ICE’s Cooling Systems

ICE’s Cooling Systems

ICE

ICE’s Cooling Systems

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28/3/2024
1. Youssef Ahmed Mohamed
2. Mohamed Ahmed Taha
3. Moamen Mohamed Abdel- Azeez
4. Waleed Hamdi
5. Khaled Mohamed Owais
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TABLE OF CONTENTS:

page
1. Introduction 2 2
2. Types of Cooling Systems 2 2
2.1. Air Cooling System 2 2
2.1.1. Advantages of Air Cooling 3 3
2.1.2. Disadvantages of Air Cooling 3 3
2.2. Liquid Cooling System4 4
2.2.1. Components of Liquid Cooling System 6 6
2.2.2. Advantages of Liquid Cooling 8 8
2.2.3. Disadvantages of Liquid Cooling8 8
3. Cylinder Liners 9 9
3.1. Function of Cylinder Liners9 9
3.2. Types of Cylinder Liners 9 9
3.3. Advantages of Cylinder Liners 10 10
3.4. Disadvantages of Cylinder Liners10 10
4. Temperature Switches 11 11
5. Cooling System Troubleshooting 13 13
6. Summary 13 13
7. References 14 14
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1. INTRODUCTION:
About 35 % percent of the total chemical energy that enters an engine in the fuel is converted to
useful crankshaft work, and about 30% of the fuel energy is carried away from the engine in the exhaust flow
in the form of enthalpy and chemical energy. This leaves about one-third of the total energy that must be
dissipated to the surroundings by some mode of heat transfer. Temperatures within the combustion chamber
of an engine reach values on the order of 2700 K and up. Materials in the engine cannot tolerate this kind of
temperature and would quickly fail if proper heat transfer did not occur. Removing heat is highly critical in
keeping an engine and engine lubricant from thermal failure. On the other hand, it is desirable to operate an
engine as hot as possible to maximize thermal efficiency.
The primary purpose of the cooling system is to assure that the engine's temperature is maintained at a
level that will ensure satisfactory engine life. This must be done without overheating any other part of the
engine. Heat may be a major factor in the wear of engine valves, seats, and guides. In addition to causing
damage to these parts, excessive heat will begin to affect the engine oil. While all oil will oxidize and lose
viscosity with an increase in temperature.

Two general methods are used to cool combustion chambers of engines:

1. The engine block of a water cooled engine is surrounded with a water jacket that contains a coolant
fluid which is circulated through the engine.
2. An air-cooled engine has a finned outer surface on the block over which a flow of air is directed.

2. TYPES OF COOING SYSTEMS:

2.1. Air Cooling System
The air-cooled system is mainly used in small engines and in some medium-sized engines. Most small-
engine tools and toys like lawnmowers, chain saws, model airplanes, etc. are air cooled. This system occupies
less space, and allows the weight and cost of these engines to be kept low. Some motorcycles, automobiles,
stationary engines and aircraft also have air-cooled engines because of their lower weights.

In air-cooled engines the current of air flows across the external surfaces of the cylinder walls and the
cylinder head to remove the necessary heat and hence to prevent them from overheating. The film heat transfer
coefficient of air is low compared to that of liquid. The rate of heat transfer is, therefore, improved by increasing
the surface area in the air-cooled system. This is accomplished by providing extended surfaces, called cooling
fins, on the outer surfaces of the engine, such as cylinder walls and the cylinder head as shown in Figure 2.1. The
outer surfaces of the engine and fins are made of good heat-conducting metals to promote maximum heat
transfer. On mobile vehicles, like motorcycles and aircraft, the forward motion of the vehicle supplies the air flow
across the finned surfaces. Deflectors and duct work are often added to direct the flow to critical locations.
Automobile engines usually have fans to increase the rate of air flow.
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Figure 2.1 cylinder and cylinder head of an air- cooled by fins.

2.1.1. Advantages of Air Cooling

1. Its design of air-cooled engine is simple.
2. It is lighter in weight than water-cooled engines due to the absence of water jackets, radiator, circulating
pump and the weight of the cooling water.
3. It is cheaper to manufacture.
4. It needs less care and maintenance.
5. Suitable for smaller engines like motorcycles and scooters.

2.1.2. Disadvantages of Air Cooling

1. Limited cooling efficiency.
2. Not ideal for high-performance or larger engines.
3. Higher risk of overheating.
4. Less precise temperature control.
5. Can be noisier due to fans.
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2.2 Liquid Cooling System

The engine block of a water-cooled engine is surrounded with a water jacket through which coolant liquid
flows (Fig. 2-2). This allows for a much better control of heat removal at a cost of added weight and a need for
a water pump. The cost, weight, and complexity of a liquid coolant system makes this type of cooling very rare
on small and/or low-cost engines.

Figure 2.2 Liquid cooling engine.

Very few water-cooled engines use just water as the coolant fluid in the water jacket. The physical
properties of water make it a very good heat transfer fluid, but it has some drawbacks. Used as a pure fluid it
has a freezing point of 0°C ,unacceptable in northern winter climates. Its boiling temperature, even in a
pressurized cooling system, is lower than desired, and without additives it promotes rust and corrosion in many
materials. Most engines use a mixture of water and ethylene glycol, which has the heat transfer advantages of
water but improves on some of the physical properties. Ethylene glycol (C 2H6O2), often called antifreeze, acts
as a rust inhibitor and a lubricant for the water pump, two properties not present when water is used alone.
When added to water, it lowers the freezing temperature and raises the boiling temperature, both desirable
consequences. This is true for mixtures with ethylene glycol concentrations from a very small amount up to
about 70%.
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In addition to good thermal properties, a coolant should satisfy the following requirements:

1. Chemically stable under conditions of use

2. Non-foaming

3. Non-corrosive

4. Low toxicity

5. Non-flammable

6. Low cost

The coolant system of a typical automobile engine is shown in Fig. 2-2. Fluid enters the water jacket of the
engine, usually at the bottom of the engine. It flows through the engine block, where it absorbs energy from the
hot cylinder walls. The flow passages in the water jacket are designed to direct the flow around the outer
surfaces of the cylinder walls and past any other surface that needs cooling. The flow is also directed through
any other component that may need heating or cooling (e.g., heating of the intake manifold or cooling of the oil
reservoir). The flow leaves the engine block containing a high specific enthalpy because of the energy it
absorbed in engine cooling. Exit is usually at the top of the engine block.

Enthalpy must now be removed from the coolant flow so that the circulation loop can be closed and the
coolant can again be used to cool the engine. This is done by the use of a heat exchanger in the flow loop called,
for some unknown reason, a radiator. The radiator is a honeycomb heat exchanger with hot coolant flowing
from top to bottom exchanging energy with cooler air flowing from front to back. Air flow occurs because of
the forward motion of the automobile, assisted by a fan located behind the radiator and either driven electrically
or off the engine crankshaft. The cooled engine coolant exits the bottom of the radiator and reenters the water
jacket of the engine, completing a closed loop. A water pump that drives the flow of the coolant loop is usually
located between the radiator exit and engine block entrance. This pump is either electric or mechanically driven
off the engine. Some early automobiles had no water pump and relied on a natural convection thermal flow
loop.

To keep the coolant fluid temperature from dropping below some minimum value, and thus keeping the
engine operating at a higher temperature and efficiency, a thermostat is installed in the coolant loop, usually at
the engine flow entrance. A thermostat is a thermally activated go-no go valve. When the thermostat is cold, it
is closed and allows no fluid flow through the main circulation channel. As the engine warms up, the thermostat
also warms up, and thermal expansion opens the flow passage and allows coolant circulation. The higher the
temperature, the greater the flow passage opening, with the greater resulting coolant flow. The coolant
temperature is, therefore, controlled fairly accurately by the opening and closing of the thermostat.
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2.2.1. Components of Liquid Cooling System

Figure 2.3 Components of liquid cooing system

1. Water Pump

A centrifugal type of pump is normally used for the cooling system. The
hub and pulley assembly of the pump is driven by a fan belt, or the pump is
mounted on a common shaft with the fan. Water or coolant enters into the
eye of the pump through the inlet pipe from the bottom of the radiator and it
is caught by the rotating vanes of the impeller and is thrown by centrifugal
force through the outlet to the water jackets. Because of the clearance
between the impeller blades and the pump casing, centrifugal pumps are
non-positive in action and will not build up dangerous pressures if an
obstruction occurs in the radiator or other parts of the system.
Figure 2.4 Water pump
2. Radiator
The purpose of the radiator is to cool the water that has absorbed heat
from the engine. It is a heat exchanger in which the water passing
downwards through it in thin streams is efficiently cooled by the forced flow
of atmospheric air over a large surface area around the pipes or tubes
carrying the water.

Figure 2.5 Radiator

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3. Pressure/Radiator Cap:

The radiator cap is also known as a pressure cap, as its primary function is
to maintain the pressure in the cooling system. The high pressure in the car
cooling system increases the boiling point of the coolant, thereby helping it
cool down more efficiently. The pressure cap is, therefore, an essential
component that needs regular replacement.
Figure 2.6 Pressure cap

4. Cooling Fan:
The radiator contains cooling fans that drive fresh air over the radiator,
allowing the engine to be cooled down further. The fan is located at the front
of the vehicle. It automatically turns on when the coolant gets too hot and
switches off when the coolant reaches adequate temperature.

Figure 2.7 Cooling fan

5. Heater Core:

The heater core serves the dual purpose of providing warmth to the car's
interior when needed. Similar in appearance to a radiator, it is connected to
the water pump with rubber hoses. A fan blower blows air through the heater
core, transferring heat from the hot coolant to the vehicle's interior.
Figure 2.8 Heater core
6. Overflow Tank (Coolant Explosion Tank):
The coolant expansion tank (shown in Fig-10) acts as a reservoir for
excess coolant whenever there is a change in the volume. For instance, when
the coolant gets hot, it expands. The overflow tank then holds the additional
quantity, thereby maintaining the accurate level of coolant in the cooling
system. The tank cap also uses a special valve to maintain the pressure level
and keep the air out of the system.
A word of caution; NEVER open the radiator cap or the overflow tank
when the engine is hot. It could lead to some fatal burns and injury. Figure 2.9 Overflow tank

7. Thermostat:
Whenever the engine is started from cold, the coolant
temperature has to be brought to the desired level in order
to minimize the warm up time. This can be achieved by a
thermostat fitted in the system which initially prevents the
circulation of water below a certain temperature through
the radiator so that the water gets heated up quickly. When
the preset temperature is reached the thermostat allows the
water to flow through the radiator.

Figure 2.10 Thermostat

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8. Hoses:
Hoses facilitate the complete circulation of coolant within the cooling
system, ensuring it flows from the radiator to various engine components and
back. Among these, the upper and lower radiator hoses are the most prominent,
distinguished by their larger size.
Figure 2.11 Hoses
9. Freeze Plug:
Freeze Plug is another car cooling system part that helps to protect the
engine. As water expands when it freezes, the coolant can also freeze in cold
areas when the vehicle is sitting idle. The freezing coolant is a threat to the
engine block and may even crack it. The freeze plug can withstand the
pressure of the running engine, but once the coolant freezes, it pops out of the
engine block. A little action can save your engine!
Figure 2.12 Freeze plug

2.2.2. Advantages of Liquid Cooling

1. Increased Cooling Efficiency: Water cooling systems are much more efficient at removing heat from
the components, which results in lower temperatures and better overall performance.

2. Reduced Noise: Water cooling systems are much quieter than air cooling systems, as they do not
require fans to circulate air.

3. Higher Density Computing: With water cooling, it is possible to pack more components into a smaller
space, which is important for high-density computing applications.

4. Longer Component Life: Lower temperatures help to extend the life of components and reduce the
risk of failure

2.2.3. Disadvantages of Air Cooling

1. Initial Cost: Water cooling systems are typically more expensive to install and maintain than air
cooling systems, as they require specialized equipment and training.

2. Complexity: Water cooling systems are more complex than air cooling systems and require more
maintenance and attention to ensure proper operation.

3. Risk of Leaks: If a water cooling system leaks, it can cause serious damage to the components and the
surrounding environment.

4. Maintenance: Water cooling systems require regular maintenance, including the replacement of
coolant and cleaning of the system, to maintain proper performance.

5. Limited Availability: Water cooling systems are not as widely available as air cooling systems and
may not be an option for some users due to environmental restrictions or other factors
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3. Cylinder Liner

A cylinder liner, or a cylinder sleeve, is a hollow cylindrical structure installed inside the engine block's
cylinder bore. These thin metallic structures play a crucial role in internal combustion engines by ensuring that
the piston and engine block do not directly contact each other. The outer surface of the liner makes complete
contact with the cylinder block, while the inner surface, in contact with the moving piston.

3.1. Functions of Cylinder Liners

1. Formation of Sliding Surface

Cylinder liners serve a crucial role in internal combustion engines by providing a smooth sliding surface
for the piston's reciprocating motion. The friction resistance on the inner walls of the liner is minimal, allowing
piston rings to glide smoothly along its surface. A thin lubricating film forms on the liner's inner surface, further
reducing frictional resistance.

2. Reduction of Wear
IC engine cylinder liners possess exceptional anti-galling properties that effectively decrease wear on
both the liner and the piston rings in contact with it. Without the presence of a cylinder liner, the piston rings
would directly contact the cylinder block. In such a scenario, the wear on the cylinder block would be
considerably higher, making it more cost-effective to replace the cylinder liner than the entire block. Galling, a
form of wear caused by adhesion forces between mating parts, is mitigated by the liner's presence.

3. Heat Transfer
Another crucial function of cylinder liners is the transfer of heat generated during the combustion process.
These liners facilitate the transfer of heat from the burning charge to the engine block and subsequently to the
surrounding environment or coolant (in the case of wet liners). The coolant acts as a heat sink, ensuring efficient
heat dissipation.

3.2. Types of Cylinder Liners

3.2.1. Dry Liners

Dry liners are designed not to be in contact with liquid coolant.

These are essentially uncomplicated, hollow cylindrical tubes that fit
inside a cylinder block. Importantly, no direct contact exists between the
liner and the water jackets containing coolants.

The liner, along with the engine block, absorbs the pressure
generated by the combustion of the charge due to the minimal clearance
between the liner and the cylinder block. Consequently, dry liners have
relatively thin walls, typically ranging from 1.5mm to 3mm. Heat
transfer initially occurs from the liner to the engine block and
subsequently to the cooling jackets, resulting in longer engine cooling Figure 3.1 Dry liner
times. Replacement of dry liners requires specialized tools, and they are
resistant to corrosion since they remain isolated from the water jackets.
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3.2.2. Wet Liners

Wet liners, in contrast, come into direct contact with cooling

water or coolants. The construction of wet liners differs slightly
from that of dry liners. Wet liners are fitted within the cylinder
block and securely locked at both ends to prevent any cooling water
or coolant leakage. These liners tend to have a greater thickness,
typically ranging from 3mm to 6mm, compared to dry liners, as
they lack the supporting structure provided by a cylinder block.

The wet liner can withstand the forces generated during the
combustion of the charge. Heat transfer in wet liners occurs directly
from the liner to the coolant, resulting in a more efficient heat
transfer rate. This allows the combustion chamber to achieve higher
temperatures, enhancing thermal efficiency. Wet liners are Figure 3.2 Wet liner
relatively easier to remove as they are not as tightly fitted as dry liners.

3.2.3. Finned Liners

Finned liners find application in air-cooled engines. These liners

feature exposed fins that are in direct contact with the open air.
When air flows through the fins, it significantly increases the heat
transfer rate, effectively cooling the engine. In some cases, fin-
cooled engines may also incorporate a wet liner to further enhance
heat transfer rates. Finned liners are commonly used in engines that
operate in open-air environments, benefiting from natural air
cooling mechanisms.

3.3. Advantages of Cylinder Liners Figure 3.3 Finned liner

1. Wear Resistance: Cylinder liners are made from materials such as cast iron, steel, or even advanced
composite materials, which are highly wear-resistant.
2. Heat Dissipation: Cylinder liners help dissipate heat generated during the combustion process.
3. Bore Restoration: Over time, the cylinder bore can wear and develop imperfections.
4. Reduced Friction: The smooth surface of cylinder liners reduces friction between the piston rings and
the cylinder walls.
5. Improved Lubrication: Cylinder liners can be designed with specific surface finishes and treatments to
enhance lubrication.
3.4. Disadvantages of Cylinder Liners

1. Increased Weight and Cost.

2. Reduced Cooling Efficiency: In some cases, the presence of a cylinder liner can slightly reduce the
efficiency of heat transfer from the combustion chamber to the engine's cooling system, as the liner
may act as a thermal insulator.
3.
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4. TEMPERATURE SWITCHES

Temperature switches are devices that prevent the engine from overheating by activating radiator cooling
fans, measuring the coolant temperature and controlling the level gauges and warning lights on the engine
control unit. They can have up to four terminals and be installed on the radiator, the cooling system tubes or the
thermostat, so that the coolant flows across the sensing element (bimetal disc or thermistor). The switching
status of the temperature switch changes depending on the input temperature. This function is used as protection
against overheating or overcooling. Basically, the thermal switches are responsible for monitoring the
temperature of machinery and equipment and are used for temperature limitation.

Bimetal temperature switches determine the temperature using a bimetal disc. These consist of two metals,
which are used as strips and have different thermal coefficients. The metals are usually from zinc and steel or
brass and steel. When, due to a rising ambient temperature, the nominal switching temperature is reached, the
bimetal disc changes into its reverse position. After cooling back down to the reset switching temperature, the
temperature switch returns to its previous state.

Thermo switches for electric fans are the simplest type of thermo switches. They are fitted with a concave or
convex bimetal disc and are installed on the radiator or in the cooling system pipes. The bimetal disc is a
sensing element that changes its state as the coolant temperatures varies. When it reaches a predetermined
temperature, the disc snaps, thus closing the circuit that activates the radiator cooling fan. There are two types
of thermo switches for electric fans:

1. For single-speed (single circuit) electric fans

2. For dual-speed or double electric fans (with several circuits)

Figure 4.1 Temperature switches

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5. Cooling System Troubleshooting

1. Radiator:
Common Problems:
• Coolant Leaks: Over time, the radiator may develop leaks, leading to a loss of coolant.
• Corrosion: Corrosion can occur, particularly in older radiators, reducing their efficiency.
Symptoms:
• Coolant Puddles: Puddles of coolant under your vehicle indicate a leak.
• Overheating: An inefficient radiator can result in engine overheating.
Solutions:
• Repair leaks with radiator sealant or replace the radiator if necessary.
• Regularly flush and maintain the radiator to prevent corrosion.

2. Water Pump:
Common Problems:
• Bearing Failure: Bearings in the water pump can wear out, causing noise and leaks.
• Impeller Damage: Damage to the impeller can reduce coolant circulation.
Symptoms:
• Coolant Leak: A visible coolant leak near the water pump.
• Engine Overheating: Insufficient coolant circulation leads to overheating.
Solutions:
• Replace the water pump if there are signs of bearing wear or impeller damage.
• Regularly inspect and replace the drive belt to maintain water pump function.

3. Thermostat:
Common Problems:
• Stuck Closed: Thermostats can get stuck in the closed position, causing overheating.
• Stuck Open: Staying open prevents the engine from reaching optimal temperature.
Symptoms:
• Overheating: A stuck-closed thermostat restricts coolant flow, leading to overheating.
• Poor Fuel Efficiency: A stuck-open thermostat affects fuel efficiency and emissions.
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Solutions:
• Replace the thermostat if it’s stuck in either position.
• Regularly check and replace the thermostat during routine maintenance.
4. Other Components (Sensors, Hoses, Expansion Tank):
Common Problems:
• Sensor Malfunctions: Sensors can fail, causing inaccurate temperature readings.
• Hose Leaks: Hoses may develop cracks or leaks, leading to coolant loss.
• Expansion Tank Issues: Cracks or leaks in the tank can affect coolant levels.
Symptoms:
• Erratic Temperature Readings: Faulty sensors may trigger incorrect temperature warnings.
• Coolant Odor: The smell of coolant inside the vehicle can indicate a hose leak.
Solutions:
• Replace malfunctioning sensors to ensure accurate temperature monitoring.
• Inspect hoses regularly and replace damaged ones.
• Replace a damaged expansion tank to maintain proper coolant levels.

6. SUMMARY
Combustion temperatures in the cylinders of IC engines can reach values of 2700 K and higher. Without
adequate cooling, temperatures of this magnitude would quickly destroy engine components and lubricants. If
cylinder walls are allowed to exceed temperatures above 200°C, material failures would occur and most
lubricating oils would break down. To keep the cylinders from overheating, they are surrounded with a water
jacket on liquid-cooled engines or a finned surface on air-cooled engines. On the other hand, to obtain
maximum efficiency from an engine, it is desirable to operate as hot as possible. With improvements in
materials and lubrication technology, modern engines can operate much hotter than engines of a few years ago.
Heat removed from engine cylinders is eventually rejected to the surroundings. Unfortunately, by
keeping the engine from overheating with heat transfer to the surroundings, a large percent of the energy
generated within the engine is wasted, and the brake thermal efficiency of most engines is on the order of 30-
40%.
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7. REFERENCES:

1. Engineering fundamentals of the internal combustion engine, Willard W. Pulkrabek.

2. IC Engines fourth edition by V.GANESAN.

3. Fundamentals of internal combustion engines, second edition H.N. Gupta

4. Mesa, C. A. (2004). The engine cooling system. Technology Transfer Systems, Inc.

5. Rundle, R. (1999). Automotive Cooling System Basics. Krause Publications.

6. https://testbook.com/mechanical-engineering/cylinder-liner-definition-construction-and-
types.