LESSON PLAN

Week: 09 Taught By: Engr. Kashif Usman

Subject: Problem in Internal Combustion Engine Class: 2nd Year

Mechanical Department Time: 70 minutes
Topic: Piston Problems
Objective(s): Students will be able to:
 Understand Temperature and scuffing
 Understand ring land damage
 Understand bosses damage
Skill focused on: Piston
Resources:
White Board, Marker, PowerPoint Presentations
Methodology:
Introduction:
Piston problems are major problems of an engine. The piston must be a good fit in the cylinder
bore over a wide range of temperatures, and at the same time it must operate under the most,
adverse conditions without seizure. It should have a reasonable expectancy of life. Piton knocking
and oil consumption is a problem of piston when loose in cylinder.
Piston knock or slap is a loud metallic knocking sound produced when the piston flops back and
forth inside its cylinder.
It is caused by excessive piston skirt or cylinder wear, clearance and possible damage. Piston slap
is normally louder when engine is cold and tends to quiet down as the engine reaches operating
temperature.
Piston pin knock occurs when too much clearance exists between the piston pin and piston pin
bore or connecting rod bushing. Excessive clearance allows the pin to hammer against the rod or
piston as the piston changes direction in cylinder.
Piston pin knock will usually make a double knock (two rapid knocks and then a short pause). II
does not change much with engine load. Worn piston rings and cylinders result in blow-by, blue
gray engine smokes low engine power, spark plug fouling and other problems caused by poor ring
sealing, burned piston is often a result of precognition or detonation damage. Abnormal
combustion excessive pressure and heat actually melt and blow a hole in the piston crown or area
around the ring lands. The engine may smoke, knock, have excessive blow-by or other symptoms.

Temperature Scuffing Effect on Piston Working:

The ordinary aluminum alloy piston ‘are more liable to wear and ‘scuffing’ action than coast iron
one, so that in more recent models the cylindrical surfaces have been given a protective coating
of aluminum oxide or tin.
When tin is used as coating it not only prevents “scuffing” or partial seizure during the running in
period of the engine but also forms a highly polished bearing surface of low frictional resistance.
The tin coating of pistons when new is now more widely used, as it has proved an effective
preventative of scuffing and seizure during the running in stages.
Worn piston rings or cylinders result in blow-by, blue gray engine smoke, low engine power spark
plug fouling and other problems caused by poor ring sealing. ‘Gumming’ of piston rings may occur
if cheap lubricants are used.
The principal requirement of a piston ring is that when compressed into the cylinder shall bear
evenly all around, and shall not have too large a gap to permit blow-by.
Piston Ring Land and Bosses Damages:
There are several piston defects. Slap is a sharp noise due to piston being a loose fit in the bore
and rocking on the thrust of the power stroke. Seizure is due to the friction on the bore tearing
up, the surface of the piston, due to it being too tight in the cylinder. ‘Seized rings’ in the state
where the lands arc burred over, gummed, or carboned so that the rings stick in the grooves and
let gas ‘blow by’. Pumping, or ring flutter, occurs when the rings are too loose in their grooves and
move up and down the piston, forcing oil to behind them. Rap can occur when the gudgeon pin
bosses are worn.
In order to prevent the escape of gases past the rings it is necessary to arrange for the latter to
exert a certain radial pressure outwards against the cylinder walls. This pressure is only sufficient
for the purpose during the normal working conditions for excessive pressure reduces engine
power and also gives rise to greater cylinder wear.
Ring clearance is provided to allow for expansion when the engine is al. its normal working
temperature

Activity– 1:Discussion on topic by Group-1

Success Criteria:

C.W: Nil
H.W: Maintain Practical Notebook

HoD Sign: ______________ Date: __________________