BONGA UNIVERSTY

Collage of Engineering and Technology

Mechanical Engineering Department

10 November 2023 Nur. Jems

Well come 2 your IC Engine classes
• Usual Class Ground rule
➢ Punctuality for (class, exam, assignments etc…)

➢ Switch off / make on silent mode your Mobile

➢ Exam cheating is strictly forbidden

➢ Side talk is forbidden unless you are told to so for group discussion and etc.

➢ Reasoning after exam (especially Once you see your grade) not allowed

10 November 2023 Nur. Jems

IC Engine Components
Chapter Outline
➢ Introduction to IC Engines
➢Engine Components
➢ Types of IC engine
➢ Selection of IC Engines
➢ Working principles of IC engine
Introduction to IC Engines
• Engine is a complex mechanical device which convert energy into
useful motion/ phycis effect. Is a part of car/ vechile which provide the
force for motion, now especially one powered by ic. Therefore, heat
engine is mechanical device which convert heat energy into
mechanical work. It is classified into two types-
➢ External combustion engine
➢ Internal combustion engine
External Combustion Engine
• In this engine, Combustion of the fuel take place outside of the cylinder. EC engine require large
space and its working fluid is steam from burning of coal or wood. Its thermal efficiency is low
and its capital cost is relatively high when compared to IC engine. But cost of fuel used is low.

• Heat from the combustion products is transferred to the working fluid through the walls of a heat
exchanger.

• An example of a reciprocating external combustion engine is the Stirling engine where heat is
added to the working fluid at high temperature and rejected at low temperature. Heat added to the
working fluid can be generated from practically any heat source, such as burning fossil fuels,
wood, or any other organic material.
 Cont.…
• The Rankine cycle upon which many steam engine designs are based
is another example of an external combustion engine. Heat added from
an external source elevates the temperature of a liquid, such as water,
until it is converted into vapor that is used to move a piston or spin a
turbine

• Example steam engine , Boiler that use wood as a fuel

Internal combustion engine
• IC Engine is a heat engine that converts chemical energy in a fuel into
mechanical energy, usually made available on a rotating output shaft.
Chemical energy of the fuel is first converted to thermal energy by means of
combustion or oxidation with air inside the engine. . This thermal energy
raises the temperature and pressure of the gases within the engine, and the
high-pressure gas then expands against the mechanical mechanisms of the
engine. This expansion is converted by the mechanical linkages of the
engine to a rotating crankshaft, which is the output of the engine. The
crankshaft, in turn, is connected to a transmission and/or power train to
transmit the rotating mechanical energy to the desired final use.
IC Engine Components
• The main engine components comprising of piston, cylinder, crank
slider crankshaft, connecting road, valves and valve train, intake and
exhaust system.
Stationary Parts of Engine
• The stationary parts of an engine include the cylinder block and cylinders, the
cylinder head or heads, and the exhaust and intake manifolds. All movable
parts are attached to or fitted into this framework.

• .Engine Cylinder Block: The cylinder block is the basic frame of a liquid-
cooled engine whether it is in-line, horizontally opposed, or V-type. The
cylinder block is a solid casting made of cast iron or aluminum that contains
the crankcase, the cylinders, the coolant passages, the lubricating passages,
and, in the case of flathead engines, the valves seats, the ports, and the guides.
•h
• Engine head: The component that closes the end of cylinders, usually containing
part of the clearance volume of the combustion chamber is called head.

• The head contains spark plug in the SI engines, and the fuel injectors in CI engines
and some SI engines. Most modern engines have the valves in the head and many
have the camshafts also positioned there (overhead valves and over head cam).

• Manifold
The main function of manifold is to supply the air fuel mixture and collects the
exhaust gases equally from all cylinder. In an internal combustion engine two
manifold are used, one for intake and other for exhaust.
• Head gasket: It is the gasket that serves as a sealant between the engine block and
the head where they bolt together to avoid any leakage and pressure loss.

Intake Manifold: Piping system that delivers incoming air to the cylinders usually
made of cast metal, plastic, or composite material. In most SI engines, fuel is added
to the air in the intake manifold system either by fuel injectors or with a carburetor.
• Cylinders: The circular cylinders in the engine block in which the pistons reciprocate back and
forth. The walls of the cylinder have highly polished hard surfaces. Cylinders may be machined
directly in the engine block.

Piston: The cylindrically shaped mass that reciprocates back and forth in the cylinder, transmitting
the pressure forces being generated by the fuel burnt in the combustion chamber for rotating the
crankshaft is called piston. The top of the piston is called crown and the sides are called skirt. Pistons
have lower thermal expansion which allows for higher tolerances.
Piston pin: Pin fastening the connecting rod to the piston is called piston pin and
also called wrist pin.

Fuel injector: A pressurized nozzle that sprays fuel into the cylinder on CI engines.

Fuel pump: Electrically or mechanically driven pump to supply fuel from the fuel
tank (reservoir) to the engine

Glow plug: Small electrical heater resistance mounted inside the combustion
chamber of many CI engines, used to preheat the chamber so that combustion will
occur when first starting a cold engine. The glow plug is turned off after the engine
is started.
• Spark Plug: The spark plug is Electrical device used to initiate combustion (generate the spark) in
an SI engine by creating a high voltage discharge spark across an electrode gap. It should be able to
withstand fluctuating pressure and temperature. So its main function is to conduct the high
potential from the ignition system into the combustion chamber.

• Radiator: The radiator is a heat exchanger which eliminates excess heat from the system and used
in engine cooling systems. The radiator usually mounted in front of the engine in the flow of air as
the automobile moves forward. An engine drive or electric fan is often used to increase air flow
through the radiator.
• Water jacket: It’s a system through which Engine coolant flows ands keeps the cylinder walls from
over heating. The coolant is usually a water ethylene glycol mixture.
• Choke valve: Butterfly valve at carburetor intake, used to control amount of air intake (create rich
fuel-air mixture) in intake system by choking/restricting the air intake for cold weather starting

• Carburetor: Venturi flow device which meters the proper amount of fuel into the air
flow by means of a pressure differential. For many decades it was the basic fuel
metering system on all automobile (and other) engines.
• Fan: Most engines have fan to increase air flow through the radiator and through the engine
compartment which increases the heat removal from the engine for cooling purposes. Fans can be driven
mechanically (with belt) or electrically.

• Oil pan: Oil reservoir usually bolted to the bottom of the engine block, making up part of the
crankcase. It acts as the oil sump for most engines.

• Oil pump: Pump used in force feed lubricating system to distribute oil from the oil sump to required
lubrication points is called oil pump. The oil pump can be electrically driven but in most cases it is
mechanically driven by the engine. Some small engines do not have an oil pump and are lubricated by
splash distribution.

• Oil sump: It is the reservoir for the oil system of the engine, commonly part of the crankcase. Some
automobile engines with overhead crankshafts have a secondary oil sump in the engine head to supply
lubrication to the cam and valve mechanism. Some engines have a separate closed reservoir called a dry
sump.
Moving Parts of an Engine
• Camshaft: Rotating shaft that is responsible for the opening and closing of the
valves at the proper time in the engine cycle, either directly or through mechanical
or hydraulic linkage (push rods, rocker arms, tappets). Most modern automobile
engines have one or more camshafts mounted in the engine head (overhead cam).
• Push rods: It is the on over head
valves engines used to operate the valve mechanism. Push rods have oil passages through
there length as part of a pressurized lubrication system.

• Valves: These are used to allow flow of air and fuel or its mixture into and burnt/exhaust
gases out of the cylinder at the proper time in the four stroke cycle engines. Most engines
used poppet valves which are spring loaded closed, and pushed/open by camshaft action.
Two stroke cycle engines have ports (slots) in the side of cylinder walls instead of
mechanical valves.

• Cooling fins: The extended surfaces in the form of metal fins used air cooled engine on
the outside surfaces of cylinders and head for cooling purposes by conduction and
convection are known as cooling fins
• Connecting rod: connecting rod is used to connect the with the
help of a piston pin and crank pin, usually made of steel or alloy forging in most engines but may
be aluminum. Connecting rod transmits the reciprocating motion of the piston to into rotary
motion of the crankshaft so this is works as a lever arm that transfers the motion from one end to
another end.

• Crankcase: Part of the engine block surrounding the rotating crankshaft. In many engines, the oil
pan makes up part of the crankcase housing.
• Crankshaft: Rotating shaft through which engine work output is
supplied to external systems. The crankshaft is connected to the
engine block with the main bearings. transmits this power of
reciprocating motion of the piston into rotary motion of the crankshaft
which is further connected to the flywheel and transmission shaft
which is used to move the vehicle.
• Flywheel: Flywheel means fluctuation of energy; it reserves the energy and uses this energy when
requires it. It is the rotating mass with large moment of inertia connected to the crankshaft of the
engine.

• The purpose of the flywheel is to store energy and furnish a large angular momentum that that
keeps the engine rotating between power strokes and smooths out engine operation. In multiple
cylinder engines, the size of flywheel is relatively smaller than the single cylinder engines. On some
aircraft engines the propeller serves as the flywheel.
• Generally
Terminology (Nomenclature) used in IC engine:
➢ Bore (D): Diameter of the cylinder or diameter of the piston face, which is the same
minus a very small clearance.
➢ Stroke (L): Movement distance of the piston from one extreme position to the other i.e.,
TDC to BDC or BDC to TDC. It is equal to twice the radius of crank circle.
➢ Piston area (A): The area of circle of diameter equal to the cylinder bore.
➢ Top-Dead-Center (TDC): Position of the piston when it stops at the furthest point away
from the crankshaft.
➢ Bottom-Dead-Center (BDC): Position of the piston when it stops at the point closest to
the crankshaft.
➢ Clearance Volume: Minimum volume in the combustion chamber with piston at TDC.
➢ Displacement or Displacement Volume 𝑉𝑠 : Volume displaced by the piston as it
travels through one stroke. Displacement can be given for one cylinder or for the
entire engine (one cylinder times number of cylinders).
𝑉𝑠 = 𝐴 × 𝐿
➢ Cylinder volume (V): Total volume of the cylinder.
𝑉 = 𝑉𝑠 + 𝑉𝑐
➢ Compression Ratio (CR): It is the ratio of the maximum volume formed in the
cylinder to the minimum (clearance) volume.
𝑉𝑚𝑎𝑥 𝑉𝐵𝐷𝑐 𝑉 𝑉𝑠 +𝑉𝑐
𝑟𝑐 = = = =
𝑉𝑚𝑖𝑛 𝑉𝑇𝐷𝐶 𝑉𝑐 𝑉𝑐
Classification of IC Engine
• Internal combustion engines can be classified based on number of different criteria.

1. Based on Method of Ignition

• (a) Spark Ignition (SI): An SI engine starts the combustion process in each cycle by use of a spark plug. The spark
plug gives a high-voltage electrical discharge between two electrodes which ignites the air-fuel mixture in the
combustion

• (b) Compression Ignition (CI): The combustion process in a CI engine starts when the air-fuel mixture self-ignites
due to high temperature in the combustion chamber caused by high compression.

2. Based on Basic Design

• (a) Reciprocating: Engine has one or more cylinders in which pistons reciprocate back and forth. The combustion
chamber is located in the closed end of each cylinder. Power is delivered to a rotating output crankshaft by mechanical
linkage with the pistons.

• (b) Rotary: Engine is made of a block (stator) built around a large non-concentric rotor and crankshaft. The
combustion chambers are built into the non-rotating block
3. Air Intake Process
• (a) Naturally Aspirated: No intake air pressure boost system exists.

• (b) Supercharged: Intake air pressure increased with the compressor driven off
of the engine crankshaft.

• (c) Turbocharged: Intake air pressure increased with the turbine compressor
driven by the engine exhaust gases.

• (d) Crankcase Compressed: Two-stroke cycle engine uses the crankcase as the
intake air compressor. Limited development work has also been done on design and
construction of four stroke cycle engines with crankcase compression.
4. Position and Number of Cylinders of Reciprocating Engines
• (a) Single Cylinder. Engine has one cylinder and piston connected to the crankshaft.

• (b) In-Line. Cylinders are positioned in a straight line, one behind the other along the length of the
crankshaft. They can consist of 2 to 11 cylinders or possibly more. In-line four-cylinder engines are
very common for automobile and other applications. In-line six and eight cylinders are historically
common automobile engines. In-line engines are sometimes called straight (e.g., straight six or
straight eight).

• (c) V Engine. Two banks of cylinders at an angle with each other along a single crankshaft. The
angle between the banks of cylinders can be anywhere from 15° to 120°, with 60°-90° being common
5. Based on Type of Cooling

a. Liquid Cooled, Water Cooled: Water is made to flow through the water jackets provided along the surface
of cylinders or liners to absorb the heat. Further the heated water is cooled with the help of radiator.

b. Air Cooled: Circulating air is used to dissipate the heat from the fins on an engine. Mostly small engines are
used with air cooled engines. Example motorcycle, 3-wheel vehicle (Bajaj).
6. Based on fuel used
• Petrol Engine (Gasoline engine): The petrol engine uses petrol for its running. Petrol or gasoline is a
hydrocarbon, made up of hydrogen and carbon compounds. Air-petrol mixture is sucked into the cylinder during
the suction stroke of the piston. The correct air-petrol mixture is obtained from the carburetto The mixture is
compressed during the compression stroke, ignited during the power stroke and the exhaust gases pushed out
during the exhaust stroke. A spark plug is fitted at the top of the cylinder which gives a spark to ignite the
mixture.
• Diesel Engine: In these types of engines, diesel oil is used for its running. Diesel
oil is light, with low viscosity and high cetane number. In the diesel engine, only
air is sucked into the cylinder during the suction stroke and compressed to high
pressure. The diesel oil is injected by an injector at the end of the compression
stroke which catches fire and burns due to the high temperature of the compressed
air. The burnt gases expand pushing the piston down during the power stroke and
finally, the gases are pushed out during the exhaust stroke.
7. Based on engine Cycle
• (a) Four-Stroke Cycle: A four-stroke cycle experiences four piston movements
over two engine revolutions for each cycle.

• (b) Two-Stroke Cycle: A two-stroke cycle has two piston movements over one
engine revolution for each cycle. Most internal combustion engines, both spark
ignition and compression ignition, operate on either a four-stroke cycle or a two-
stroke cycle.
• Four stroke SI engines

• 1. First Stroke: Intake Stroke or Induction: The piston travels from TDC to BDC with the intake
valve open and exhaust valve closed. This creates an increasing volume in the combustion chamber,
which in turn creates a vacuum. The resulting pressure differential through the intake system from
atmospheric pressure on the outside to the vacuum on the inside causes air to be pushed into the
cylinder.

• 2. Second Stroke: Compression Stroke: When the piston reaches BDC, the intake valve closes
and the piston travels back to TDC with all valves closed. This compresses the air-fuel mixture,
raising both the pressure and temperature in the cylinder. The finite time required to close the intake
valve means that actual compression doesn't start until sometime aBDC. Near the end of the
compression stroke, the spark plug is fired and combustion is initiated.
• 3. Combustion stroke: Combustion of the air-fuel mixture occurs in a very short
but finite length of time with the piston near TDC (i.e., nearly constant-volume
combustion). It starts near the end of the compression stroke slightly bTDC and
lasts into the power stroke slightly aTDC.

• Third Stroke: Expansion Stroke or Power Stroke With all valves closed, the high
pressure created by the combustion process pushes the piston away from TDC.
This is the stroke which produces the work output of the engine cycle. As the
piston travels from TDC to BDC, cylinder volume is increased, causing pressure
and temperature to drop.
• 4s
Four-Stroke CI Engine Cycle
• 1. First Stroke: Intake Stroke The same as the intake stroke in an SI engine with one major
difference: no fuel is added to the incoming air.

• 2. Second Stroke: Compression Stroke The same as in an SI engine except that only air is
compressed and compression is to higher pressures and temperature. Late in the compression stroke
fuel is injected directly into the combustion chamber, where it mixes with the very hot air. This
causes the fuel to evaporate and self-ignite, causing combustion to start.

• 3. Combustion stroke: Combustion is fully developed by TDC and continues at about constant
pressure until fuel injection is complete and the piston has started towards BDC.

• 4. Third Stroke: Power Stroke The power stroke continues as combustion ends and the piston
travels towards BDC
• Two stroke engine:

• -No piston stroke for suction and exhaust operations

• -Suction is accomplished by air compressed in crankcase or by a blower

• -Induction of compressed air removes the products of combustion through exhaust ports

• -Transfer port is there to supply the fresh charge into combustion chamber

• In two stroke suction and compression is one stroke while power and exhaust are
performed in the second stroke.
• During the Compression stroke, the piston rises and pulls a mixture of air, fuel, and oil into the crankcase through an intake valve.
At the same time, an air-fuel-oil mixture is compressed in the combustion chamber.
• During the Power stroke, combustion retracts the piston, which closes the intake valve and pulls more air-fuel-oil mixture into the
combustion chamber. At the same time, exhaust is expelled from the combustion chamber through an exhaust port.
Two-stroke Engine
• The two-stroke engine is similar to that of the four-stroke-cycle engine in its reciprocating mechanism.
It uses the piston-crankshaft mechanism, but requires only one revolution of the crankshaft for a
complete power-producing cycle. The two-stroke engine does not use inlet and exhaust valves. The gas
exchange is implemented by scavenging and exhaust porthole openings in the bore wall.

• its mechanism is very simple b/c no valve mechanism.

• The power output is fairly high because it achieves one power stroke per two revolutions of the
crankshaft. However, although the power output is high, it is used only for small motorcycle engines and
some large diesel applications. Since the new gas pushes out the burnt gas, the intake and exhaust gases
are not clearly separated. As a result, fuel consumption is relatively high and cleaning of the exhaust gas
by a catalytic converter is difficult.
•H
9. Based on Cycle of Operations

• According to the cycle of operations, the automobile engines may be of the following three types.

• Otto Cycle or Constant Volume Cycle. The engines operating on this cycle are known as Otto-cycle engines.
The petrol engines operate on this cycle. An I.C. engine does not undergo a cyclic change but it is assumed
here that the working medium is pure air which does not undergo any chemical change. The ideal Otto cycle
consists of the following operation.

• 1-2 Adiabatic compression.

2-3 Heat addition at constant volume.
3-4 Adiabatic expansion.
4-1 Heat rejection at constant volume
Diesel Cycle or Constant Pressure Cycle:
• Diesel cycle was introduced by Dr. Rudolph Diesel in 1897. The engines operating on this cycle are known as
Diesel engines. The figure shows the p-v diagram for a Diesel cycle

• 1-2 Adiabatic compression.

2-3 Heat addition at constant pressure
3-4 Adiabatic expansion.
4-1 Heat rejection at constant volume

• . The air is compressed in the cylinder during the compression stroke from point 1 to 2. Now the heat is added
at constant pressure from point 2 to 3, and then the air is expanded adiabatically from point 3 to 4. Finally, the
heat is rejected at constant volume from point 4 to 1. The air returns to its original condition and the cycle is
complete.
• Dual Cycle (or Dual Combustion Cycle): In these types of engines, fuel is injected in the cylinder
before the end of the compression stroke so that combustion proceeds partly at constant volume
and partly at constant pressure. Such a cycle is known as Dual cycle.
• It consists of the following operations.

✓ 1-2. Adiabatic compression

✓ 2-3. Heat addition at constant volume
✓ 3-4. Heat addition at constant pressure
✓ 4-5. Adiabatic expansion
✓ 5-1. Heat rejection at constant volume.
What are the to be factors considered when selecting an IC engine for a given application ?

✓ Determine the intended application (generator, vehicle, or industrial machinery)

✓ Power Output: (required horsepower (HP) or kilowatts (kW)) its measure of the engine's ability to
perform work, such as turning a shaft or moving a vehicle

✓ Fuel type and its Efficiency: (gasoline, diesel, natural gas, propane, and biofuels)

✓ Emissions out put

✓ Durability and Reliability

✓ Size and Weight:

✓ Cost
✓ Maintenance requirements and expected lifespan of the engine.

✓ Consult with an expert

10 November 2023 Nur. Jems

Engine selection criteria
• Torque: This is the twisting force that an engine can produce, typically measured
in pound-feet (lb-ft) or Newton-meters (Nm). Torque is an important measure of
an engine's ability to accelerate and tow heavy loads.

• Operating Speed: The operating speed is typically measured in revolutions per

minute (RPM).

• Engine CC (cubic centimeters) or engine displacement, is a measurement of the

total volume of air and fuel that can be drawn into all of the engine's cylinders
during one complete engine cycle. The engine displacement is typically measured
in cubic centimeters (cc) or liters (L). Its used to determine an engine's power output

10 November 2023 Nur. Jems

10 November 2023 Nur. Jems
• any question??????

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