Module1 - Engine Components - Cooling, Lubrication-Lecture Notes

Automotive Engineering (18ME752)
AUTOMOTIVE ENGINEERING
18ME752
OPEN ELECTIVE
7th Sem Mechanical Engineering
Prof. Raju MG
Assistant Professor
Department of Mechanical Engineering

Acharya Institute of Technology
Bengaluru-107
Prof. Raju MG., Dept. of Mechanical Engg. Acharya Institute of Technology, Bengaluru-107 1
1. Explain the various methods of cylinder arrangements in multicylinder

engine
The various types of cylinder arrangements in multicylinder engine are
i)Inline
ii)V-type
iii)Opposed type
iv)Radial
v)W-type
Inline type
All cylinders are arranged linearly in one in one cylinder bank and transmit power to single
crankshaft
V-type
The V-type is essentially two inline engine set at an angle and utilises a common Crankshaft
they run smoothly without much vibration
The two cylinders are arranged horizontally opposite to each other i.e., they are placed 180o apart
facing each other with a common crank shaft. In this type, the reciprocating parts are perfectly
balanced. As two cylinders are not in line, the force in connecting rod produces a rocking couple.
The opposed cylinder engines are used where Light weight and short length are important as in
light aircraft.
Radial
In this type, a number of cylinders are arranged in radial fashion with a common crank shaft which
is placed at the centre as in figure. The number of cylinders generally used is 5, 7, 9 etc., to obtain
uniform firing intervals. This type is compact in size and gives higher Brake power per weight
ratio. This is mainly used in air craft engine
2. List the major components of an engine and mention its function

The major components of engine are
Cylinder head, Cylinder block, Piston, Piston rings, Connecting rod, Crankshaft, Camshaft,
Valve and valve actuating mechanism, Manifolds
Cylinder block
It is the part of the engine in which the conversion of thermal energy to mechanical work takes
place. The piston reciprocates inside the cylinder. Since energy conversion takes place inside the
cylinder it must withstand high pressure and temperature. It must be able to resist wear and tear
and must dissipate heat. So
material selection is an import ant consideration. Ordinary cast iron is used in light duty engines
but in heavy duty engines alloy steels are used. The cylinders are provided with liners so that they
can be replaced when worn out. Liners are made of nickel chrome iron
Cylinder Head
The cylinder head closes one side of the cylinder. They are usually cast as a single piece and are
bolted to the top of the cylinder. Between the cylinder and the cylinder head, gasket is provided
Gasket is provided in order to act as sealing (to prevent gases escaping during the expansion stroke)
and also to reduce shock.
Piston and Piston rings
Piston is the main part of the engine. The main function of the piston is to compress the charge
and to transmit the gas force to the connecting rod during the power stroke. Piston rings are
circumferential rings that are provided in the piston grooves. The piston rings are not fully circular;
there is a clearance (Ring gap)between the two ends. This is provided because during the expansion
stroke piston rings expand
There are two types of piston rings one is compression rings and another one is oil scraper rings.
The upper rings are the compression rings. They help in sealing and preventing the gas from
leaking past the piston into the casing. The lower rings are the oil scraper rings. They are provided
to remove the oil film from the cylinder walls
Connecting Rod
The connecting rod connects the piston and the crankshaft. The piston is connected to the
connecting rod by means of gudgeon pin. It converts the reciprocating motion into rotary motion.
The upper end of the connecting rod is called small head that is connected to the piston and the
lower end is called big end.
Crankshaft
It is steel forged and smooth finished. Both the ends of the crankshaft are supported in the bearings.
One end is provided with the flywheel. The crankshaft is provided with counter weights for
balancing.
Cam and Camshaft
The main function of the camshaft is to open and close the valves at the appropriate time. The cam
is operated by means of gear arrangement driven by the flywheel. The cam converts rotary motion
into linear motion that operates the rocker arm. The motion of the rocker arm operates the valves.
Sometimes two camshafts are provided to operate inlet valve and exhaust valve separately.
Valves
Valves play a major role in allowing the air fuel mixture into the cylinder (inlet valve) for
combustion and also releasing the exhaust gases from the cylinder after combustion (outlet valve).
Manifolds
There are two types of manifolds
Inlet manifold
It is a pipe like structure that connects the carburetor with the inlet valves. The air fuel mixture
from the carburettor passes through the inlet manifold to the inlet valves.
Exhaust manifold:
This pipe like structure connects the outlet valve to the atmosphere. The exhaust gas from the
cylinder passes through the exhaust manifold into the atmosphere.
3. Explain wet and dry liner with the help of diagrams
Dry Liner
Cylinder block
Dry liner
This type of liner is made in the shape of a barrel with flange at the top which keeps it into
position. The entire outer surface bears against the cylinder block casting and hence has to be
machined very accurately both from the inside and the outside. It is put in position by shrinking
the liner. If the liner is too loose in the cylinder block, results in poor heat dissipation because
of the absence of good contact between them. This will result in higher operating temperature.
Improper lubrication results in piston. Too tight a liner is even worse than too loose case. This
produces distortion of cylinder block, inner cracking, hot spots and scuffing.
Wet Liner
This type of liners is in direct contact with cooling water on outside and hence the entire outer
surface does not require very accurate machining. But the water tight joints have to be provided,
at the top, the linear is provided with a flange which fits into the groove in the cylinder block.
At the bottom three grooves. The middle grove is left empty and the top and bottom ones are
inserted packing rings, made with synthetic rubber.
4. Write the functions and Characteristics of Piston
Functions
It is cylindrical shaped component that fits inside the cylinder. The primary functions of piston
are
• To compress the charge during the compression stroke.
• To receive the force or impulse produced by the combustion of fuel and to transmit this
force to the crankshaft through connecting rod.
Characteristics
• The piston should be silent in operation
• It should have corrosion resistant properties
• It should have light weight
• It should have high thermal conductivity
• It should have long life
• It should have shortest possible length and design should be such that seizure doesnot
occur
5. Explain the construction details of piston with neat sketch
A typical piston shown in the figure. The top of the piston is called head or crown. Generally low
performance engines have flat head as shown in figure. Towards the top of the piston few grooves
are cut to house the piston rings. The bands left between the grooves are known as lands. These
lands support the rings against the gas pressure. The supporting webs transmit the force of
explosion directly from the crown to the piston pin bosses, thereby relieving the ring groove
portion of large loads and thus preventing deformation of the ring groove portion of large loads
and thus preventing deformation of the ring grooves. The part of the piston below the rings is
called skirt, Its function is to form a guide suitable for absorbing side thrust due to gas pressure.
The side thrust is produced on account of the inclination of the connecting rod with the cylinder
axis. The skirt is provided with bosses on the inside to support the piston pin. It must be sufficient
length to resisit tilting of the piston under load.
6. What is piston slap and it can be controlled

Piston slap is the major force contributing towards noise levels in combustion engines. This type
of noise depends upon a number of factors such as the piston-liner gap, type of lubricant used,
number of piston pins as well as geometry of the piston
Some methods to reduce the slap noise are:

1) Reduction of of liner-cylinder gap
2) Use of stiff & damped liner.
3) Use of piston pin offest, crankshaft offest to change timings.
4) Using elliptical shaped rings.
7. What are functions of piston rings and explain with diagram

Functions:
• It forms a seal so that high pressure gasses from the combustion chamber will not escape
into the crankcase
• It provide easy passage for heat flow from piston to the cylinder walls
• It maintains enough lubrication oil on cylinder walls throughout the stroke length. This
reduces ring and cylinder wear.
Piston rings are located towards the top of the piston. The top two piston rings are called
compression rings and are designed to maintain cylinder pressure. The bottom ring is called oil
ring, it scrap the excess oil from the cylinder walls and return it through slots to the piston ring
grooves.
A properly constructed and fitted ring will rub against the cylinder wall with good contact all
around the cylinder. The ring will ride in grooves that are cut into the piston head. The material
generally used for piston rings is fine gained alloy cast iron containing silicon and manganese.
Rings with molybdenum filled face have also been introduced recently. Alloy steels are also used.
The number of rings vary depending on the engine design, it varies from two to four
8. Explain the Piston Pin
Piston pin is also known as wrist pin or gudgeon pin, used to connect Piston and connecting
rod. It transfers combustion chamber pressure and piston forces to the connecting rod. It is in
tubular shape to provide adequate strength with minimum weight. It passes through the piston
bosses and small end of the connecting rod. It is made of low carbon case hardened steel (carbon
- 15%, silicon - 0.3%, manganese - 0.5%).
9. Explain the Connecting Rod with a neat sketch

The connecting rod connects the piston and the crankshaft. The piston is connected to the
connecting rod by means of gudgeon pin. It converts the reciprocating motion into rotary
motion. The upper end of the connecting rod is called small head that is connected to the piston
and the lower end is called big end, which is connected to crank shaft.
A combination of axial and bending stresses act on the rod in operation. The axial stresses are
due to gas pressure in the cylinder and inertia force caused by reciprocating motion. Bending
stresses are caused due to centrifugal effects. Connecting rods are manufactured by casting and
forging processes. The rod has an I-beam cross section to provide maximum rigidity with
minimum weight. Generally, rods are made by drop forging of steel or duralumin and also cast
from malleable cast iron
10. Explain the crank shaft with a neat sketch

The function of the crankshaft is to transform reciprocating (linear) motion of piston into rotary
motion. The crankshaft transmits the power developed by the engine to the road wheels through
transmission system. The crankshafts are made of carbon steel.
A simplified sketch of the crank shaft for a four cylinder engine is as-in figure. It consists of
(i).Main journals (ii).Crank pins (iii).Crank webs (iv).Counter weights (v).Oil holes
The crank shaft is held in position by a number of main bearings and they form axis for the
rotation of crank shaft. Their number is always one more or one less than the number of
cylinders. The crank pins are the journals for the connecting rod big end bearings and are
supported by the crank webs. The distance between the axis of the main journal and the crank
pin centre lines is called 'crank through'. Oil holes are drilled from main journals to the crank
pins through 'crank webs for lubricating big end bearings.
When the engine is running, due to rotation of both crank shaft and connecting rod big end,
each crank pin will be subjected to centrifugal forces. This will tend to bend the crank shaft. To
avoid these counter weights are used. The counter weights are formed as integral part of the
crank web or may be attached separately as in fig. On the front of the crank shaft, it is mounted
with
i). Timing gear or sprocket which drives the crank shaft.
ii). Vibration damper
iii). Pulley for driving the water pump, fan and the generator. On the rear end, it is mounted
with a fly wheel. On the main bearing journals, thrust bearing is located so as to support the
loads in the direction of shaft axis. Such loads may arise due to clutch release forces etc
11. Explain the Engine valves

The valves are the devices which controls the flow of the intake and the exhaust gases to and from
the engine cylinder. These valves are operated by means of cams driven by the crankshaft through
a timing gear or chain. These are provided on the cylinder head,
• Inlet valve is used to take the fresh mixture into the cylinder.
• Exhaust valve is used to expel burnt gases from the cylinder
During the operation the intake valves reaches to 500 degrees Celsius and approx. 800 to 900
degrees for exhaust valves
The engine valves may be classified into

1. Poppet valve
2. Sleeve valve
3. Rotary valve
Poppet valve is generally used for automobile engines
Silicon - Chrome steel (Carbon - 0.4%, nickel- 0.5%, manganese - 0.5%, silicon -3.5%, chromium
- 8%) is the material used for inlet valves. For exhaust valves, molybdenum is added to it. Recently
austenitic steels are used for exhaust valves. To make it corrosion resistant, the valve may be coated
with aluminium.
12. With a neat sketch explain Poppet valve
The valves are the devices which controls the flow of the intake and the exhaust gases to and
from the engine cylinder. They are also called poppet valves. These valves are operated by
means of cams driven by the crankshaft through a timing gear or chain
Its name is derived due to its motion of popping up and down. As the shape resembles a
mushroom, this valve is also called as 'mushroom' valve. It consists of a head and a stem. It is
simple in construction and self centring. Sealing efficiency maintenance is much easier with
this poppet valve
13. With a neat sketch explain Sodium cooled valve
Engine exhaust valves are some of the most highly stressed components on the entire engine.
These valves can reach up up 800 degrees C in modern engines and actuate move over 70 times
per second. Because of the tremendous amount of heat these valves see, they need to be properly
cooled to prolong their life.
solution to properly cool the valves was to fill the hollow valve stems about 67% with sodium. At
room temperature sodium is a solid, however at normal engine operating temperature the sodium
turns to a liquid. In this liquid state the sodium has remarkable heat transfer properties. The
movement of the valves up and down help transfer heat from the base of the valve to the tip of the
stem. The top part of the cylinder head then extracts heat from the stem and dissipates it into the
coolant flowing through the head as well as the oil circulating under the valve cover.
14. Write the classification of valve operating mechanism and explain any
one type
The valves located in the cylinder head are operated by an eccentric projection called cam, which
is driven at half the crankshaft speed. Different valve operating mechanisms are
• Side valve mechanism

• Overhead valve mechanism
• Overhead inlet and side exhaust valve mechanism
Side valve Mechanism
This mechanism is used for L-head engines. In this type inlet and exhaust valves are mounted in a
single row and operated from the same crank shaft. Now a days this mechanism is obsolete due to
complicated shape of combustion chamber which leads to detonation
Overhead valve mechanism
This mechanism is suitable for I and F head design. The cam operates the valve lifter which in turn
actuates the push rod. This action rotates the rocker arm about a shaft or a ball joint in some design
to cause one end to push down on the valve stem to open the valve
The advantages of overhead valve mechanism are
• Higher volumetric efficiency

• Leaner air-fuel mixture can be burnt
• Higher compression ratio can be achieved
15.Explain the various components of the valve actuating mechanisms

The various components of valve actuating mechanism are
i) Camshaft
ii) Valve tappet
iii) Push rod
iv) Rocker arm
Cam Shaft: It provides a means for opening the valves. It carries one cam for each valve to be
operated. It also provides a drive for the ignition distributor and the mechanical fuel pump. The
cam shaft is driven by the crank shaft by means of timing gears or chain drive at half the speed
of crank shaft. It is forged from alloy steel or cast from hardenable cast iron and is case
hardened.
Valve tappet (valve lifter or cam follower) : It follows the shape of the cam lobe on the
cam shaft and hence converts angular movement of the cam in to a reciprocating motion. This
is placed slightly eccentric with earn to make the cam wear uniform and is located between
push rod and cam.
Push Rod: This is placed between valve tappet and rocker arm and transmits reciprocating
motion of valve tappet to the rocker arm. Push rods are made of steel and may be either solid
or hollow. Hollow push rod is lighter and results in reduced inertia forces. It provides a
passage for the oil to lubricate the valve actuating mechanism.
Rocker Arm: It may be solid or hollow and changes (reverse) the upward motion of the push
rod to down ward motion of the valve and vice versa. It is made of steel (forged or stamped)
or iron (cast).
16. Define Valve timing diagram and explain actual valve timing diagram of
SI engine
A valve timing diagram is a graphical representation of the opening and closing of the intake and
exhaust valve of the engine, The opening and closing of the valves of the engine depend upon the
movement of piston from TDC to BDC, This relation between piston and valves is controlled by
setting a graphical representation between these two, which is known as valve timing diagram
• Inlet Valve (IV) opens 15o before TDC

• Inlet Valve (IV) closes 30o after BDC to take the advantage of momentum of rapidly moving
gases
• Ignition occurs 35o before TDC: this is to allow the time delay between the spark and
commencement of combustion
• Exhaust Valve (EV) opens at 50o before BDC: else pressure will rise enormously and the
work required to expel the gas will increase
• Exhaust Valve (EV) closes at 20o after TDC: this is to increase the volumetric efficiency
The inlet valve opens before TDC and closes after BDC: This is arrangement so as to get maximum
charge inside the cylinder. When the IV opens, the charge outside the valve has to be accelerated
upto the valve inlet velocity and this takes time. In order that maximum inlet velocity occurs at the
earliest possible moment during the intake stroke, the IV is opened early. The kinetic energy of
the moving charge is used at the end of the intake stroke to produce a ramming effect by closing
the IV slightly after BDC. The ramming effect thus increases the volumetric efficiency.
The exhaust valve opens before BDC so as to exhaust the combustion products efficiently. Thus
by virtue of its excess pressure above atmosphere, some exhaust gas leaves the cylinder. This
makes the exhaust gas to flow freely from the cylinder by the time piston commences the exhaust
stroke. Again by closing the EV after TDC, the kinetic energy of the exhaust gas can be utilized
to assist in maximum exhausting of the gas. In the process, the IV begins to open before the EV
closes and this is called valve overlap.
17. Explain actual valve timing diagram of CI engine
• Inlet Valve (IV) opens 25o before TDC

• Inlet Valve (IV) closes 25o after BDC to take the advantage of momentum of rapidly moving
air
• Fuel injection occurs 5o before TDC and closes 25o after TDC: this is to allow the time delay
period and commencement of combustion
• Exhaust Valve (EV) opens at 50o before BDC: else pressure will rise enormously and the
work required to expel the gas will increase
• Exhaust Valve (EV) closes at 15o after TDC: this is to increase the volumetric efficiency
18. What is the purpose of the valve overlap?

Valve overlap is a condition where both valves (inlet valves and exhaust valves) are both open.
The purpose of the overlap is to flush the exhaust gasses using fresh air. When both valves are
open together it will allow fresh air to enter and then push the exhaust gas so that in the next cycle,
the fresh air content becomes more maximal
In petrol engine, more overlapping is not advisable, because air and fuel mixture may pass out
with the exhaust gases and is uneconomical. But in diesel engine, only air is drawn during suction
stroke and hence such problem will not arise. This overlapping helps in scavenging, resulting in
an increased output.
19. Explain port timing diagram of SI engine
20. What are the requirements while designing combustion chamber in SI

engine
The design of combustion chamber has an important influence upon the engine performance and
its knock properties. The design of combustion chamber involves the shape of the combustion
chamber, the location of the spar shape of the combustion chamber, the location of the sparking
plug and the disposition king plug and the disposition of inlet and exhaust valves.
Basic requirements of a good combustion chamber
• High power output High power output

• High thermal efficiency and low specific fuel consumption
• Smooth engine operation Smooth engine operation
• Reduced exhaust pollutants.
i) Higher power output requires the following

a) High compression ratio.
b) Small or no excess air.
c) Complete utilization of the air –no dead pockets.
d) An optimum degree of turbulence.
e) High Volumetric Efficiency.
ii) High thermal efficiency requires the following
a) High compression ratio:
b) A small heat loss during combustion.
c) Good scavenging of the exhaust gases
iii) Smooth engine operation
a) Moderate rete of pressure rise during combustion
b) Absence of detonation
• Compact combustion chamber

• Proper location of the spark and exhaust valve
• Satisfactory cooling of the sparkplug points (to avoid pre-ignition) and exhaust valve
head which is the hottest region of the combustion chamber
iv) Reduced exhaust pollutants

Exhaust pollutants can be reduced by designing a combustion chamber that produces a faster
burning rate of fuel. A faster burning with its shorter burning time permits operation with
substantially higher amounts of exhaust gas recirculation, which reduces the oxides of
nitrogen in the exhaust gas without substantial increase in the hydrocarbon emissions
21. What is air swirl? What are the methods of swirl generation in CI engine
In CI engine fuel is injected near the end of compression and mixing of fuel and air take place
inside the combustion chamber. Thus combustion chamber has to perform duty of carburetor,
within a period of some 20 to 35 degrees of crank angle. The combustion chamber design should
be such that it has to provide proper mixing of fuel and air in a short time. To achieve this, an
organized air movement called air swirl is provided to produce high relative velocity between
the fuel and air.
Different methods are used to generate air swirl in CI engine combustion chamber, they are
22. Explain the with neat sketch the different types of combustion chambers
in SI engine
• T-head combustion chamber.
• L-head combustion chamber.
• I-head (or overhead valve) combustion chamber.
• F-head combustion chamber
These chambers are designed to obtain the objectives namely:
• A high combustion rate at the start.
• A high surface-to-volume ratio near the end of burning.
• A rather centrally located spark plug.
T Head Type Combustion chambers
This type of combustion chambers was used in the early stages of the engine’s development.
In this type of combustion chamber, the knocking tendency is more because of the distance
across the combustion chamber is long. There is need of two cam shafts for the two valves.
which is another disadvantage.This was first introduced by Ford Motor Corporation in 1908.
Diadvantages
• Requires two cam shafts (for actuating the in-let valve and exhaust valve
separately) by two cams mounted on the two cam shafts.
• Very prone to detonation due to long flame travel. There was violent detonation
even at a compression ratio of 4. This is because the average octane number in 1908
was about 40 -50
L-head combustion chamber
It is a modification of the T-head type of combustion chamber. It provides the two values on
the same side of the cylinder, and the valves are operated through tappet by a single camshaft.
This was first introduced by Ford motor in 1910-30 and was quite popular for some time. This
design has an advantage both from manufacturing and maintenance point of view. The spark
plug is placed at the centre of the combustion chamber, the flame travel length is reduced. The
knocking is also reduced with this head design.
I- head (or overhead valve) combustion chamber
• Since 1950 or so mostly overhead valve combustion chambers are used.
• This I-Head type combustion chamber is also called as the overhead valve combustion
chamber. Both inlet and the exhaust valves are located on the top of the cylinder head.
• The main advantage of this combustion chamber is that it can achieve high compression
ratios, and also less tendency to the knock. High volumetric efficiency. We can avoid the
thermal failures by keeping the hot exhaust valve in the head instead of the cylinder.
F-head combustion chamber
The F-Head type combustion chamber in the above diagram, One exhaust valve is in the cylinder
head, the inlet valve in the side, and the spark plug is in the cylinder head. Again this has the same
disadvantage as the T-Head type combustion chamber as the two valves need to be operated by
two different camshafts.
23. Explain the importance of turbulence in CI engine
i) It is essential to have well organised movement of air within the combustion chamber for
• Speedy evaporation of fuel
• To enhance air fuel mixing
• To increase combustion speed and
• To increase efficiency.
ii) The main aim of the CI combustion chamber design is to ensure proper mixing of fuel with
the air in a very short time. To achieve this well organised movement of air is essential.
Turbulence in the CI engines is quite systematic and built into the design. It would be desirable
to understand various types of movements of the air within the combustion chamber.
• Turbulence is quite high during suction and recedes towards BDC.

• Again during compression the turbulence increases as swirl, squish and tumble.
24.Explain the with neat sketch the different types of combustion chambers
in CI engine
Unlike spark Ignition combustion chambers, the main important function of the combustion
chamber of CI engines is to allow the injected fuel to properly mix with the pre-compressed air in
a short time. In Compression Ignition engines, Turbulence is necessary to mix the fuel within a
short period after injecting the fuel into the combustion chamber. It can be controlled by the
combustion chamber shape and design
There are two different types of combustion chambers for CI Engines.
• Direct Injection type

• Indirect Injection type
Direct Injection type combustion chambers
Direct Injection type combustion chambers are also known as the open type combustion chambers.
This open type combustion chambers, the combustion chamber volume will be located in the
cylinder. The fuel will be injected directly into the combustion chamber with the help of the fuel
injector.
There are four design variants available in Direct Injection type combustion chambers. those are
i) Shallow depth chamber

ii) Hemispherical chamber
iii) cylindrical chamber
iv) Toroidal chamber
Shallow depth chamber
Shallow depth combustion chambers are mostly used in the heavy engines running with the low
speeds. As you can see the shallow depth chamber diagram, the depth of the cavity provided in
the piston is quite small and the diameter is large. Due to the large diameter, there will be almost
negligible squish.
Hemispherical chamber
In hemispherical chamber, the depth to the diameter ratio can be varied. so that the squish can be
controlled to attain better performance.
Cylindrical Chamber
In a few modern diesel engines, this type of combustion chambers was implemented. As you can
see the Cylindrical Chamber diagram, the shape of the combustion chamber is truncated cone with
the base angle of 30°. The Squish can be varied by varying the depth. The swirl can be produced
by masking the valve for nearly 180°of the circumference. Squash also can be controlled by
varying the depth.
Toroidal Chamber
This Toroidal chamber design is mainly focused to provide the powerful Squish along with the
air moment. As the more Squish, the mask needed on the inlet valve is small and there is better
utilization of oxygen.
Indirect Injection type combustion chambers
There are three variant designs available in indirect Injection type combustion chambers. those
are
i) Swirl Chamber
ii) Pre-combustion chamber
iii) Air cell chamber
Swirl Chamber
This is also known as the Ricardo swirl chamber. Swirl combustion chamber consists of the
spherical-shaped chamber located in the cylinder head separated from the engine cylinder. During
the compression stroke, 50% of the air will be transferred to this swirl chamber. In this spherical
shaped swirl chamber, the fuel will be injected with the help of a nozzle and the combustion will
be initiated.
The main drawback of this chamber is that the heat loss is greater compared to the open combustion
chambers.
These chambers are used where the less quality of fuels are used. Where reliability is the main
objective than the fuel economy.
Pre-combustion chamber
It consists of the Prechamber connected to the main chamber. This Prechamber located in the
cylinder head. This Prechamber volume accounts for 40% of the total combustion space.
During the compression stroke, the air will be injected into the Prechamber the combustion will
be initiated in it. But the bulk combustion will be taken place in the main chamber only. About
80% of the energy will be released in the main combustion chamber.
The rate of pressure rise and the maximum pressure attain during the combustion process is
comparatively low than the open combustion chambers.
Air-Cell Chamber
The air cell is more complex than the pre-combustion chamber. As the piston moves up on the
compression stroke, some of the air is forced into the major and minor chambers of the energy
cell. When the fuel is injected through the pintle type nozzle, part of the fuel passes across the
main combustion chamber and enters the minor cell, where it is mixed with the entering air.
Combustion first commences in the main combustion chamber where the temperature is higher,
but the rate of burning is slower in this location, due to insufficient mixing of the fuel and air. The
burning in the minor cell is slower at the start, but due to better mixing, progresses at a more rapid
rate. The pressure built up in the minor cell, therefore , force the burning gases out into the main
chamber, thereby creating added turbulence and producing better combustion in the this chamber.
In mean time, pressure is built up in the major cell which then prolongs the action of the jet stream
entering the main chamber, thus continuing to induce turbulence in the main chamber
25.Write the advantages and disadvantages of direct and indirect combustion

chambers
Advantages of Direct Injection type combustion chambers
• Minimum Heat loss during the compression because of lower surface area to volume ratio
results in better efficiency.
• Cold starting problems can be avoided.
• The multi-hole nozzle can be possible and hence fine atomization can be achieved.
Disadvantages of Direct Injection type combustion chambers
• High fuel injection pressure required. Hence complex design of fuel injection system.
• Metering of fuel should be accurate. Particularly for small engines.
Advantages of indirect Injection type combustion chambers
• Injection pressure required is low.
• The direction of the spray is not that important.
Disadvantages of indirect Injection type combustion chambers
• Poor cold starting performance.
• Specific fuel consumption is high.
26.Explain the different engine positioning in automobile

(a) Front Position
In most of the lighter vehicles (both private and commercial), the engine is placed at the front and
conventionally rear wheel drives are used. In some of the vehicles drive is also given to front
wheels only. The engine position remains 'the same in heavy commercial vehicles, but the cab is
brought forward over the engine to increase the pay load. The engine position at the front with rear
wheel drive system needs greater length of propeller shafts, as it has to run from front (engine side)
to the rear (road wheels) of the vehicle. Also, in this system, the numbers of universal joints
required are more.
(b)Rear Position
In this system, the engine is mounted close to the back axle, thereby reducing the length of drive
from engine to the axle. In this position, length of propeller shaft required is reduced and is suitable
for small cars. This position provides more space to the passengers, results in economy of drive
parts and also better engine service is possible. The fixing of gear shift lever, oil gauge and fuel
gauges, accelerator linkage is very complicated due to missing of natural draft of air during forward
motion of vehicle to the radiator.
The major portion of total weight of the vehicle lies on the rear wheels and hence helping in traction
up the hill. With rear position of the engine, the luggage has to be accommodated at front, near the
driver seat, which is a problem as wheel arches are already occupied a large place there.
(c) Under Floor Position

This position of the engine is in the centre, under the chassis and is used in public service vehicles
and heavy lorries. This position of the engine eliminates the heat and noise in the cabin. In this
position the advantages of gravitational flow of the fuel and lubricants are also taken. It also
reduces length of the drive shaft from engine to rear axle. The engine repairs and hence
maintenances are easy.
27.What are the various methods of engine cooling? Explain with sketch the
thermo syphon system of cooling
The various methods of cooling are
• Air cooling
• Water cooling: it include Thermosyphon and pump circulation type
• Liquid cooling
Thermo syphon system of cooling
In this method of water cooling, the circulation of water is obtained due to the difference in
densities of hot and cold regions of the cooling water. There is no pump to circulate the water. The
hot water from the engine jacket being lighter rises up in the hose pipe and goes in the radiator
from the top side. It is cooled there and hence goes down at the bottom side of the radiator from
there it goes again to the engine jackets. The system is quite simple and economical but the cooling
is rate is slow. To maintain continuity of water flow, the water must be maintained up to the certain
minimum level, if the water level falls down, the circulation will discontinue and the cooling
system will fail.
28.With neat sketch explain pump circulation system of water cooling
The main function of the cooling system in automobile is to maintain the optimum temperature of
engine during operating condition. Figure shows the pump circulation system of water cooling.
The major parts of this system are water jackets, water pump, thermostat, radiator, radiator pressure
cap and hose pipe. In this system the circulation of water is obtained by a pump. The pump is
driven by means of a belt from the engine crankshaft.
This principle is similar to thermo siphon system but the heat dissipated by the engine is so large
that it is not possible to cool the engine by thermo siphon principle. To enable faster cooling, a
pump is introduced to the system between the radiator and the engine block. When the pump
rotates water is circulated with some force, therefore heat of the engine block is removed quickly
without any difficulty.
29.Explain the different types of thermostat valves

A thermostat is used to regulate the rate of cooling. It keeps the cooling water temperature at a
predetermined value.
Two types of thermostats are used in automobiles.
1.Bellows or aueroid type
2.Wax or hydrostatic type
Bellows type
This thermostat consists of metallic bellows filled with some volatile liquids like alcohol, acetone,
ether etc., whose boiling temperature ranges between 70-85°C. One end of bellows contains a
valve and to the other end a frame is attached' which fits in to the cooling passage. The thermostat
is fitted in the water hose pipe at the engine outlet. After the engine has started, cooling system
should not operate during warming up duration~ that engine warms up early. During this warming
up period, the liquid inside the bellows has not yet changed its state and hence does not exert any
pressure on the valve. Therefore the valve remains in closed position.
If the temperature of the cooling water exceeds a pre-determined as 80°C the liquid inside the
bellows. Vaporizes and exerts a pressure on the valve. The valve opens and allows water
circulation through the radiator, As water temperature rises, valve opens gradually, thus controls
the flow of water through the radiator according to engine cooling requirement.
Wax thermostat
This thermostat is more reliable to operate within the specified temperature range and is not
sensitive to pressure variations. The heat carried by the coolant is transmitted to the copper loaded
wax having high thermal expansion coefficient
The expansion of copper loaded wax makes the rubber plug to contract against the plunger and
hence exerts a force on it in upward direction. This makes the plunger to move upward and opens
a valve in the thermostat (Not shown). This allows the coolant to flow through the radiator.
30. Explain the Automobile Radiator with a neat sketch

A radiator is a heat exchanger that is used to transfer thermal energy from one medium to another
for the essence of cooling and heating. Radiators are consisting of a large area of the cooling
surface and use the stream of air to take away the surrounding heat. with easy access to the coolant
heat, efficient cooling is achieved.
Automotive radiator is one of the components of water-cooling system in automotives. It consists

of:
(a) Upper tank (header)
(b) Core
(c) Lower tank (collector)
(d) Overflow pipe
(e) Drain pipe
Radiator ensure the close contact of the hot coolant coming out of the engine with outside air, so
as to ensure high rates of heat transfer from the coolant to air. Hot coolant from the engine enters
the radiator at the top (upper tank) and is cooled by the cross-flow of air, while flowing down the
radiator. The coolant collects in the lower tank from where it is pumped to the engine for cooling.
31. What are the objectives of the lubrication system

The main objects of lubrication are
(a) It reduces power loss by minimizing friction between moving parts.
(b) Decreases wear and tear of the moving components.
The lubrication also serves other purposes like.
• Cooling effect
• Cushioning effect
• To act as cleaning agent
• Sealing action
32. Explain splash type of lubrication with neat sketch
This was employed for the engines of early motor cycles. It is one of the cheapest methods of
engine lubrication. A scoop is made in the lowest part of the connecting rod and the oil is stored
in the oil trough, it being pumped there from the crankcase oil sump. When the engine runs, the
scoop causes the oil to splash on the cylinder walls each time it passes through its BDC position.
This affects the lubrication of engine walls, gudgen pin, main crankshaft bearings, big end
bearings.
33. Explain Pressure Feed System(Forced feed) type of lubrication with neat
sketch Pressure Feed System
This system is most commonly used in modern car engines. In this system, the oil forces oil
under pressure to the main bearings, connecting rod and cam shaft bearings and also to the
timing gears. Drilled assuages in the crank shaft carry oil from the main bearings to the
connecting rod bearings. The cylinder walls, piston pin, piston and piston rings are
lubricated by oil spray from the connecting rod and crank shaft. For the cam shaft and timing
gears, there is a separate oil line from the main oil gallery. The basic components of the wet
lubricating system are pump, strainer, pressure regulator, filter etc
34. Explain the major components of Electric car
Traction Battery Pack: The function of the battery in an electric car is as an electrical energy
storage system in the form of direct-current electricity (DC).
DC/DC converter: This device converts higher-voltage DC power from the traction battery pack
to the lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary
battery
Power electronics controller: This unit manages the flow of electrical energy delivered by the
traction battery, controlling the speed of the electric traction motor and the torque it produces.
Charge port: The charge port allows the vehicle to connect to an external power supply in order
to charge the traction battery pack
Electric traction motor: Using power from the traction battery pack, this motor drives the
vehicle's wheels. Some vehicles use motor generators that perform both the drive and
regeneration functions.
Onboard charger: Takes the incoming AC electricity supplied via the charge port and converts
it to DC power for charging the traction battery
Thermal system (cooling): This system maintains a proper operating temperature range of the
engine, electric motor, power electronics, and other components
Transmission (electric): The transmission transfers mechanical power from the electric traction
motor to drive the wheels
35. List the advantages and disadvantages of Electric vehicles
Advantages
• No Petrol/Diesel Required
• More Convenient
• No Emissions
• Low Maintenance
• Reduced Noise Pollution
• Easy Driving
Disadvantages
• Limited Recharge Points

• The Initial Investment is high
• Short Driving Range and Speed
• Longer Recharge Time
• Normally 2 Seaters
• Battery Replacement cost is high
35. Explain the major components of Hybrid Vehicle
36. List the advantages and disadvantages of Electric vehicles

Module1 - Engine Components - Cooling, Lubrication-Lecture Notes

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Automotive Engineering (18ME752)

7th Sem Mechanical Engineering

Department of Mechanical Engineering

1. Explain the various methods of cylinder arrangements in multicylinder

2. List the major components of an engine and mention its function

3. Explain wet and dry liner with the help of diagrams

4. Write the functions and Characteristics of Piston

5. Explain the construction details of piston with neat sketch

6. What is piston slap and it can be controlled

Some methods to reduce the slap noise are:

7. What are functions of piston rings and explain with diagram

8. Explain the Piston Pin

9. Explain the Connecting Rod with a neat sketch

10. Explain the crank shaft with a neat sketch

11. Explain the Engine valves

The engine valves may be classified into

12. With a neat sketch explain Poppet valve

13. With a neat sketch explain Sodium cooled valve

• Side valve mechanism

Side valve Mechanism

Overhead valve mechanism

The advantages of overhead valve mechanism are

• Higher volumetric efficiency

15.Explain the various components of the valve actuating mechanisms

• Inlet Valve (IV) opens 15o before TDC

17. Explain actual valve timing diagram of CI engine

• Inlet Valve (IV) opens 25o before TDC

18. What is the purpose of the valve overlap?

19. Explain port timing diagram of SI engine

20. What are the requirements while designing combustion chamber in SI

• High power output High power output

i) Higher power output requires the following

a) Moderate rete of pressure rise during combustion

• Compact combustion chamber

iv) Reduced exhaust pollutants

L-head combustion chamber

I- head (or overhead valve) combustion chamber

• Since 1950 or so mostly overhead valve combustion chambers are used.

F-head combustion chamber

23. Explain the importance of turbulence in CI engine

• Turbulence is quite high during suction and recedes towards BDC.

There are two different types of combustion chambers for CI Engines.

• Direct Injection type

i) Shallow depth chamber

Shallow depth chamber

Indirect Injection type combustion chambers

25.Write the advantages and disadvantages of direct and indirect combustion

26.Explain the different engine positioning in automobile

(c) Under Floor Position

Thermo syphon system of cooling

28.With neat sketch explain pump circulation system of water cooling

29.Explain the different types of thermostat valves

30. Explain the Automobile Radiator with a neat sketch

Automotive radiator is one of the components of water-cooling system in automotives. It consists

31. What are the objectives of the lubrication system

32. Explain splash type of lubrication with neat sketch

34. Explain the major components of Electric car

35. List the advantages and disadvantages of Electric vehicles

• Limited Recharge Points

35. Explain the major components of Hybrid Vehicle

36. List the advantages and disadvantages of Electric vehicles

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