IC Engines

Engines
• Device which transforms one form of
energy into another.

HEAT ENGINES
• Engine which converts thermal energy into
mechanical energy
 Heat Engines

External Combustion Internal Combustion

Engines Engines
 External Combustion Engine (EC)

A working fluid is used for transferring the heat of

combustion to the engine where the heat of
combustion is converted into mechanical energy..
Heat of combustion Mechanical energy
Steam Turbine
Steam from boiler
(Mechanical energy)

Example (Electrical energy)

Steam turbines and Steam boilers
• Work fluid is recycled an reused

• Bulky in size

• Not desirable for mobile plants

 Internal Combustion Engine (IC)

Air is taken from the atmosphere and the combustion

of fuel and air occurs in the engine which converts
thermal energy into mechanical energy…
Air Fuel Mixture Combustion Work

Chemical Energy Thermal Energy

Mechanical energy
Example
Automobiles, Ships and slow speed Aircrafts
• Combustion of fuel and oxidizer (air) in
combustion chamber

• Gas with high temp and pres is created in

this exothermic reaction

• This gas is allowed to expand and will

move engine parts (piston)

• High thermal efficiency

 ENGINE COMPONENTS
• Cylinder
• Cylinder head
• Piston
• Inlet and exhaust valves
• Inlet manifold
• Exhaust manifold
• Connecting rod
• Crank
• Flywheel
 Cylinder

• Cylindrically shaped container

• Piston reciprocates inside it
• Guides the piston
• Closed by cylinder head & piston
• Combustion happens inside cylinder
• And Power is developed
• A thin layer of oil provides lubrication
• Made of high grade aluminum alloy

• Lined with sleeves or liners of some

harder metals to resist wear

• Liners also help to withstand high

temperature generated inside cylinder.
 Cylinder Head
• Made of cast iron

• Acts as a cover to close the cylinder

• Provisions for inlet and exhaust valves

• Spark plug for petrol engines

• Fuel injector for diesel engines

 Cylinder head
top view

• 2 inlet and 1 exhaust

valves
 Piston
• Close fitting member reciprocates inside
the cylinder
• Combustion chamber is formed between
piston and cylinder head
• Purpose is to transfer force frm expanding
gas in the cylinder to the crankshaft via
connecting rod
• Made of aluminium alloy
 Inlet and Exhaust Valves
• Provided in cylinder head
• Admission of fresh air’
• Rejection of burnt gases
• Usually kept closed by valve springs
• Openings regulated by cam
• This cam is keyed to the shaft called
camshaft and is connected to the engine
shaft
 Inlet manifold
• Metal tube connecting the intake system
to the inlet valves
• Air or air fuel mixture enters through the
inlet manifold
• Primary function is to evenly distribute the
combustion mixture to each intake port in
the cylinder head
 Exhaust Manifold
• Tube connecting exhaust system to the
exhaust valve of the engine
• Collects engine exhaust from multiple
cylinders and delivers to the exhaust pipe
• Normally aims at offering low resistence to
air flow.
 Connecting Rod
• Interconnects piston and crank
• Transmits gas force from piston to
crankshaft
• Transforms reciprocating motion into
rotary motion
 Crankshaft
• Rotating member
• Receives power from connecting rod
• Connects to a flywheel at one end to
reduce pulsations
• Connected with torsional dampers to
reduce the torsion effect caused by
cylinders at farthest ends
 Flywheel

• Heavy wheel mounted on crank shaft

• Maintains angular velocity of crank shaft
constant
• Mechanical device with significant moment
of inertia to store rotational energy
• Resist changes in speed when a
fluctuating torque is applied
 Functions of flywheel

• Brings mechanism out of dead centers

• Stores energy required to rotate shaft
during preparatory stokes
• Makes crankshaft rotation uniform
• Facilitate starting of engine and to
overcome short term loads
 Nomenclature
Cylindrical bore
• Inside dia of cylinder
Top dead center (TDC)
• Extreme position of the piston at the top of
the cylinder
Inner dead center (IDC)
• Top dead center in case of horizontal
engines
Bottom dead center (BDC)
• Position of the cylinder when is farthest
from TDC
Outer dead center (ODC)
• BDC in horizontal engines
Stroke
• The travel of piston from one dead center
to another
Stroke length
• The distance between two dead centers
Swept volume (Vs)
• The volume of cylinder in between two
dead centers
Clearance volume (Vc)
• The volume of cylinder between TDC and
cylinder head
Compression ratio (r)
• The ratio of the volume of the cylinder
between the bottom dead center and the
cylinder head to the clearance volume
 Classification of IC Engines
• Based on
1. Ignition system
2. Type of fuel
3. Working cycle
4. Number of strokes
5. Application of engine
6. Cooling system
7. Speed of the engine
8. Number of cylinders
9. Cylinder arrangement
 1.Based on ignition systems
• Based on the ignition system employed for
igniting the charge in the engine cylinder
• 1.a.Spark ignition engines

• 1.b.Compression ignition engines

 1.a.Spark ignition engines (SI)
• Electric spark is used to ignite the fuel air
mixture
• Petrol engines and gaseous fuel engines
belongs to this category
 1.b. compression ignition (CI)
• Air is compressed to high temp and pres
and fuel is injected in the form of spray
• Fuel catches fire due to the high temp and
pres.
• Diesel engines belongs to this category
 2. Based on the type of fuel
• 2.a gas engines – eg. methane
• 2.b. petrol engines
• 2.c. diesel engines
• 2.d. dual fuel engines
- Gaseous fuel or highly volatile fuel is
mixed with air during suction stroke and a
viscous fuel is injected at the end of
compression stroke
 3. Based on working cycle
• Otto engine
• Diesel engine
• Dual combustion engine
- Works on dual combustion cycle, a
combination of both Otto and diesel cycle.
 4. Based on number of strokes
• Four stroke engines
- One cycle of operation is completed in 4
strokes of piston – ie. In two revolution of
crank shaft
• Two stroke engine
- One cycle of operation completed in 2
strokes of piston – ie. In each revolution of
crankshaft
Four stroke engine
Two stroke engine
 5. Based on application

• 5.a. stationary engines – power plants

• 5.b. mobile engines - automobiles

 6.Based on cooling system
• 6.a. Air cooled engines – heat is directly
dissipated into air
• 6.b. Water cooled engines – heat is
removed by circulating water through
water jackets running through the engines
Air cooled engine
 7. Based on speed of engine

• 7.a. Low speed engines – up to 350 rpm

• 7.b. Medium speed engines –

350 – 1000rpm

• 7.c. High speed engines –

above 1000 rpm
8.Based on number of cylinders
• 8.a.Single cylinder engines –

• 8.b.Multi cylinder engines

 9. Based on cylinder arrangement
• 9.a. Vertical engines
• 9.b. Horizontal engines
• 9.c. In- line engines
• 9.d. V – engine
• 9.e. Radial engine
• 9.f. Opposed cylinder engine
 9.a. Vertical engine
• The axis of the cylinder is vertical
 9.b. horizontal engine
• Axis of cylinder is horizontal
 9.c. In - line engine
• All cylinders are arranged linearly
transmitting power to a single crankshaft
 9.d. V engine
• Two cylinders are kept at an angle forming
shape of letter v an utilize the same
crankshaft
 9.e. Radial engine
• Cylinders are placed radially and equally
spaced around a common crankshaft
 9.f. Opposed cylinder engine
• Two cylinders are placed in opposite sides
of a common crankshaft
 Diesel engines
• Rudolph diesel
• Operates on theoretical cycle called diesel
cycle
• Operate on four stroke or two stroke
 Diesel cycle
• Constant pressure cycle
 4 stroke diesel cycle
• One cycle of operation is completed in
four strokes of the piston
• Two revolutions of the crankshaft
• The 4 strokes are :-
1. Suction stroke
2. Compression stroke
3. Expansion or working stroke
4. Exhaust stroke
 Suction stroke
• Piston moves from TDC to BDC
• Inlet valve is in open
• Air is drawn inside the engine
cylinder
• Exhaust valve is closed
• Pres inside cylinder is less than
Atmos pres
 Compression stroke

• Both valves are closed

• Air sucked in is trapped
in the cylinder
• Piston moves towardsTDC
and Compress the trapped air
To high pres(35 bar) and
Temp(600Oc)
 Expansion stroke
• Power stroke
• Fuel is injected as fine spray using fuel injector
at the end of compression stroke
• Fuel burns at const pres, theoretically & pushes
the piston down
• Fuel supply is cut off at point 3
• High pres gas expand up to point 4 doing wrk
on piston
 Exhaust stroke

• Piston moves from BDC to TDC

• Exhaust valve is open
• Burn gas escapes
• Pres inside cylinder is slightly greater than
atmos pres
 4 stroke SI Engine
• Heat supplied and rejected at const
volume
• Works on petrol
• Air and fuel is mixes in carburetor
• It enters the combustion chamber
• Air fuel mixture is ignited using spark plug
• compression ratio between 6 – 11
 Suction Stroke
• Piston moves from
TDC to BDC
• Inlet valve is open
• Exhaust valve is closed
• Air and fuel is mixed in carburetor and is
sucked into cylinder
Compression stroke
• Both valves closed
• Piston moves from bdc to tdc
• Adiabatic process
• Air fuel mixture is compressed
• Just b4 end of comprsn spark is
produced and mixture is ignited at
const volume
 Power stroke
oBoth valves remain closed’
oCombination of isochoric heat addition
and adiabatic expansion
oPiston moves down from TDC to BDC
oThis stoke provides the power for al the
other preparatory strokes
oWork is done on the piston
oExhaust valve opens at the end of the
stroke
 Exhaust stroke
• Exhaust valve is open
and inlet valve closed
• Piston moves from
BDC to TDC ejecting
the burnt gases.
Two stroke engines
 Intake – first stroke
•When the piston moves up Air / air fuel
mixture is drawn into the chamber due
to vacuum
•During this time the transfer port and
the exhaust port will remain closed
•The inlet port will be unveiled open by
the piston
 Transfer / exhaust
second stoke
•As the piston moves down it
uncovers the transfer port and
the compressed air rushes into
the combustion chamber from
the crankcase
•This will also eject the exhaust
gases out through the exhaust
port
•Some of the fresh mixture/ air
also will be lost

•When the piston moves down the inlet port is closed and
the air/mixture trapped inside the crankcase is
compressed
Compression – first stroke
•The piston then rises and compress the
air/mixture
•Flywheel is used to gain momentum for the
piston to rise
•At the same time another intake is
happening beneath the piston
Power –second stroke

When the piston reaches top the

air/mixture is burned by using fuel
injector/spark plug respectively
And as a result the piston moves
down
Advantage
• More powerful
• Light weight
• Simple construction
• Used in chain saws, snow mobiles….
Disadvantage
• High pollution rate
Comparison factors of SI and CI
Engines
S.I engine C.I Engine

1.Intake

air and petrol is admitted during Air alone is admitted during sution
suction stroke stroke

2. Fuel ignition

by spark plug By the compressed hot air

3. Cycle of operation

otto cycle( const volume cycle) Diesel cycle ( const. pres cycle)

4. Compression ratio

Low (6-10) High(16-19)

S.I C.I

5. Fuel admission

Through carburetor Through fuel injector

6. Engine speed

High speed ( up to 5000rpm) since Low speed( up to 3500 rpm)

petrol engine is lighter

7. Weight

Low weight due to lesser compression Sturdier and heavier due to high
ratio compression ratio

8. Cold starting

Ease Greater cranking to overcome the

higher compression ratio due to cold
air
9. Fire hazard

Highly volatile and greater fire hazard Less volatile and reduced risk

10. Engine cost

Less costly More costly

11. Fuel consumption

more less

12. Maintenance cost

Less High

13. Space

Less more

14. Vibration and noise

Low High due to high operation pressure

Working cycle

Fuel
Method of fuel
introduction
Method of fuel
ignition
Fuel economy
Compression
ratio
Weight

Initial cost
Maintenance
cost
Comparison factors of two stroke
and four stroke
Four stroke cycle engine Two stroke cycle engine

1.One power stroke per two rev of One power stroke per single rev of
crank shaft crank shaft

2. More space for same power Less space for same power

3. Requires inlet and exhaust valves Requires inlet, exhaust and transfer
ports

4.Heavier flywheel is required Lighter fly wheel

5. Lubrication is essential due to Less lubrication due t ports and low

frequent movement of valves wear an tear
6. Water cooled engines mostly Air cooled

7.air/air fuel mixture is completely Lower efficiency due to escape of fresh

utilized thereby higher efficiency charge and also due to incomplete
removal of burnt gases

8. Lower fuel consumption per horse Higher fuel consumption per horse
power power

9. Heavy structure Compact and light

10. More costly Less costly

11. Less polution More polution

 Air system for SI Engine

Engine
Atmos Air Carbur Silenc
cylinde
air filter etor er
r
 Fuel system for SI Engine

Engine
Fuel Fuel Fuel Carbur
cylinde
tank pump filter etor
r
 Diaphragm pump
• Used to pump fuel to carburetor from fuel
tank
• Actuated by cam
• Cam is connected to engine camshaft
• Consists of high grade cotton diaphragm,
impregnated with synthetic rubber
• Movement of diaphragm sucks fuel from
tank and pushes it to carburetor
1. Cam
2. Rocker arm
3. Link
4. Diaphragm
5. Diaphragm spring
6. Pump chamber
7. Inlet valve
8. Outlet valve
9. Outlet pipe
10. Spring
• As the cam rotates the rocker arm pushes
the diaphragm in or out
• The down ward movement of diaphragm
sucks fuel from tank through strainer
• And the up ward movement pushes the
fuel to carburetor
• Rocker arm spring provides constant
contact with cam
• When the float chamber is filled further
pumping is stopped by closing the outlet
pipe of pump
 Carburetor
• Used to produce a homogenous air fuel
mixture
• Produce the desired air fuel ratio at all
speeds and loads
Principle
• When a volatile fuel is placed in high
velocity air stream, the fuel gets vaporized
• Invented by Karl Benz
 Consist of
Parts 1. Jet
2. Venturi tube
3. Float chamber
4. Throttle valve
5. Float
6. Float needle
7. Air vent
• Petrol is pumped into
float chamber using a
fuel pump
• Level is maintained
constant by float
• It will close or open the
inlet based on fuel level
 Working
• During suction stroke air flows through the
venturi tube
• The velocity is increased around the jet and
hence pressure reduced
• Float chamber have atmos pres due to air
vent
• Pres diff, force the fuel to flow tru the jet
• Jet is placed 1.5 mm higher than the normal
float level to avoid fuel wastage at idle and
stopped condition
• Throttle valve
control the speed
and power of
engine
• More the throttle
valve closed lesser
the air flow due to
higher hindrance
 Fuel system for CI Engine

Low High
Fuel Filter Fuel Engine
filter press pres
tank injector cylinder
pump pump
 injection

Solid
Air injection
injection

Air High power

pump
compressor and wgt
 Diesel fuel pump
• Two major parts
1. pumping element ( plunger and barrel)
2. delivery valve and seating
• Plunger reciprocates inside the barrel
using a cam and tappet mechanism
• Barrel have an inlet port and overflow port
• When the plunger is at BDC it unveils both
ports
• Hence fuel enters the barrel
• As the plunger moves up, it closes both
ports and the fuel is trapped inside
• The pressure of the trapped fuel increases
as the plunger moves up
• When it exceeds the spring force of the
delivery valve, the valve is opened and the
fuel is pushed
• At a particular position the helical groove
opens the overflow port and the pressure
inside the barrel drops, closing the delivery
valve
• The plunger is rotated using a rack and
there by the stroke length of plunger can
be adjusted
• There by the fuel quantity is adjusted
• When the stopper is pulled the plunger
turns and opens the port there by stopping
the pump
 Fuel injector
• Purpose is to inject a small volume of fuel
into fine spray and make each drop into
contact with sufficient oxygen for complete
burning
Ignition system for petrol engine
 Battery ignition system
• Spark is produced by spark plug
• Spark is produced by a high volt electric
discharge between spark plug electrodes
• Consists of primary and secondary circuit
• Primary circuit consists of battery switch
ignition coil condenser contact breaker
• Secondary circuit consists of secondary
winding, distributors, and spark plug
• About 15000 volts are needed to make the
spark jump at 1 mm gap
• 6 -12 volt from battery is stepped up into
high tension volt of 20 - 30 000.
• This high tension voltage is made to jump
between the electrodes there by producing
spark
• Condenser is to avoid arching between
contact breakers
• Primary consists of about 300 windings
whereas secondary winding consists of
about 21000 turns
Magneto ignition system
Battery ignition Magneto ignition

Current is obtained from battery From magnet

Good sparking at low speed Poor sparking

Engine cannot be started w/o battery Engine can be started w/o battery

More space Less space

Complicated wiring Simple wiring

Less costly More costly

Spark intensity falls as speed Spark intensity improves as speed

increases increases
Spark plug
• Used to produce spark
• Consists of two electrodes
• One is connected to high voltage
produced by ignition system
• The other electrode is connected with the
outer metallic shell of spark plug
• The two electrodes are separated by
porcelain material
• There is a small gap between the two
electrodes
• When the high voltage is applied at one
electrode a spark is produced due to the
jumping of electrodes and which in turn
ignites the fuel air mixture
Lubrication system
• Reduce friction
• Failure will result in engine parts
expansion due to temp rise
• Reduces wear between moving parts
• Oil also removes heat from the moving
parts
• Oil also seals the small gaps preventing
leakage of gases
• Minimise the power loss
• Reduce noise
 Types of lubrication
• Petroil lubrication
• Wet sump lubrication
– Splash lubrication
– Pressure lubrication
– Partial pressure lubrication
 Petroil lubrication
• Used in scooters
• About 3- 6 % of oil is added along with
petrol
Splash method
Pressure lubrication
 Pressure feed system
• Oil is pumped using a pump under
pressure to all bearings, valve mechanism
and gears
• The piston walls, piston pins and piston
and lubricated by oil splash
 Desirable properties of
lubricants
• Maintain sufficient viscosity at all temp
• Must not vaporize
• Should have high specific heat to remove
heat from parts
• Must be free from corrosive acids,
moisture, etc
• Should poses adhesive quality to get
binded with metal surface
• Cohesive property to form a continuous
film
 Cooling system
• Air cooling
• Water cooling
Air cooled
 Advantages
• Simpler design
• Lighter weight
• No freezing water probs
• Less space
• Engine warming up is faster
 Disadvantages
• Not effective as water cooling
• Un even cooling
• Not suitable for multicylinder engines
• Apt for low power engines
• Fans consume power
Water cooled
 Advantages
• More efficient cooling
• Uniform cooling
• Engine overheating is reduced
• Engine temp can be controlled
 Disadvantages
• More weight
• More maintenance
• Freezing of water in cold weather
• Pump consumes more power
• Scale formation in water jackets and
hence greater maintenance
• Complicated design
 Refrigeration
• Simple vapour compression system
• Vapour absorption system
Simple vapour compression
system
Vapour absorption system
Psychrometric chart
 Air conditioning
• Winter air conditioning
• Summer air conditioning
Winter air conditioning
summer air conditioning