UNIT-IV I.C.

ENGINES
Introduction
An engine is machine that converts heat energy into mechanical force or motion or action. There are different types of engines are used in practice such as heat engine, steam engine etc. A heat engine which converts thermal energy into mechanical work is called heat engine. In heat engine, chemical energy of the fuel (petrol, diesel etc) is first converted into the thermal energy by means of combustion of air with fuel. Then thermal energy is converted into useful work by engine mechanism.

Types of Heat Engine

1. Internal Combustion Engines (I.C. Engines) 2. External Combustion Engines (E.C. Engines) 1. Internal Combustion Engines (I.C. Engines): In this combustion of fuel-air mixture takes place inside the working cylinder. Example: Buses, Cars, Mopeds etc. 2. External Combustion Engines (E.C. Engines): In this combustion of fuel-air mixture takes place outside the working cylinder. Example: Steam engines, steam turbines, etc.

Classification of I.C. Engines

I.C. Engines are classified based upon 1. Number of Strokes: a) 4- stroke and b) 2-stroke 2. Fuel used: a) Petrol (or) Gasoline Engine c) Gas Engine b) Diesel Engine d) Dual Fuel Engine

3. Working Cycle: a) Otto Cycle (Petrol Engine) b) Diesel Cycle c) Dual Combustion Cycle 4. Fuel Supply: a) Carbureted type and b) Injection type

5. Method of Ignition: a) Spark Ignition Engine (S.I. Engine) b) Compression Ignition Engine (C.I. Engine) 6. Method of Cooling: a) Air Cooled and b) Water Cooled 7. Number of Cylinders: a) Single Cylinder and b) Multi Cylinder

8. Speed: a) Low Speed Engine b) Medium Speed Engine c) High Speed Engine 9. Valve Arrangement: a) Over Head Valve Arrangement b) Side Valve Arrangement 10. Arrangement of the Cylinder: a) Vertical Engines b) Horizontal Engines c) Radial Engines d) V-type Multi cylinder Engines e) In- line Engines f) Opposite Cylinder Engines g) Opposite piston Engines 11. Application: a) Stationary Engines b) Marine Engines c) Locomotive Engines d) Automotive Engines e) Air Craft Engines 12. Lubrication: a) Wet Sump Lubrication b) Dry Sump

I. C. Engine Terminology
1. Bore: The inside diameter of the engine is known as bore. 2. Stroke: It is the linear distance travelled by the piston in the cylinder between the extreme upper and lower portions of the piston (TDC & BDC). 3. Top Dead Center (TDC) : It is the extreme portion of the cylinder on the top. 4. Bottom Dead Center (BDC) : It is the extreme portion of the cylinder on the bottom. Note that in the vertical cylinder TDC & BDC are used. In the horizontal cylinder, the inner dead center (IDC) and outer dead center (ODC) are used.

5. Compression Ratio: It is the ratio of the volume when the piston is at BDC to the volume, when the piston is at TDC. Or Cr = Maximum Cylinder Volume / Minimum Cylinder Volume 6. Cylinder Volume (V): It is the sum of swept volume & the clearance volume. V= Vs + Vc 7. Swept Volume (Vs): It is the volume of space generated by the movement of piston from one dead center to another dead center. 8. Clearance Volume (Vc): It is the space in the cylinder, when the piston is at TDC.

I. C. Engine Parts
1. Engine Cylinder: Cylinder is round sleeve in which piston reciprocates forward and backward. Combustion of air and fuel mixture takes place. The cylinder is closed by cylinder head. 2. Piston: The piston is connected to a mechanism which slides within the cylinder. It has three grooves to accommodate piston rings. A piston is a component of reciprocating engines. It is located in a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod.

3. Piston rings: The piston rings are fitted into the grooves provided around the piston. These rings provide gas tight seal between piston and the cylinder wall to prevent leakage of fuel or gases of combustion. 4. Piston pin: Or Gudgeon pin connects the piston to the upper end of the connecting rod. 5. Valves: There are two types: (a) Inlet valve- which admits the fresh charge into the cylinder. (b) Outlet valve (or Exhaust valve): to send exhaust gases outside the cylinder. 6. Water Jacket: It is used to cool the engine. 7. Fly wheel: It is a big wheel attached on the crank shaft. It maintains the speed of the engine. 8. Connecting rod: It is attached to the piston pin. It converts the up & down motion (reciprocating motion) of the piston to a rotary motion of the crank shaft. 9. Crank shaft: It is the device used for getting power from the motion of the piston and connecting rod and this power is applied to the flywheel. 10. Cam shaft: It operates opening and closing of the engine valves. It has number of cams which are driven by crank shaft through timing gears. The function of the cam is to convert the rotary motion into reciprocatory motion. 11. Crank case: It is the bottom portion of IC engine which holds the cylinder. It also serves as pump for the lubricating oil.

Four Stroke Cycle Engines

In this section, four stroke petrol and diesel engines working principle is discussed. In this there will be 4 strokes namely Suction, Compression, Expansion/Working/Power and Exhaust Strokes. This type of engines consists of one power stroke in every four stroke or during two revolutions of the crank.

a) Four Stroke Cycle Petrol Engine:

Petrol engine is also called as Spark Ignition Engine (S.I) . It is also known as Otto Cycle . It requires four strokes of the piston to complete one cycle of operation. Principle: Petrol engine works on the principle of Otto Cycle (constant volume cycle) which was developed by a German Scientist by Nikolaus Otto in 1876. Petrol from the fuel tank goes to the fuel filter where it is filtered and then it goes to the carburetion process in the carburetor. Carburetor is device which atomises and vaporizes the fuel and mixes with the air in the varying proportions to suit the changing operating conditions of the engine. The process of breaking and mixing up of fuel with the air is called carburetion.

In the carburetor, the petrol evaporates and mixes with the air. Piston inside the cylinder slides up and down to create the vacuum. Since the pressure is more inside the cylinder compared to the atmosphere, sucks the petrol air mixture and compresses it. An electric spark is produced from the spark plug ignites the mixture. The hot combustion products push the piston down. The crank shaft connected with the piston converts the up and down motion into rotary motion. The burnt gases are sent out through exhaust valves. This is known as Otto cycle. Detailed Discussions on different strokes: 1. Suction Stroke: During the suction stroke, the inlet valve (I) opens, air and fuel mixture is sucked into the cylinder. In this fuel is petrol and air- fuel mixture is called is Charge. The piston moves downwards from TDC to BDC. During this stroke exhaust valve (E) is closed. 2. Compression Stroke: During this stroke, both the inlet and exhaust valves are closed. The charge is compressed as the piston moves upwards from BDC to TDC. As a result of compression, pressure and temperature of the charge are increased. Now the charge is ignited using the spark plug. Thus increases the pressure and temperature of the products of the combustion, but volume remains constant. These two strokes complete one revolution of the crank shaft. 3. Expansion (or) Working Stroke: During this stroke, both the valves are closed. Due to the rise in pressure, the piston is pushed down with a great force. The hot burnt gases expand pushing the piston from TDC to BDC. It is also called as Working Stroke as work is done by the expansion of hot gases. 4. Exhaust Stroke: During this stroke, the exhaust valves opens as piston moves from BDC to TDC. This movement of the piston pushes out the hot gases from the cylinder. The exhaust gases are exhausted through the exhaust valves into the atmosphere. This completes the cycle. Again the inlet valve opens and the same operations are repeated.

b) Four Stroke Cycle Diesel Engine:

Diesel engine is also known as Compression Ignition engine since the ignition takes place due to the high temperature produced during the compression of the air in the engine cylinder. Fuel is the diesel which cannot be vapourized, is injected into the cylinder in the form of fine spray with the help of fuel pump and the injector. The mixture ignites spontaneously and here no spark plug is required for

igniting the air fuel mixture. The temperature and pressure increases and this makes the piston to move. The up and down motion of piston is converted into rotary motion by the crankshaft. The working is similar to that of a petrol engine and the only difference is a fuel injector is present instead of a spark plug. In a four stroke cycle diesel engine the four strokes are completed in two revolutions for one cycle. This is known as Diesel Cycle .

Detailed Discussions on different strokes: 1. Suction Stroke: During suction stroke, the inlet valve opens and the exhaust valve remains closed. The piston travels downwards from TDC. Air is drawn in, from outside to enter in the cylinder through the inlet valves till the piston reaches BDC. The air is taken inside at the atmospheric pressure. 2. Compression: At the end of the suction stroke, both the inlet and the exhaust valves remain closed. The piston moves upwards from BDC to TDC. The air is sucked in during suction stroke and is compressed to a high pressure and temperature with a decrease in volume.

3. Expansion (or) Power stroke: Just before beginning of this stroke, fuel (diesel) is injected in the form of fine spray into the cylinder through the nozzle known as fuel injection valve . At this moment, the fuel is ignited by the hot compressed air as compression ratio of diesel engine is high (16 to 20) and it starts burning at constant pressure. The fuel is continuously injected for 20% of the expansion stroke. The ignited mixture of air and fuel (diesel) expands and forces the piston downwards from TDC to BDC. During the expansion stroke both the valves remain closed. 4. Exhaust stroke: During the exhaust stroke, the inlet valve is closed and the exhaust valve is opened. The piston is on its upstroke from BDC to TDC forcing the burnt gases out of the cylinder through the exhaust valve. This completes the cycle and the engine cylinder is ready to suck the fresh air once again.

Two Stroke Cycle Engines

In a two stroke cycle engine, one cycle is completed in two strokes of the piston in one revolution of the crank shaft. It has only ports at the cylinder walls and has no valves.

a) Two Stroke Cycle Petrol Engine:

Scavenging: In the two stroke petrol engine the exhaust gases are removed from the cylinder with the help of fresh compressed charge. This process of removing exhaust gases is called scavenging. A specific shape is given to the piston as shown, called deflector, which helps to prevent the loss of incoming charge and helps for exhausting the hot gases effectively. In the case of single cylinder engines used in scooters and motor cycles, three ports are provided namely, inlet, transfer and exhaust ports. Through the inlet port fresh charge from the carburetor is taken into the cylinder crank case. Through the transfer port, the fresh charge from the bottom of the piston is supplied to the cylinder. Through the exhaust port, the hot gases are pushed out. The two strokes consist of one upstroke (BDC to TDC) and one downward stroke (TDC to BDC) for every power stroke. The two strokes are: 1. First stroke (or) Upstroke (Compression, Suction & Ignition) 2. Second stroke (or) Down stroke ( Expansion & Exhaust) In this engine there is no separate stroke for the suction and exhaust strokes, so an alternate method is used to scavenge the cylinder. The downward motion of the piston is used to pressurize fresh charge in the crank case through the transfer port in the cylinder through the transfer port in the cylinder wall. Two stroke cycle petrol engines are small and light for their power output and mechanically very simple. The efficiency of this engine is very low and it is more polluting than 4 stroke engine. As regards to power cubic centimeter, a two stroke engine produces more power than an equivalent four stroke engine due to the advantage of having one power stroke for every 360 degree of crank shaft rotation where as 4 strokes engine requires 720 degree of crank shaft rotation to produce one power stroke. FIRST STROKE:

Initially piston is at its BDC. At this stage air fuel mixture has already filled in the cylinder. When the piston moves from BDC to TDC, the transfer port and exhaust port are closed. Due to the movement of the piston towards TDC, the mixture or charge in the cylinder is compressed. At the same time the upward movement of the piston creates a partial vacuum in the crank case and a fresh charge is drawn into the crank case through the inlet port which is in open condition.

SECOND STROKE: An electric spark is produced by the spark plug just before the completion of compression stroke over the compressed charge. Thus the charge is ignited in the combustion chamber. Due to the combustion of air petrol mixture the pressure and temperature of hot gas produced increases and this increased pressure moves the piston downwards and the work is done by the hot gas. During the downward motion of the piston the inlet port is covered by the piston and the charge already passed to the crank case is now compressed. During this process, the exhaust port is opened first and then the transfer port will be opened. When the exhaust port is opened, the expanded gas escapes through the port. The compressed air- petrol mixture passes through the transfer port and fills the upper portion of the cylinder due to the deflector on the top of the piston. Simultaneously, the burnt exhaust gas is forced out through the exhaust port that remains open.

Note: Deflector deflects the fresh charge to the top of the cylinder expelling the burnt gases through the exhaust port. Then the piston is pushed down wards and the cycle is repeated.

b) Two Stroke Cycle Diesel Engine:

The two stroke cycle diesel engine also uses one upstroke and one down stroke for every one power stroke. This also does not contain suction and exhaust stroke. So an alternate method is used to scavenge the cylinder. The downward motion of the piston is used to pressurize fresh air in the crank case, which is then blown to the cylinder through transfer port in the cylinder wall. Two stroke cycle diesel engines are bigger and heavier for their power output compared to petrol engines. They are mechanically simple compared to 4 stroke engines. The efficiency of this engine is very low. Working Principle: FIRST STROKE: When the piston moves from BDC to TDC the transfer port is closed and exhaust port is closed. During the movement of piston from BDC to TDC, the pressure in the crank case decreases as the vacuum is created so that fresh air is drawn into the crank case through the inlet port. The diesel fuel is forced under pressure in the form of fine spray to the engine cylinder through the fuel injector nozzle into the hot compressed air just before the end of compression. At this moment, the

temperature of the compressed air is high enough to ignite the fuel. The temperature and pressure of the products of combustion are increased suddenly. The pressure of the hot gases produced moves the piston downwards and the work is done by the hot gases. When the exhaust port is opened due to downward motion of the piston, the expanded gas starts to escape through the exhaust port. SECOND STROKE: when the piston moves down from TDC to BDC during the power stroke, it initially opens the exhaust port. The cylinder pressure drops as the expanded gases of the combustion come out from the cylinder. Next to the opening of exhaust port, the piston opens the transfer port and air partially compressed in the crank case enter the engine cylinder from the crank case. This air moves up to the top of the cylinder due to the deflector on the top of the piston. The entry of fresh air pushes out the remaining exhaust gases through the exhaust port at the same time fuel is injected and this cycle is repeated.

COMPARSION BETWEEN FOUR STROKE AND TWO STROKE CYCLE ENGINE SL.NO FOUR STROKE The cycle is completed in two revolutions of the crankshaft, thus 4 strokes of the piston One power stroke is obtained for every two revolutions of the crank shaft For a given size of the engine power is produced is less since only one power stroke is obtained for two revolutions of the crank shaft Heavy flywheel is needed as the turning moment is not so uniform because of only one working stroke for two revolutions of crank shaft It contains valves and valve mechanisms Thermal efficiency is high Less rate of wear and tear Engine is heavy and bulky for the same power developed Less cooling and lubrication requirement Four stroke engines are used where efficiency is of great importance TWO STROKE The cycle is completed in one revolution of the crank shaft One power stroke is obtained for every one revolutions of the crank shaft For a given size of the engine power is produced is more since only one power stroke is obtained for one revolution of the crank shaft Light flywheel is needed as the turning moment is more uniform because of only one working stroke for each revolutions of crank shaft It has ports instead of valves Thermal efficiency is low Higher rate of wear and tear Engine is light and compact for the same power developed Higher cooling and lubrication requirement Two stroke engines are used where low cost and light weight are of prime consideration.

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COMPARSION BETWEEN PETROL ENGINE AND DIESEL ENGINE SL.NO PARTICULARS PETROL ENGINE DIESEL ENGINE By compressed air (C.I. Engine) Air alone is admitted and fuel is injected High (16 to 20) Through fuel injector Diesel Cycle (Constant pressure cycle) Low speed 1500 rpm Difficult More More Less Fuel injection does not require frequent maintenance More Buses, Tractors, Trucks etc. More Due to heavy weight of engine and more vibration, vehicle chassis is made very strong

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Fuel Ignition Charge during suction stroke Compression ratio Fuel Admission Cycle of operation Engine Speed Engine starting in cold weather Engine cost Fuel Consumption Fuel Cost Maintenance Weight Uses Vibration and Noise Vehicle Chassis

By spark plug (S.I. Engine) Air + Fuel mixture Low (6 to 8) Through carburetor Otto Cycle (Constant Volume Cycle) High speed about 3000 rpm Easy Less Less More Requires change of spark plug after few thousands kilometer Less Automobiles, airplanes Almost nil Due to less weight of engine and smooth working vehicle chassis is not made very strong

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