine (Ignition)

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Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

RECIP. ENGINE OVERHAUL

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

GENERAL DESIGN AND CONSTRUCTION

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

TYPE OF RECIPROCATING ENGINE

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

MAJOR ENGINE COMPONENTS

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Radial Engine Crankcase

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Bearing - To support and reduce friction between moving part:

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

STATICALLY BALANCE DYNAMIC BALANCE

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

PLAIN CONNECTING ROD

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

MASTER AND ARTICULATED ROD

Malaysian Institute of Aviation Technology

FOR TRAINING PURPOSE ONLY

FORK AND BLADE TYPE

- Consists of fork-connecting rod and blade

Malaysian Institute of Aviation Technology