INDEX

Ex.No DATE NAME OF THE EXPERIMENT Page MARK SIGN

l Piston Engine - Identification of Components

2 Jet Engine - Identification of Components
3 Disassembly of a piston engine & Its
Components
4 Cleaning and visual Inspection of piston
engine components
5 Non-destructive testing checks of Piston
enl!;ine.
6 Reassembly of a piston engine & Its
Components
7 Cleaning and visual Inspection of engine
components - Jet
8 Dimensional checks of components - jet

9 Non-destructive testing checks of Jet engine.

10 Disassembly/ Reassembly of a jet engine

I
EXP NO 1 PISTON ENGINE - IDENTIFICATION OF COMPONENTS

AIM: To identify the components of piston engine.

PROCEDURE:
Engine is a device which converts chemical energy of fuel into thermal and to
mechanical energy. A piston engine is a heat engine that uses one or more
reciprocating pistons to convert pressure into a rotating motion. In most types, the
linear movement of the piston is converted to a rotating movement via a connecting rod
and a crankshaft mechanism.

MAJOR COMPONENTS

CYLINDER
A cylinder is the central working part of a reciprocating engine the space in which a
piston travels. Multiple cylinders are commonly arranged side by side in a bank, or
engine block, which is typically cast from aluminum or cast iron before receiving
precision machine work.

PISTON
A piston is a component of reciprocating engines, reciprocating pumps, gas
compressors and pneumatic cylinders, among other similar mechanisms. It is the
moving component that is contained by 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. In a pump, the
function is reversed and force is transferred from the crankshaft to the piston for
the purpose of compressing or ejecting the fluid in the cylinder. In some engines,
the piston also acts as a valve by covering and uncovering ports in the cylinder
wall.
CRANKSHAFT

The crankshaft, sometimes casually abbreviated to crank, is the part of an

engine that translates reciprocating linear piston motion into rotation. To
convert the reciprocating motion into rotation, the crankshaft has "crank throws"
or "crankpins", additional bearing surfaces whose axis is offset from that of the
crank, to which the "big ends" of the connecting rods from each cylinder attach.

CAMSHAFT

In internal combustion engines with pistons, the camshaft is used to operate

poppet valves. The cams force the valves open by pressing on the valve, or on
some intennediate mechanism as they rotate. The relationship between the
rotation of the camshaft and the rotation of the crankshaft is of critical
importance. Since the valves control the flow of the air/fuel mixture intake and
exhaust gases, they must be opened and closed at the appropriate time during
the stroke of the piston. For this reason, the camshaft is connected to the
crankshaft either directly, via a gear mechanism.

CONNECTIONG ROD

In a reciprocating piston engine, the connecting rod connects the piston to the
crank or crankshaft. Together with the crank, they fonn a simple mechanism
that converts linear motion into rotating motion.

VALVES
In general a valve is a device for regulating or determining the check on the flow of a
liquid or a gas by a movable part which opens or closes into a passage. The main purpose
of a valve in IC engine is to open and close parts which are into the combustion chamber
of the engine namely intake and exhaust ports.

PROPELLERS
They are essential aircraft parts that provide the necessary thrust for moving the aircraft.
The propeller is connected to the engine by means of a shaft. The propeller consists of
two or more blades and a central hub to which the bladesare attached.

RESULT: Thus, the identification of piston engine component is done.

 EXP NO l: JET ENGINE IDENTIFICATION OF
COMPONENTS

AIM: To identify the Jet engine components

PROCEDURE:

The various components of jet engine is as follows:

Compressor - The compressor is the first component in the engine core. The compressor is
made up of fans with many blades and attached to a shaft. The compressor squeezes the air
that enters it into progressively smaller areas, resulting in an increase in the air pressure. This
results in an increase in the energy potential of the air. The squashed air is forced into the
combustion chamber.

Combustor - In the combustor the air is mixed with fuel and then ignited. There are as many
as 20 nozzles to spray fuel into the airstream. The mixture of air and fuel catches fire. This
provides a high temperature, high-energy airflow. The fuel burns with the oxygen in the
compressed air, producing hot expanding gases. The inside of the combustor is often made of
ceramic materials to provide a heat-resistant chamber. The heat can reach 2700°.

Turbine - The high-energy airflow coming out of the combustor goes into the turbine,
causing the turbine blades to rotate. The turbines are linked by a shaft to turn the blades in the
compressor and to spin the intake fan at the front. This rotation takes some energy from the
high-energy flow that is used to drive the fan and the compressor. The gases produced in the
combustion chamber move through the turbine and spin its blades. The turbines of the jet
spin around thousands of times. They are fixed on shafts which have several sets of ball-
bearing in between them.

Nozzle - The nozzle is the exhaust duct of the engine. This is the engine part which actually
produces the thrust for the plane. The energy depleted airflow that passed the turbine, in
addition to the colder air that bypassed the engine core, produces a force when exiting the
nozzle that acts to propel the engine, and therefore the airplane, forward. The combination of
the hot air and cold air are expelled and produce an exhaust, which causes a forward thrust.
The nozzle may be preceded by a mixer, which combines the high temperature air coming
from the engine core with the lower temperature air that was bypassed in the fan. The mixer
helps to make the engine quieter

Other components includes:

Reduction gear box
Air Intake Casing
Bearings (Support Housing)
RESULT:

The identification of Jet engine component is completed

 J!ISASSEMBLY OF PISTON ENGINE & ITS COMPONENTS

To dismantle a piston engine and study its components.

rooLS REQUIRED:
o Special tools for notching crank shaft.
o Universal socket for spark plug
o Selected spanner no: 6-19
o Ring spanner no: 6-22
o Adjustable spanner
o Plier, cutter and screwdriver
o Value depression tool
o Crow foot spanner

PROCEDURE:
I. Remove controls completely with universal joints.
2. Remove air scoop, plug leads, distribution covers.
3. Remove induction system with carburetor.
4. Unscrew push rod ball socket from rockers.
5. Take out push rod and push rod covers.
6. Remove cylinder baffle plate.
7. Remove cylinder.
8. Remove piston rings.
9. Extract gudgeon pin, air clip.
10. Withdraw gudgeon pin and piston. Remove magnetos.
11. Remove gearbox with timing gear cover.
12. Turn the engine cover on its stand. Remove starter.
13. Remove adaptor, thrust bearing cover and top cover.
14. Detach big and bearing caps. Withdraw connecting rod.
15. Remove main, intermediate bearing caps.
16. Lift crankshaft. Unscrew idle gear hub bolt.
17. Draw off gear wheel. Remove magneto drivers.
18. Unscrew camshaft gagging the gear.
19. Remove camshaft rear bearing bush.
20. Withdraw camshaft. Remove tappet and guides.
21. The parts are kept for visual inspection.

RESULT:
Thus, the disassembly of piston engine is carried according to instructions in the
manufacturer's maintenance manual.
 PISTON ENGINE - CLEANING, VISUAL INSPECTION
OF PISTON ENGINE

To perform cleaning, visual inspection for the following piston engine components.

I. Cylinder head
2. Cylinder barrel
3. Crankshaft
4.Piston assembly

TOOLS REQUIRED:

i. Petroleum solvent
ii. Magnifying Glass

PROCEDURE:

1) CYLINDER HEAD

Cleaning:
Clean the cylinder head with petroleum solvent
Visual Inspection:
I. Inspect the cylinder head visually using magnifying glass and a
powerful light source for loose, scored pitted or damaged valve seat.
2. Similarly ,inspect the cylinder head also.

2) CYLINDER BARREL

Cleaning:
Clean the cylinder barrel with petroleum solvent.

Visual Inspection:

Inspect the barrel visually for general flaws, cracks and conditions using magnifying
glass.
3) c~BAFI'
CleaJllBg•
ciean the cylinder barrel with petroleum solvent.

ViSUal Inspection:
Check for cracks, corrosion, pitting etc by magnifying lens

) pJSTON ASSEMBLY:
4

Cleaning:

Check for completeness of the piston assembly and clean it by dipping in

petroleum solvent

v15ual Inspection:
l. Examine the piston surface for excessive pitting, cavities or surface distortion
2. Check the piston rings, lands and piston grooves, piston pin holes and
holebases for any damages.

RESULT:

Thus the cleaning and visual inspection of piston engine component has been completed
~-0 SNON. DESTRUCTIVE TESTING CHECKS OF PISTON ENGINE

~ : To find the crack or invincible

using various NDT Tee 1ques
hn
. defect in the components and internal detiect

DYE PENEJ'RANT METHOD

~TEJUALS REQUIRED:

I. ))ye penetrant
2.veveloper
3 Re111over
4: Ultra Violet Lamp (UV Lamp)

pROCEDURE:
1. Component to be cleaned with solvent thoroughly before checking
2. Apply Die Penetrant .solution (Aerosol Container) on the cleaned surface
evenly and allow 20 mm.to get dry
3. Apply developer to make the penetrant to spread to all the surface and allow IS
min.
4. By using remover over the surface the excess penetrant will be removed and
penetrant which is penetrated will remain in the crack if any
5. With the help of UV Lamp, we can identify the presence of crack

This method is useful to identify the presence of defect over the surface only

MAGNETIC PARTICLE INSPECTION

MATERIALS REQUIRED:

I. Magnetic particle tester

2. Magnetic powder
3. UVlight
4. Test block

PROCEDURE:

1. Induce a magnetic field in the specimen

2. Apply magnetic particles to the specimen's surface
3. View the surface, looking for particle groupings that are caused by defects
4. Demagnetize and clean the specimen

RESULT:
Thus the NDT checks of the piston engine components are carried out as per
instructions given in manufacturer's maintenance manual.
 EXPNO6 REASSEMBLY OF PISTON ENGINE

~: . . ft . .
To re-assemble the piston engme a er mspect10n and dimensional checks.

fOOLS REQUIRED:
a. Special universal socket for spark plug
b. Setspanners6'-19'
c. Ring spanners 6'-22'
d. Adjustable spanner
e. Pliers and cutters
f. Screwdriver different sizes

g. Hammer
h. Value depression tool
i. Crow foot spanner

PROCEDURE:
a. Insert the tappet and the guides in the crank case.
b. Fix the camshaft after positioning bearing bush.
c. Fix the magneto drive gear.
d. Fix the idle gear and screw the hub bolt.
e. Fix the crankshaft and position the bearing caps.
t: Fix the connecting rod and the bearing caps.
g. Position the top crankcase and then tighten all bolts and nuts.
h. Fix the gearbox with timing gear cover.
i. Fix the magnetos.
j. Fix the position in the connecting rod.
k. Assemble the piston rings on the piston groove and insert the cylinder
over piston and tighten all cylinder large nuts.
L Fix the cylinder baffle plates.
m. Position the push rod covers and push rods.
 Fix the rocker shafts.
Jl.
fix the induction system and carburetor.
0,
Fix the air scoop, plug heads wit~ distribution cover.
P·
Fix the carburetor controls with universal rods.
q.
Fix the starter and other accessories.
r.
·x the spark plug in cylinder head bush and tighten t
s. F' ds o connect torques and
connect the plug lea .
t Fix the rocker covers.

jus, the piston engine is reassembled as per maintenance manual

 DIMENSION CHECK OF COMPONENTS

nrrv out the dimensional checks of Piston engine and Jet engine component
To C<>1•;

1o<>LS REQUIRED:
_ vernier Caliper
1
. screw Gauge
2
3. Ruler
4_ Micrometer .
S. Dial gauge and indicator
6. Vernier caliper
7. Telescopic gauge
s. Plug gauge
9. Magnifying glass
IO. Screw Gauge
PISTON ENGINE

PROCEDURE

CYLINDER HEAD
1. Check internal dimensions of intake and exhaust valves.
2. Check diameter and roundness of guide bore with gauge.
3. Check wear and tear in rocker arm bush.

CYLINDER BARREL
Check for inner and outer bore diameter
I. Maximum clearance between piston skirt and cylinder is 0.021"
2. Maximum taper of cylinder wall in 0.018".
3. Maximum ovality is 0.018".

CRANKSBAFf
Check the length of the crank shaft
Check for the pin , rib and bearing diameter

PISTON ASSEMBLY
1. Check inside diameter of piston pinhole (0.03"-0.004").
2. Check clearance between piston skit and cylinder and piston diameter topand
bottom (0.021'').
Check outside diameter of piston pin against inside diameter of holein
piston (0.0002"-0.001 ").
 Measure fit between piston and plug and checks outside
4· diameter of plugs (0.0002"-0.00 l ").

coNNECTING ROD
1. Check the length of the connecting rod
2. Check for small end internal and external diameter
3. Check for the distance between small end center to big end
centre

CAMSHAFT
1. Check for the cam diameter and cam shaft diameter
2. Check for the cam thickness and cam length

JET ENGINE

PROCEDURE

COMPRESSOR INTAKE:

1. Check the inner and outer diameter , bore diameter using Vernier caliper
2. Measure the flange thickness using screw gauge
3. Find the length of the compressor

TAIL RACE
1. Find out the outside, inside and hole diameter of the tail race.

ANNULAR COMBUSTION CHAMBER

1. Find out the outer diameter of the body

2. Measure the outer diameter of the assemble
3. Note the Height of the assembly.

COMBUSTION CHAMBER CASING

1. Find out the inner, outer body diameter

2. Check the thickness of the flange
3. Find the fitting hole diameter using vernier caliper
TURBINE

1. Check the length of the shaft

2. Find the distance between two blades
3. Measure the thickness of the blade

NOZZLE

1. Find the length of the Nozzle and exhaust cone length using Vernier caliper.
2. Check the thickness of the flange.

RESULT:

Thus, the dimensional check of piston engine and jet engine component has been carried
out
 EXPNO9 NDT CHECK OF JET ENGINE

AIM:
To find the crack or invincible defect in the components and internal defect
using various NDT Techniques

DYE PENETRANT METHOD

MATERIALS REQUIRED:

1. Dye Penetrant
2. Developer
3. Remover
4. tntra Violet Lamp (UV Lamp)

PROCEDURE:

1. Component to be cleaned with solvent thoroughly before checking

2. Apply Die Penetrant solution (Aerosol Container) on the cleaned surface
evenly and allow 20 min.to get dry
3. Apply developer to make the penetrant to spread to all the surface and allow
15min.
4. By using remover over the surface, the excess penetrant will be removed
andpenetrant which is penetrated will remain in the crack if any
5. With the help of UV Lamp, we can identify the presence of crack

This method is useful to identify the presence of defect over the surface only

MAGNETIC PARTICLE INSPECTION

MATERIALS REQUIRED:

Magnetic particle tester

Magnetic powder
tJV light
block
PROCEDURE:

1. Induce a magnetic field in the specimen

2. Apply magnetic particles to the specimen's surface
3. View the surface, looking for particle groupings that are caused by defects
4. Demagnetize and clean the specimen

RESULT
Thus the NDT checks of the piston engine components arecarried out as per
instructions given in manufacturer's maintenance manual.
EXP NO 10 DISASSEMBLY & REASSAMBLY OF\PISTON)ENGINE

AIM:

To disassemble and reassemble the turbojet engine in a proper sequence.

TOOLS REQUIRED:
0
¼ *1/4 BS or 12-13 set spanner
0
10-11 set of ring spanner
D
8-9 set of ring spanner
° C-spanner
°
0
Common screw driver
Ball peen spanner
0
Plier and side cutter
DISASSEMBLY PROCEDURE:

1. Loosen the fine nuts using appropriate spanner and remove the inlet case from
the accessory case.
2. Loosen the 10 nuts using no 10-11 set of ring spanner and detach air casing from
compressor case.
3. Remove 15 bolts using no 8-9 set spanners. Detach compressor casing from diffuser.
4. Loosen retaining nut with C-spanner and remove centrifugal impeller.
5. Remove front ro_ller bearing and the sleeve.
6. Remove 2 ignition connection and fuel turners from the combustion chamber outer
case.
7. Now take out the turbine along with the shaft from the rear side.
8. Take out the combustion chamber.
9. Loosen the bolts and nuts from the exhaust pipe flange and detach the exhaust
pipe from the combustion chamber.
10. Loosen the clamps of the propelling nozzle and disconnect the nozzle from the
exhaust pipe.
11. Keep all the removed parts separately in the cleaned tray in sequence so that
there is no possibility of mixing with each other.
12. Wherever blanking is required, blank it and place identification slips .

.REASSEMBLY PROCEDURE:
1. Remove all blanking and clean them thoroughly.
z. Attach air intake case front accessory by tightening all the 5 nuts using 12-13 set
 hammer
3. Attach air intake case rear to the compressor case by tightening all the nuts
using 10-11 set ring spanner
4. Now assemble the compressor in the front and turbine at the rear of the shaft by
inserting the shaft in front of the diffuser case.
5. Enclose the combustion chamber outer case over the flame tube and tighten
all the 15 bolts.
6. Encage 2 ignition and 5 fuel burners connection and tighten the nuts.
7. Encage the exhaust pipe to combustion chamber outer case flange and tighten all
the bolts and nuts.
8. Attach the propelling nozzle to the rear side exhaust pipe and together with the
clamp.

RESULT:
Thus, the turbojet engine is disassembled and then reassembled as per the maintenance
manual instruction