Function & materials of piston

rings,valves & valve seats, valve springs,

connecting rod, crankshaft, camshaft,
front axle & Steering system.
19120028 - CH. JIMITESH, 19120038 - G.HITESH KUMAR,
19120039 - G. SIPRA, 19120040 - GSJ ADITYA, 19120042 - HARSH K VERMA
 PISTON RINGS AND ITS FUNCTIONS

▪ Piston rings are considered as one of the

prominent components of internal
combustion engine, their performance
influences major aspects related to engine like
fuel consumption, oil consumption,
minimization of frictional power loss.
▪ In general Piston rings act to carry the heat
away from the hot piston into cooled cylinder
wall or block of the engine.
▪ Piston rings are metallic split rings which are
attached to the outer diameter of a piston in
an internal combustion (IC) engine. In general
pistons are accustomed with multiple rings.
 ▪ Automotive engines commonly consists of 3 rings per cylinder. The above 2 rings are
known as compression rings. These are primarily used for sealing the combustion
chamber. They are located nearer to combustion space and it need to withstand
significant pressure and temperature variations.
▪ Whereas the bottom ring is known as the oil control ring and it is used to control the
supply of oil to the cylinder wall in order to lubricate the piston skirt and the control
rings. These are located below the compression rings and further from combustion
space and not exposed to larger pressure and temperature variations experienced
by the compression rings.
FUNCTIONS:
The main functions of piston rings include:
▪ Sealing the combustion chamber in order to ensure the minimal loss of gases to the
crankcase.
▪ Maintaining the proper quantity of the oil between the piston and the cylinder wall.
 ▪ Piston rings are used to improve the heat transfer from the piston to the
cylinder wall.
▪ It is also used to the regulate the oil consumption by scraping oil from the
cylinder walls back to the sump.
FAILURE OF PISTON RING:
▪ Piston ring failure can lead to ‘blow by’ this allows the gases in the combustion
chamber to escape from the combustion space and enter the crankcase.
▪ This effects the engine’s efficiency as the reduction in the maximum peak
pressure achieved during the powers stroke.
▪ It also leads to the exposure of crankcase to higher temperature and pressure
this leads to the explosion of crankcase.
 MATERIALS USED FOR PISTON RING

▪ Cast iron, aluminium alloys and steel are generally used for
making piston rings.
▪ Wear resistance is considered as one of the most important
requirement in the materials used for the manufacture of piston
rings.
▪ It also needs material which having low friction coefficient to
enable the rings to slide along the cylinder surface and also
possess high yield strength and hardness.
▪ Grey modified cast iron meets the requirements mentioned
above.
▪ Carbon Steel piston are made up of SAE G2500 grade gray iron
due to its good fluidity at elevated temperatures it was used.
▪ Carbon steels minimize the effects of differential thermal expansion between
the piston and cylinder walls.
▪ Pistons made up of aluminium alloy generally have higher concentration of
silicon. This higher concentration results in higher wear resistance.
 VALVES
Engine valves control fluid or gas flow in internal combustion engines from cylinders
to combustion chambers while the engine is working.
A motor vehicle engine has two valves: the Inlet valve and the Exhaust valve.
INLET VALVE
The fuel enters the cylinder through the inlet valve. After the valve is closed
combustion takes place. These valves are made with austenitic stainless as it is both
corrosion-resistant and heat-resistant. If the valve is subjected to less heat then we
can use nickel-chromium alloy steel.
OUTLET VALVE
The burnt gases escape through the outlet valve. These valves are made with
silichrome steel made which is a combination of silicon and chrome and has unusual
heat resistance.
The valves used in car engines are termed poppet or mushroom valves.
 TYPES OF ENGINE VALVE MECHANISMS

1) Valve mechanism for operating the valve in the engine block (straight poppet valve).
Used in L, T, and F engines.
▪ The valve port is the entry and exit for fuel and gases.
▪ The valve seat insert is used to insert the valve seat properly.
▪ The valve face is the hottest and the valve stem is the coolest of the valve.The
Engine Block Portion is where the engine is inserted.
▪ Spring Retainer is used to get the valve back to its position.
▪ The clearance is the gap between the valve and the camshaft and only touch when
there is motion in the camshaft generated by the crankshaft. This clearance allows
for the expansion of the valve stem as the engine becomes heated. This is known as
valve tappet clearance.
The valve-tappet clearance depends upon the following
factors:
▪ Length of the valve stem
▪ The material of the valve.
▪ The temperature at which the engine operates.
If sufficient clearance is not given, the valve will not seat
properly when the engine becomes heated, which will
cause power loss and lifting of the valve. So it is better to
have more clearance than less clearance.
▪ two rotations by the crankshaft are equal to one
rotation by the camshaft.
Valve mechanism for operating the valve in the cylinder
head (overhead poppet valve).
▪ Widely used in automobiles due to the endurance of
the test of time.
- It is a 4-stroke engine, and one stroke
happens at a time. The camshaft gears are
connected to the crankshaft gears.
During the first stroke, the fuel+air
mixture is sucked. During the second
stroke, the fuel is compressed in the
cylinder where the inlet and the outlet
valves are closed. Before the 3rd stroke,
the spark plug is ignited due to the high
pressure created. Gases escape from the
outlet valve during the 4th stroke.
VALVE COOLING
▪ The outlet valve runs hotter than the inlet valve as it has to deal with hot
gases, whereas the inlet valve has to deal with cool charge. The valve stem
passes heat to the valve guide and the valve face passes heat to the valve
seat, and this helps to keep the valve cool. So proper water circulation is
needed in order to keep the valve cool.
▪ If the valve face fits properly on the valve seat and completely closes the
combustion chamber, there will be no loss of compression and power.
Uneven contact may cause a valve to run several hundred degrees hotter
than normal, which will shorten the valve life.
 VALVE SEAT

▪ The valve seat in an engine is the surface against which the

valve rests during the engine operating cycle when valves
are closed. it is very important and even slightly misaligned
can cause valve leakage which affects the engine efficiency.
▪ Valve seats are often formed by first press-fitting an
approximately cylindrical piece of a hardened metal alloy,
such as Stellite, into a cast depression in a cylinder head
above each eventual valve stem position, and then
machining a conical-section surface into the valve seat that
will mate with a corresponding conical section of the
corresponding valve.
▪ The most common materials used for making valve seats
are copper alloys, They have excellent thermal conductivity,
good wear characteristics, and reasonably high strength.
 VALVE SPRING

▪ It is a helical spring used to hold closed a valve in the cylinder head

of an internal-combustion engine and any spring that closes a valve
after it has been opened mechanically or by flow pressure.
▪ The valve spring keeps the valve closed. The spring provides back
pressure against which the rocker arm (for overhead valve engines)
or the cam bucket (for overhead cam engines) operates. The
pressure provided by the spring allows the cam to impart its
opening and closing characteristics based on the cam lobe profile.
▪ Valve springs are typically made by cold coiling of wire that has
been subjected to shaving, cold drawing, hardening, and
tempering. Fatigue strength and sag resistance are two major
factors. Nitriding and specially designed shot peening can further
enhance fatigue properties. Valve springs in applications working at
elevated temperatures or corrosive atmospheres are made of a
precipitation-hardened stainless steel grade.
 CONNECTING ROD
▪ A connecting rod is a component of a
reciprocating engine that connects the piston
to the crankshaft.
▪ The piston is attached to one end of the
connecting rod, and the other end is attached
to the crankshaft.
▪ The connecting rod acts as a link between the
piston and the crankshaft, converting the
reciprocating motion of the piston into
rotational motion of the crankshaft.
▪ The length and design of the connecting rod
can affect engine performance and efficiency,
as well as the balance and smoothness of the
engine.
 ▪ When the fuel in the engine cylinder is ignited, it creates a
CONNECTING
▪
ROD
high-pressure force that pushes the piston downwards.
This force is transferred to the connecting rod, which in
turn rotates the crankshaft.
▪ As the crankshaft rotates, it converts the linear motion of
the piston into rotary motion that can be used to power
the vehicle.
▪ The connecting rod is typically made of a strong and
lightweight material such as steel or aluminum alloy.
▪ The connecting rod is designed to be strong and durable,
as it is subjected to high forces and stresses during engine
operation.
 CRANKSHAFT
•The crankshaft is called the backbone of an engine
because it converts the reciprocating motion of piston
into the rotary motion of the crankshaft.
•The crankshaft is typically a large, long, and sturdy shaft
with one or more offset crankpins that are used to
attach the connecting rods from the pistons.
•The crankshaft is designed to be strong and durable, as
it is subjected to high stresses and forces during engine
operation.
•It is typically made of a high-strength alloy steel that is
capable of withstanding these forces without bending or
breaking.
▪ When the piston moves downward in the cylinder, it exerts
a force on the connecting rod, which transfers the force to
the crankshaft.
▪ As the crankshaft rotates, the force from the connecting
rod causes it to turn, producing rotational motion.
▪ This rotational motion is used to power the engine and
ultimately the vehicle.
▪ The crankshaft has several important features, including the
main bearings, which support the weight of the crankshaft
and provide a smooth and stable rotating motion.
▪ The crankshaft also has counterweights, which help balance
the rotating mass of the crankshaft and reduce vibrations in
the engine.
▪ In summary, the crankshaft is a critical component in an
engine, converting reciprocating motion into rotational
motion and providing the power needed to drive the
vehicle.
 CAMSHAFT
● The major function of the camshaft is to operate the intake
and exhaust valves through the cam lobe.
● the gear drive transmits the power for the rotation of oil
pump, therefore the oil pump sucks the oil from the oil
sump and transits the same to the oil gallery.
● The camshaft is typically located in the cylinder head of the
engine and is driven by the engine's crankshaft through a
timing belt or chain. As the camshaft rotates, the lobes
push on the lifters or rocker arms, which in turn open the
valves.
● The shape and positioning of the camshaft's lobes
determine when the valves open and close, which is critical
to the engine's operation.
 CAM LOBE AND TAPPET
➢ The cam lobe of the camshaft is placed directly above the
bucket tappet.
➢ such that the lobe comes around it and pushes down the
bucket tappet and the valve, thus opening the valve.
➢ In an overhead camshaft with rocker arm, the cam lobe
comes under the valve lifter, and causes the rocker arm to
rock or turn the lobe and pushes down the valve steam
and it moves down to open.
➢ When the cam lobe passes the valve lifter the valve
spring retains back to the original length.
➢ To close the valve the rocker arm turns back and the valve
lifter is pushed down on the cam.
 CAMSHAFT

▪ In summary, The camshaft is designed

to open the intake valve to let air and
fuel into the cylinder, and then close it
to allow the fuel to be compressed.
▪ After the fuel is ignited, the camshaft
opens the exhaust valve to release the
exhaust gases, and then closes it again
to prepare for the next cycle.
FRONT AXLE
➢ A front axle is a component in a vehicle that connects the
front wheels to the chassis.
➢ It is typically a solid metal shaft that runs from one side of
the vehicle's frame to the other and supports the weight of
the front of the vehicle.
➢ The front axle also provides a mounting point for the steering
system, which allows the driver to control the direction of the
vehicle.
➢ In most modern vehicles, the front axle is a solid beam axle,
which means that both wheels are attached to a single solid
shaft.
➢ The wheels rotate around this shaft, which allows them to
move independently of each other, but they are always
parallel to each other.
➔ In case of a commercial vehicle the front axles are
generally dead axles.
➔ It is made of drop forged alloy steel consisting of 0.4%
carbon steel and 1.3% nickel steel.
➔ In summary, the front axle is a critical component in a
vehicle's suspension and steering systems.
➔ It connects the front wheels to the chassis and allows
them to move independently of each other, while still
maintaining traction and control.
➔ The front axle also contains the steering system and
differential, which allow the driver to control the
direction of the vehicle and maintain control during
turns
 STEERING SYSTEMS

▪ Steering is the term applies to the collection of components, linkages, etc. which will
allow a vehicle to follow the desired direction.
▪ An automobile is steered with the help of steering gears and linkage, which transfer
the motion of the hand operated steering wheel to the pivoted front wheel hubs via
steering column.
▪ The other parts that are used for steering a vehicle are steering wheels pads, steering
shafts, steering boxes, steering arms and steering stabilizers. These parts are made of
durable materials like stainless steel, iron, aluminium, rubber, and plastics.
Needs of Steering System-
▪ It should multiply the turning effort applied on the steering wheel by the driver.
▪ It should be to a certain extent irreversible. In other words, the shocks of the road
surface encountered by the wheels should not be transmitted to the drivers hand.
 FUNCTION OF STEERING SYSTEM

▪ Control of front wheel direction.

▪ Transmit road feel to the drivers
hand.
▪ Maintain correct amount of effort
needed to turn the wheels.
▪ Absorb most of the shock going to
the steering wheel as the tire hits
holes and bumps in the road.
▪ Allow for suspension action.
 TYPES OF STEERING SYSTEMS

▪ Manual steering system – relies solely on the driver to provide steering force
▪ Power steering system – uses hydraulic or electric power to help the driver apply
steering force.
▪ Both manual and power steering systems have common components.
▪ Input components:
▪ Steering wheel
▪ Steering column
▪ Steering shaft

Steering wheel and column Steering shaft

 STEERING GEARS
The steering gear is a device for converting the rotary motion of the steering wheel into
straight line motion of the linkage with a mechanical advantage.
The steering gears are enclosed in a box, called the steering gear box, there are many
different designs of steering gear box.
They are as follows:
1. Worm and Wheel Steering gear- The system consists of worm wheel which is carried in
bearings in a cast iron case. The case is made in halves. The outer end of the worm
wheel is fixed to a drop arm which is having ball end to connect the side rod. The side
rod is connected to the steering arm which is fixed to the stub axles. The worm which is
keyed on to a steering shaft have a mesh with the worm wheel. The steering wheel is
mounted at the upper end of the steering shaft. When driver rotates the steering wheel
then drop arm moves either backward or forward direction. This motion results in
motion of the stub axles.
2. Cam and lever/ Peg Steering gear- Here a helical groove is formed at the bottom end of
the steering wheel shaft. The helical groove engages the projected pin of the drop arm
spindle lever. The drop-arm is made rigid with the lever/peg by a splined spindle.
▪ The top and front motion is obtained at the drop-arm when the steering wheel shaft is
turned. This motion results the turning of the stub axles. The end play of the steering
wheel shaft can be adjusted by putting a suitable washer at the lock nut. The meshing of
the projected pin in helical groove is also adjusted by a screw provided at the end of the
lever spindle. In the recent models, the projected pin is made in the form of a roller. The
projected pin may be one or two in number, accordingly they are referred as cam and
single lever or double lever steering gear mechanism.

Worm and wheel steering gear Cam and lever/ Peg steering gear
3. Recirculating ball Steering gear- It consists of a worm at the end of steering rod. A nut
is mounted on the worm with two sets of balls in the grooves of the worm, in between
the nut and, the worm. The balls reduce the friction during the movement of the nut on
the worm. The nut has a number of teeth on outside, which mesh with the teeth on a
worm wheel sector, on which is further mounted the drop arm.
▪ When the steering wheel is turned, the balls in the worm roll in the grooves and cause
the nut to travel along the length of the worm. The balls, which are in 2 sets, are
recirculated through the guides. The movement of the nut causes the wheel sector to
turn at an angle and actuate the link rod through the drop arm, resulting in the desired
steering of the wheels. The end play of the worm can be adjusted by means of the
adjuster nut provided.
▪ To compensate for the wear of the teeth on the nut and
the worm, the two have to be brought nearer bodily.
To achieve this, the teeth on the nut are made tapered
in the plane perpendicular to the plane of Figure.
POWER STEERING-
Power steering has two types of device for steering effort one type is a hydraulic
device utilizing engine power. The other type utilizes an electric motor. For the former,
the engine is used to drive a pump. For the latter, an independent electric motor in the
front luggage compartment is used the pump. Both develop fluid pressure, and this
pressure acts on a piston within the power cylinder so that the pinion assists the rack
effort. The amount of this assistance depends on the extent of pressure acting on the
piston. Therefore, if more steering force is required, the pressure must be raised. The
variation in the fluid pressure is accomplished by a control valve which is linked to the
steering main shaft.
ELECTRIC POWER STEERING (EPS OR EPAS) is designed to use an electric motor to
reduce effort by providing steering assist to the driver of a vehicle. Sensors detect the
motion and torque of the steering column, and a computer module applies assistive
torque via an electric motor coupled directly to either the steering gear or steering
column. This allows varying amounts of assistance to be applied depending on driving
conditions.
HYDRAULIC POWER STEERING (HPS) is a hydraulic system for reducing the
steering effort on vehicles by using hydraulic pressure to assist in turning the
wheels. It is intended to provide for easier driving direction control of the car
while preserving "feedback", stability and unambiguity of the trajectory specified.

HYDRAULIC VS. ELECTRIC POWER STEERING-

▪ Hydraulic Power Steering System is complicated compared with Electric Power
Steering.
▪ Hydraulic Power Steering System usually weighs more than Electric Power
Steering.
▪ Hydraulic Power Steering uses hydraulic fluids for operation whereas there is
no such fluid needed for Electric Power Steering, thus Electric Power Steering
needs less maintenance compared to hydraulic power steering.
▪ Electric Power Steering gives better response at different speeds as compared
to Hydraulic Power Steering.
▪ Electric Power Steering is less prone to problems and faults and are more
durable as compared to Hydraulic power steering.
▪ Hydraulic power steering extracts power from engine, so it reduces the fuel
mileage of the engine. Electric power steering consumes power from battery
which is also charged by engine, but it consumes less power compared to
Hydraulic power steering. So a car having Electric power steering will give more
mileage than one with Hydraulic power steering.
Thank you