Fundamentals of Internal Combustion Engine

ME 4101 Internal Combustion Engine
ME 4101
Internal Combustion Engine
Md. Shahjahan Durjoy

Lecturer, Department of Mechanical and
Production Engineering, AUST
Fundamentals of
“The engine is the ideal teaching tool, it features all of the
elements of engineering: materials, fluids, thermodynamics,
lubrication, chemistry, electronics etc. The only this missing is
nuclear reaction”
- Phil Myers
Founder of Engine Research center
University of Wisconsin, Madison
Md. Shahjahan Durjoy, Department of MPE, AUST Fundamentals of ICE ME 4101 (Spring 2022) Slide number 1
ME 4101 Internal Combustion Engine Heat Engines
Heat Engines
Any type of engine or machine which derives heat energy from the combustion of fuel or any other source and
converts this energy into mechanical work is termed as a heat engine. In other words, heat engine is a device
which transforms the chemical energy of a fuel into thermal energy and utilizes this thermal energy to perform
useful (mechanical) work.
Figure L-1.1: Toyota Corolla (2003) 1.8L L4 DOHC 16 valves VVT-i Engine
Heat Engines(cont.)
Types of Heat Engines
Heat engines may be classified into two main classes as follows :
1. External Combustion Engines
2. Internal Combustion Engines
External Combustion Engine
• In external combustion engines, the combustion of the fuel in presence of air takes place outside the engine
cylinder.
• For example, in the steam engine, the heat energy released from the fuel is utilized to raise the high-pressure
steam in a boiler from water. Here, steam is the working fluid, which enters into the cylinder of the steam engine
to perform mechanical work.
• In an external combustion engine, the products of combustion of fuel (flue gas) do not enter into the engine
cylinder and hence they do not form the working fluid. Examples of external combustion are hot air engines,
steam turbine and closed cycle gas turbine. These engines are generally used for driving locomotives, ships,
generation of electric power etc.
Heat Engines(cont.)
External Combustion Engine (cont.)
Figure L-1.2: Example of External Combustion Engine

Heat Engines (cont.)

In case of internal combustion engine, combustion of the fuel with oxygen of the air occurs within (inside) the
cylinder of the engine. Example of internal combustion engine; spark ignition engine and compression ignition
engine.
Figure L-1.3: Classification of Heat Engines (with examples)


Advantages of reciprocating internal combustion engines over external combustion engines
Reciprocating internal combustion engines offer the following advantages over external combustion engines :
1. Overall efficiency is high
2. Greater mechanical simplicity
3. Power to weight ratio is high
4. Internal Combustion Engines are compact and thus require less space
Advantages of the external combustion engines over internal combustion engines

The external combustion engines claim the following advantages over internal combustion engines :
1. Because of external combustion of fuel, cheaper fuels can be used. Even solid fuels can be used advantageously.
Where as in internal combustion engine, only gaseous and liquid can be used
3. Due to external combustion of fuel it is possible to have flexibility in arrangement.
Figure L-1.4: Cutaway drawing of

2.2-liter displacement four-cylinder
spark ignition engine. Bore 87.5 mm,
stroke 92 mm, compression ratio 8.9
(Internal Combustion Engine
Fundamentals by John B. Heywood)
ME 4101 Internal Combustion Engine Internal Combustion Engine Classification
Internal Combustion Engine Classification

According to cycle of operation :
1. Four stoke cycle engines
2. Two stroke cycle engines
According To Method of Ignition :

1. Constant volume heat addition engine or otto cycle engine. It is also called a spark-ignition engine, SI
engine or Gasoline engine
2. Constant pressure heat addition engine or diesel cycle engine. It is also called a compression-ignition engine, CI
engine or Diesel engine
3. Gasoline direct injection
According to fuel employed :

1. Engines using volatile liquid fuels, for example, gasoline, alcohol, kerosene, benzene etc. The fuel is generally
mixed with air to form a homogeneous charge in a carburetor outside the cylinder and drawn into the
cylinder in its suction stroke. The charge is ignited near the end of the compression stroke by an externally
applied spark and therefore these engines are called spark ignition engines
2. Engines using gaseous fuels like Compressed Natural Gas(CNG), Liquefied Petroleum Gas(LPG), blast furnace
gas and biogas. The gas is mixed with air and the mixture is introduced into the cylinder during the suction
process. Working of this type of engine is similar to that of the engines using volatile liquid fuels (SI gas engine)
Internal Combustion Classification (cont.)

According to fuel employed (cont.) :
3. Engines using viscous (low volatility at normal atmospheric temperatures) liquid fuels like heavy and light diesel
oils. The fuel is generally introduced into the cylinder in the form of minute droplets by a fuel injection system
near the end of the compression process. Combustion of the fuel takes place due to its coming into contact with
the high temperature compressed air in the cylinder. Therefore, these engines are called compression-ignition
engines.
4. Engines using two fuels. A gaseous fuel or a highly volatile liquid fuel is supplied along with air during the
suction stroke or during the initial part of compression through a gas valve in the cylinder head and the other
fuel (a viscous liquid fuel) is injected into the combustion space near the end of the compression stroke. These
are called dual-fuel engines.
Figure L-1.5: 5RT-flex50DF two stroke duel fuel engine

According to air intake process :
1. Naturally aspirated: Intake air pressure is not increased by any method
2. Supercharged: Intake air pressure is increased with the compressor driven off the engine crankshaft
3. Turbocharged: Intake air pressure increased with the turbine-compressor driven by the engine exhaust gases
4. Crankcase compressed: Two stroke-cycle engine which uses the crankcase as the intake air compressor.
Limited development work has also been done on the design and construction of four-stroke cycle engines with
crankcase compression.
Figure L-1.6: Supercharger (left) and Turbocharger (right)


According to arrangement of cylinder:
i) Single cylinder engine: Engine has one cylinder and piston connected to the crankshaft
(ii) In-line or straight engines: Cylinders are positioned in a straight line one behind the other along the
length of the crankshaft.
(iii) V-engine:
» An engine with two cylinder banks (i.e., two-in-line engines) inclined at an angle to each other and with one
crankshaft.
» Most of the high powered automobiles use the 8-cylinder V-engine (4-cylinder in-line on each side of V)
Figure L-1.7: Single cylinder engine (left), In-line or straight engines (middle) and V-engine (right)

According to arrangement of cylinder(cont.):
(iv) Opposed cylinder engine
» Two banks of cylinders opposite each other on a single crankshaft (like a V-engine with 180° V).
» These are common on small aircraft and some automobiles with even number of cylinders from two to eight or
more.
(v) W-engine
» Same as V-engine except with three banks of cylinders on the same crankshaft
» Not common, but some have been developed for racing automobiles
Figure L-1.8: Opposed cylinder engine (left) and W-engine (right)

(vi) Opposed piston engine
» When a single cylinder houses two pistons, each of which driving a separate crankshaft, it is called opposed piston
engine.
» The movement of the pistons is synchronized by coupling the two crankshafts. Opposed piston arrangement is
inherently well balanced Opposed piston. This engine usually functions on principle of two-stoke engines. e.g
Leyland L60
Figure L-1.9: Opposed piston engine (left) and example of opposed piston engine Leyland L60 (right)

(vii) Rotary engine
» It is an engine with pistons positioned in a circular plane around the central crankshaft. The connecting rods of
the pistons are connected to a master rod which, in turn, is connected to the crankshaft.
» In a radial engine the bank of cylinders always has an odd number of cylinders ranging from 3 to 13 or more.
» Operating on a four-stroke cycle, every other cylinder fires and has a power stroke as the crankshaft rotates,
giving a smooth operation.
» Many medium and large size propeller-driven air cooled aircraft uses rotary engines. For large aircraft two or
more banks of cylinders are mounted together, one behind the other on a single crankshaft, making one powerful
smooth engine.
Figure L-1.10: Rotary

engine (left) mechanism
and example of radial
engine Boeing-Stearman
N2S (right)

According to method of cooling the cylinder
(i) Air-cooled engine (ii) Water-cooled engine
According to valve or port design and location
Four-stroke cycle:
(i) Overhead (or I-head) valves, T head
(ii) Underhead (or L-head) valves, with two, three, or four valves per cylinder (a)
(iii) Fixed or variable valve control (timing, opening and closing points, and lift)
(iv) Rotary valves
Two-stroke cycle:
(i) Cross-scavenged porting (inlet and exhaust ports on opposite sides of cylinder
at one end) (b)
(ii) Loop-scavenged porting (inlet and exhaust ports on same side of cylinder at
one end)
(iii) Through- or uniflow-scavenged (inlet and exhaust ports or valves at different
ends of cylinder)
According to the lubrication system Figure L-1.11:

(i) Wet sump lubrication (a) T head, (b) L
(ii) Dry sump lubrication head, (c)I head
port design (c)
ME 4101 Internal Combustion Engine Energy Balance in an Internal Combustion Engine
Energy Balance in an ICE
Figure L-1.12: The energy flow through the reciprocating engine
ME 4101 Internal Combustion Engine Energy Balance in an Internal Combustion Engine
Energy Balance in an ICE (cont.)

• Figure L-1.12 shows the energy flow through the reciprocating engine. The analysis is based on the first law of
thermodynamics which states that energy can neither be created nor destroyed, it can be converted from one
form to other.
• In an I.C. engine fuel is fed to the combustion chamber where it burns in the presence of air and its chemical
energy is converted into heat. All this energy is not available for driving the piston since a portion of this energy
is lost through exhaust, coolant and radiation. The remaining energy is converted to power and is called
indicated energy or indicated power (I.P.). The ratio of this energy to the input fuel energy is called indicated
thermal efficiency [ηth (I)].
• The energy available at the piston passes through the connecting rod to the crankshaft. In this transmission of
energy/power there are losses due to friction, pumping, etc. The sum of all these losses, converted to power, is
termed as friction power (F.P.). The remaining energy is the useful mechanical energy and is termed as shaft
energy or brake power (B.P.). The ratio of energy at shaft to fuel input energy is called brake thermal efficiency
[ηth (B)]. The ratio of shaft energy to the energy available at the piston is called mechanical efficiency (ηmech ).
ME 4101 Internal Combustion Engine Application of Internal Combustion Engine
Application of Internal Combustion Engine

The applications of various engines separately are listed below :
1. Small two-stroke petrol engines : These engines are employed where simplicity and the low cost of the prime
mover are primary considerations.
• The 50 c.c. engines develops maximum brake power (B.P.) of 1.5 kW at 5000 r.p.m. and is used in mopeds.
• The 100 c.c. engine developing maximum brake power of about 3 kW at 5000 r.p.m. is used in scooters. The 150
c.c. engine develops maximum brake power of about 5 Kw at 5000 r.p.m.
• The 250 c.c. engine developing a maximum brake power of about 9 kW at 4500 r.p.m. is generally used in motor
cycles.
Figure L-1.13: Air cooled motorcycle engine
ME 4101 Internal Combustion Engine Application of Internal Combustion Engine
Application of Internal Combustion Engine

2. Small four-stroke petrol engines
These engines are primarily used in automobiles.
3. Four stroke diesel engines :

• The four-stroke diesel engine is manufactured in diameter ranging from 50 mm to 600 mm with speeds ranging
from 100 to 4400 r.p.m., the power delivered per cylinder varying from 1 to 1000 kW.
• Diesel engine is employed for the following :
— Pumping sets
— Construction machinery
— Air compressors and drilling jigs
— Tractors
— Jeeps, cars and taxies
— Mobile and stationary electric generating plant
— Diesel-electric locomotive
— Boats and ships
Figure L-1.14: Toyota 1DZ Diesel engine

ME 4101 Internal Combustion Engine Basic Mechanism of Internal Combustion Engine
Basic Mechanism of ICE

• Combustion is the basic chemical process of releasing energy from a fuel and air
mixture. In an internal combustion engine (ICE), the ignition and combustion of the
fuel occurs within the engine (inside the cylinder) itself. The engine consists of a fixed
cylinder and a moving piston. The expanded combustion gases push the piston, which
in turn rotates the crankshaft and ultimately, through a system of gears in the
powertrain, this motion drives the vehicle’s wheels.
• There are two kinds of internal combustion engines currently in production: the spark
ignition gasoline engine and the compression ignition diesel engine. Most of
these are four-stroke cycle engines, meaning four piston strokes are required to complete
a cycle. The cycle includes four distinct processes: intake, compression, combustion and
power stroke, and exhaust.
• Spark ignition gasoline and compression ignition diesel engines differ in how they
supply and ignite the fuel. In a spark ignition engine, the fuel is mixed with air and
then inducted into the cylinder during the intake process. After the piston compresses
the fuel-air mixture, the spark ignites it, causing combustion. The expansion of the
combustion gases pushes the piston during the power stroke. In a diesel engine,
only air is inducted into the engine and then compressed. Diesel engines then spray the Figure L-1.15:
fuel into the hot compressed air at a suitable, measured rate, causing it to ignite. Strokes of SI
Engine
ME 4101 Internal Combustion Engine Basic Components of Internal Combustion Engine
Basic Components of ICE

A cross-section of an air-cooled I.C. engine with principal parts is shown in Figure L-1.15
A. Parts common to both petrol and diesel engine :

1. Cylinder, 2. Cylinder head
3. Piston, 4. Piston rings
5. Gudgeon pin, 6. Connecting rod,
7. Crankshaft, 8. Crank,
9. Engine bearing, 10. Crankcase,
11. Flywheel, 12. Governor,
13. Valves and valve operating mechanisms.
B. Parts for petrol engines only :

1. Spark plugs, 2. Carburettor
3. Fuel pump.
C. Parts for Diesel engine only :

1. Fuel pump. 2. Injector.
Figure L-1.16: Air cooled IC engine with common part


1. Cylinder
• The engine cylinder contains gas (fresh charge during intake and compression and flue gas after the power
stroke) and guides the piston
• An ideal form of cylinder consists of a plain cylindrical barrel in which the piston slides
• The movement of the piston or stroke being in most cases, longer than the bore. This is known as the “stroke to
bore ratio”.
• The cylinder is made of hard grade cast iron and is usually, cast in one piece.
2. Cylinder Head
• One end of the cylinder is closed by means of a removable cylinder head which usually contains the inlet valve
for admitting the mixture of air and fuel and exhaust valve [Fig. L-1.18 (right)] for discharging the product of
combustion. The valves are control by the means of cams [Fig. L-1.18 (left)].
• The passage in the cylinder head leading to and from the valves are called ports
• The pipes which connect the inlet ports of the various cylinders to a common intake pipe for the engine is
called the inlet manifold
• The exhaust ports are similarly connected to a common exhaust system, this system of piping is called exhaust
manifold

2. Cylinder Head
Figure L-1.17: Intake manifold (left) , Exhaust manifold (right) (Toyota

Corolla 2003)

2. Cylinder Head (cont.)
• The main purpose of the cylinder head is to seal the working ends of the cylinders and not to permit entry
and exit of gases on cover head valve engines
• The inside cavity of head is called the combustion chamber, into which the mixture is compressed for
firing.
• Its shape controls the direction and rate of combustion
Figure L-1.18: Simple Cam mechanism (left) , Inlet and Exhaust valves (right)

3. Piston
• A piston is fitted to each cylinder as a face to receive gas pressure and transmit the thrust to the connecting rod.
As the piston is fitted inside the cylinder, it can slide freely through the piston bore
• There is a small gap between the cylinder wall and piston called piston clearance.
• Pistons are made of cast iron or aluminium alloy for lightness.
Figure L-1.19:
Engine cylinder
and piston

4. Piston rings
• The piston must be a fairly loose fit in the
cylinder. If it were a tight fit, it would expand as
it gets hot and might stick tight in the cylinder.
If a piston sticks it could damage the engine.
• On the other hand, if there is too much piston
clearance between the piston and cylinder walls,
much of the air-fuel-mixture or product of
combustion will leak past the piston, which is
called blowby.
• If such phenomenon occurs then, the push on the
piston will be much less effective, thus efficiency
will be lower.
Figure L-1.20: Piston head’s exploded

view indicating the piston rings

4. Piston rings (cont.)
• To provide a good sealing fit between the piston and cylinder and control excessive blowby, pistons are
equipped with piston rings, as shown in Figure L-1.21. The rings are usually made of cast iron of fine grain and
high elasticity which can withstand produced heat
• The rings are split at one point so that they can be expanded and slipped over the end of the piston and
into ring grooves which have been cut in the piston.
Figure L-1.21: Section through a piston


4. Piston rings (cont.)
• When the piston is installed in the cylinder the rings are compressed into ring grooves which have been cut in
the piston
• The rings fit tightly against the cylinder wall and against the sides of the ring grooves in the piston. Thus, they
form a good seal between the piston and the cylinder wall. The rings can expand or contact as they heated up
and cooled down. Thus they are free to slide up and down the cylinder wall
• There are two types of rings in four stroke engines; compression ring and oil control ring. Compression rings
form a sliding seal between piston and cylinder wall. Oil control ring scrape off the lubricating oil between the
piston and cylinders wall thus preventing blow by and wearing of pistons.
Figure L-1.22: Compression ring (left) , Oil control ring (right)

5. Gudgeon pin (or wrist pin or piston pin)

The pin fitted through the piston bosses and at the small end of the connecting
rod to allow the connecting rods to swivel.
6. Connecting rod
The connecting rod transmits the piston load to the crank, causing the latter
to turn, thus converting the reciprocating motion of the piston into a rotary
motion of the crankshaft. The lower or “big end” of the connecting rod turns on
“crank pins”.
Figure L-1.23: Exploded

view of Piston
Figure L-1.24: Connecting rod
7. Crank
The piston moves up and down in the cylinder. This up and down motion is called reciprocating motion. That is
rotary motion is required to make wheels turn. To change this reciprocating motion to rotary motion a crank and
connecting rod are used. (Figure L-1.25). The connecting rod connects the piston to the crank.
Figure L-1.25: Crank, The crank end of the connecting rod is called rod “big end”. The
piston end of the connecting rod is called the rod “small end”.

8. Crankshaft
The crank is part of the crankshaft. The crankshaft of an internal combustion engine receives via its cranks the
efforts supplied by the pistons to the connecting rods. All the engines auxiliary mechanisms with mechanical
transmission are geared in one way or the another to the crankshaft. The crankshaft converts the
reciprocating motion to rotary motion. The crank shaft mounts in bearings which, encircle the journals so it
can rotate freely
Figure L-1.26: Crank

shaft and other parts
The shape of the crankshaft i.e. the mutual arrangement of the cranks depend on the number and arrangement of
cylinders and the turning order of the engine. Figure L-1.26 shows a typical crankshaft layout for a four cylinder
engine.

8. Crankshaft (cont.)
The shape of the crankshaft i.e. the mutual arrangement of the cranks depend on the number and arrangement of
cylinders and the turning order of the engine. Figure L-1.27 shows a typical crankshaft layout for a four cylinder
engine.
Figure L-1.27: Crank shaft layout


9. Crankcase
The main body of the engine to which the cylinders are attached and which contains the crankshaft and crankshaft
bearing is called crankcase. This member also holds other parts in alignment and resists the explosion and inertia
forces. It also protects the parts from dirt etc. and serves as a part of lubricating system.
10. Flywheel
A flywheel secured on the crank shaft performs the following functions : (a) Brings the mechanism out of dead
centers. (b) Stores energy required to rotate the shaft during preparatory strokes, (c) Makes crankshaft rotation
more uniform. (d) Facilitates the starting of the engine and overcoming of short time over loads as, for example,
when the machine is started from rest.
Figure L-1.28: Flywheel


11.Spark-plug
It provides the spark which is produced by applying high voltage, in order to ignite the air fuel mixture in the
power stroke.
• The spark-plug consists of a metal shell having two

electrodes which are insulated from each other with an
air gap. High tension current jumping from the supply
electrode produces the necessary spark
• The spark plug firing end temperature must be kept

low enough to prevent pre-ignition, but high enough to
prevent fouling. This is called “thermal performance,”
and is determined by the heat range selected
• The optimal firing end temperature is approximately

500°C (932°F) to 800°C (1472°F)
Figure L-1.29: Spark-plug

ME 4101 Internal Combustion Engine Terminologies related to Internal Combustion Engine
Terminologies related to ICE
Figure L-1.30: Terminology

related to ICE

Cylinder Bore (d): The nominal inner diameter of the working cylinder is called the cylinder bore and is
designated by the letter d and is usually expressed in millimeter (mm).
Piston Area(A): The area of a circle of diameter equal to the cylinder bore is called the piston area and is
designated by the letter A and is usually expressed in square centimeter (cm2)
Stroke (S): As the piston reciprocates inside the engine cylinder, it has got limiting upper and lower positions
beyond which it cannot move and reversal of motion takes place at these limiting positions. The linear distance
along the cylinder axis between two limiting positions, is called “stroke” and is designated by the letter S .
Top Dead Centre (T.D.C.): The top most position of the piston towards cover end side of the cylinder is
called “top dead centre”. In case of horizontal engines, this is known as inner dead center.
Bottom Dead Centre (B.D.C.): The lowest position of the piston towards the crank end side of the cylinder
is called “bottom dead center”. In case of horizontal engines it is called outer dead center.
Stroke to Bore Ratio: L/d ratio is an important parameter in classifying the size of the engine. An engine
with same stoke length and bore diameter is often called a square engine ; If stoke length > bore diameter then
the engine is called under square ; and if stoke length < bore diameter the engine is over square.

Displacement or swept Volume (Vs): The nominal volume swept by the working piston when travelling
from one dead center to the other is called the displacement volume. It is expressed in terms of cubic centimeter
(cc) and given by,
Engine Capacity: The displacement volume of a cylinder multiplied by the numbers of cylinders in an engine
will give the engine capacity. For example, if there are K cylinders in an engine, then
Clearance Volume: The nominal volume of the combustion chamber above the piston when at the top dead
center is the clearance volume. It is designated as VC and expressed in cubic centimeter (cc)
Compression Ratio: It is the ratio of the total cylinder volume when the piston is at the bottom dead center,
VT , to the clearance volume, VC. It is designated by the latter r.
ME 4101 Internal Combustion Engine
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Fundamentals of Internal Combustion Engine

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ME 4101 Internal Combustion Engine

Md. Shahjahan Durjoy

Figure L-1.2: Example of External Combustion Engine

Heat Engines (cont.)

Figure L-1.3: Classification of Heat Engines (with examples)

Heat Engines (cont.)

Advantages of the external combustion engines over internal combustion engines

Heat Engines (cont.)

Figure L-1.4: Cutaway drawing of

Internal Combustion Engine Classification

According To Method of Ignition :

According to fuel employed :

Internal Combustion Classification (cont.)

Figure L-1.5: 5RT-flex50DF two stroke duel fuel engine

Internal Combustion Classification (cont.)

Figure L-1.6: Supercharger (left) and Turbocharger (right)

Internal Combustion Classification (cont.)

Internal Combustion Classification (cont.)

Figure L-1.8: Opposed cylinder engine (left) and W-engine (right)

Internal Combustion Classification (cont.)

Internal Combustion Classification (cont.)

Figure L-1.10: Rotary

Internal Combustion Classification (cont.)

According to the lubrication system Figure L-1.11:

Energy Balance in an ICE

Figure L-1.12: The energy flow through the reciprocating engine

Energy Balance in an ICE (cont.)

Application of Internal Combustion Engine

Figure L-1.13: Air cooled motorcycle engine

Application of Internal Combustion Engine

3. Four stroke diesel engines :

Figure L-1.14: Toyota 1DZ Diesel engine

Basic Mechanism of ICE

Basic Components of ICE

A. Parts common to both petrol and diesel engine :

B. Parts for petrol engines only :

C. Parts for Diesel engine only :

Figure L-1.16: Air cooled IC engine with common part

Basic Components of ICE

Basic Components of ICE

Figure L-1.17: Intake manifold (left) , Exhaust manifold (right) (Toyota

Basic Components of ICE

Basic Components of ICE

Basic Components of ICE

Figure L-1.20: Piston head’s exploded

Basic Components of ICE

Figure L-1.21: Section through a piston

Basic Components of ICE

Figure L-1.22: Compression ring (left) , Oil control ring (right)

Basic Components of ICE

5. Gudgeon pin (or wrist pin or piston pin)

Figure L-1.23: Exploded

Basic Components of ICE

Figure L-1.24: Connecting rod

Basic Components of ICE

Basic Components of ICE

Figure L-1.26: Crank

Basic Components of ICE

Figure L-1.27: Crank shaft layout

Basic Components of ICE

Figure L-1.28: Flywheel

Basic Components of ICE