SUBJECT: ENGINE CONSTRUCTIONAL DETAILS-

PART 2

FACULTY NAME: ROSHAN GEORGE

CONSTRUCTIONAL DETAILS OF AN
ENGINE
 VIBRATION DAMPER

● Vibration damper is also called a

harmonic balancer.

● It is mounted on the front end of the

crankshaft.

● It consists of a damper flywheel-cum-

crankshaft pulley and a driving flange
connected together with 'a rubber ring in
between

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 ● The twisting and untwisting of crankshaft
causes vibrations.

● The vibration damper reduces the torsional

vibrations by means of the dragging effect
produced by the inertia of damper flywheel.

● The rubber ring is also flexed during this

dragging which tends to avoid the vibrations
and keep the crankshaft speed uniform

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 ENGINE VALVES
● Engine valves are broadly divided into 3 categories
○ Poppet valve
○ Sleeve valve
○ Rotary valve
● Among these the poppet valve is the most commonly used one in
automobiles
 POPPET VALVE

● The poppet valve derives its name from its motion

of popping up and down.

● This valve is also called "mushroom valve"

because of its shape which is similar to a
mushroom.

● It consists of a head, a stem, margin, face, spring

retainer lock groove, tip.

● Inlet valve may face angle 30 or 40 degree

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 Valve face angle

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 ● Exhaust valve face angle is 45 degree

● For better sealing valve and its seating is

provided with a differential angle of about ½
deg to 1 deg

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Material:
● Silico-chrome steel containing about 0.4% carbon, 0.5% nickel, 0.5%
manganese, 3.5% silicon and 8% chromium is the material generally used for
inlet valves. For early exhaust valves, molybdenum was added to it.
● The more recent materials for exhaust valves are the austenitic steels and
precipitation hardening steel
 Sodium cooled valve

● The exhaust valve temperatures in modern engines reach

very high values of the order of 750°C.

● In heavy duty engines, it may be still higher.

● Therefore, cooling of exhaust valves becomes very

important

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 ● In heavy-duty engines, sodium cooled valves are used.

● Sodium is a high conductivity metal which melts at 105°C.

● Sodium is filled up to about 40 per cent volume of the

hollow stem of the valve.

● When the valve is operating, the liquid sodium moves up

and down in the hollow stem.

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 ● When valve goes up it absorbs heat from the hot valve
head

● On coining back down it gives the same heat to the stem,

from where it goes via the valve guide, to the cylinder
block and from there to cooling water jackets

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 Valve seat and Guide

• Valve seat

● For cylinder blocks or heads made of grey

iron, the inlet valve seats are directly
machined on the cylinder blocks or heads.

● These are called integral seats.

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 ● If Aluminium heads are used, separate valve seat inserts are
employed even for inlet valves.

● For the exhaust valves, always the separate valves seat inserts
are used.

● Valve seat inserts are alloy steel consisting of chromium, silicon,

tungsten or cobalt

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 Valve Guide

● The valve is maintained in a central position with

respect to the valve seat with valve guide while
opening and closing.

● The simplest valve guide is a reamed hole in the

cylinder block or head in which the valve stem
moves.

● This type of integral valve guide is cheaper to

provide, reduces weight and the heat transfer is
also better

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 ● The modern tendency is to provide separate valve guides

● These are particularly required where the valve stem and cylinder
head materials are not compatible.

● Material : Pearlitic cast iron, alloy iron containing nickel and

chromium.

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 Valve Springs

● Helical springs are used to keep the valve in

constant contact with the tappet and the
tappet with the cam.

● Valve springs closes the valves

● Materials are hard-drawn carbon steel or

chrome-vanadium steel.

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 ROCKER ARM

● Its function is to reverse the upward motion of the push rod to down ward
motion of valve.
● Rocker arm is made of forged or stamped steel or iron (cast).
● Generally hollow steel tubing.

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 VALVE ACTUATING MECHANISMS

● Valve actuating mechanism operate each valve, inlet valve or exhaust

valve with the help of a cam driven at half the crankshaft speed.
● Valve actuating mechanisms are broadly divided into two types.
○ Mechanisms with side camshaft.
○ Mechanisms with overhead camshaft.
1. Mechanisms with side camshaft.
a. Double row side valve mechanism (T-head)
b. Single row side valve mechanism(L-head)
c. Overhead inlet and side exhaust valve mechanism(F-head)
d. Single row overhead valve mechanism (I-head).
2. Mechanisms with overhead camshaft.
a. Overhead camshaft mechanism inverted bucket follower
b. Overhead camshaft mechanism with end-pivoted rocker arm
c. Overhead camshaft mechanism with inlet operated by inverted
bucket follower and exhaust operated by pivoted rocker arm.
d. Double overhead camshaft mechanism with inverted bucket
follower
e. Overhead camshaft mechanism with seperate rocker arms.
 A. Double row side valve mechanism (T-
head)

● The shape of the combustion chamber

provides poor combustion and low engine
performance.

● This type of mechanism is obsolete

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 B. Single row side valve mechanism (L-head)
● The inlet and the exhaust valves are all
arranged in a single row and operated from
the same camshaft

● Once quite popular on account of the

following advantages.

● (i) Low engine height. (ii) Low production

cost. (iii) Quiet operation. (iv) Ease of
lubrication

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 ● Inefficient on account of the complicated shape of the
combustion chamber which is more prone to detonation.

● Restrictions of space on the size of inlet valves that would be

used

● Difficulties were experienced in cooling the exhaust valves.

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 C. Overhead inlet and side exhaust valve
mechanism (F-head)

● F-head engines were found to be less

efficient and were also more expensive

● These valves have also become obsolete.

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 D. Single row overhead valve mechanism (I-
head)

● This type is used quite extensively these

days.

● The cam operates the valve lifter which in

turn actuates the push rod.

● The push rod operates the rocker arm, which

actuates the valve

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 Advantages of this system include

● Higher volumetric efficiency than side valve

design

● Higher compression ratio is possible.

● Leaner air fuel mixtures can be burnt.

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 • Disadvantages of this system include

● The valve operation, on account of the elasticity

of the system and the resulting vibrations, is not
very 'precise while accelerating or operating at
high engine speeds.

● Large valve lifter clearances are required.

● Noisy operation.

● Greater maintenance required.

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OVERHEAD CAMSHAFT MECHANISM

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 A. Over head camshaft mechanism inverted bucket follower

● This type of mechanism is direct and very rigid so that valve mechanism
follows precisely the designed cam-profile lift.

● Tappet clearances are also quite small and do not require adjustments
very often.

● Drive to the camshaft is quite complicated, positive lubrication is required.

● Valve clearance adjustment is difficult

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 B. Overhead camshaft mechanism with end-pivoted rocker arm

● The inertia of rocker arm follower is less compared to the sliding bucket
type described earlier and adjustment of tappets is easy.

● The elastic bending of the rocker arm results in the stiffness of the
system and hence precision of valve operation is decreased.
● Side-thrust is produced to the valve stem and guide and hence more
wear and noise occur

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 C. Overhead camshaft mechanism with inlet operated by inverted
bucket follower and exhaust operated by pivoted rocker arm

• This mechanism have inlet and exhaust valves in separate rows

● They are operated by a single overhead camshaft with inverted

bucket type follower and the pivoted rocker arm

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D. Double overhead camshaft mechanism inverted bucket follower
 D. Overhead camshaft mechanism with seperate rocker arms.

● In this mechanism the double-row valves are operated by two

separate overhead camshafts.

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 CAMSHAFT
● A camshaft is a shaft with a cam for each intake and exhaust value.

● Cam has a high spot called cam lobe which controls the valve
opening

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● Camshaft provides a means of actuating the opening and controlling the
opening and closing intervals of the inlet and the exhaust valves relative to
each piston position along its respective stroke.
● Provides a drive for the ignition distributor and the mechanical fuel pump.
● Cam is a rotating member which imparts reciprocating motion to another
member, called follower or valve tappet.
● The camshaft consists of a number of cams at suitable angular positions for
operating the valves at approximate timings relative to the piston movement
and in a sequence according to the selected firing order
● There are two lobes on the camshaft for each cylinder of the engine; one to
operate the intake valve and the other to operate the exhaust valve.
● The camshaft can be located in either cylinder block or the cylinder head.
● To provide provision for lubrication and metal expansion, a clearance of 0.05
to 0.125 mm is usually provided between the bearing journals and the bores.
● Material : Forged from alloy steel or cast from hardenable cast iron.
CAMSHAFT DRIVE
CAMSHAFT DRIVE
● Each cam must open and close its respective inlet or exhaust valve

once every two revolutions of the crankshaft.

● Hence the camshaft is made to rotate at half the crankshaft speed.

● The drive from crankshaft to the camshaft may be either chain drive

or gear drive where

● camshaft gear or sprocket wheel is twice as large as the crankshaft
gear or sprocket wheel.
● The latest type of drive is, which is made of rubber moulded on to a
stretching cord
● Timing gears are made of cast iron, steel ,aluminium or laminated
fibre.
● Chains are made with links of alloy steel with grounded and case
hardened pins.
● Sprockets are made nylon, aluminium, steel or iron.
 VALVE TAPPET (CAM FOLLOWER)

● The valve tappet or Valve Lifter or Cam follower follows the shape of the cam lobe of

the camshaft.

● There are mainly three types of tappet

○ Fixed type

○ Adjustable type

○ Hydraulic tappet
VALVE TAPPET
● Provides a method of converting the angular movement of the cam into a

reciprocating motion in the valve train.

● Placed in between the push rod and the cam, so that sideways thrust of the cam is

not exerted on the push rod.

● Tappet is placed slightly eccentric with respect to the cam so that tappet keeps on

rotating slightly in every stroke which makes it wear uniformly.

● Clearance is be allowed between the cam and the tappet to allow for expansion due

to heat. This clearance is known as valve lash

● Tappet is placed slightly eccentric with respect to cam to make the tappet rotate and

to provide uniform wear

● Material : Valve tappet is made from chilled low alloy cast iron consisting of iron,

carbon, silicon, manganese and chromium

● Vibration damper on a crankshaft reduces

a. Longitudinal vibrations
b. Torsional vibrations
c. Transverse vibrations
d. All of these

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● The main causes of crankshaft vibration are _________

a. Variation in torque
b. Cyclic variation of gas and combustion products
c. Unbalanced weight of parts
d. All of the mentioned

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● Crankshafts are usually manufactured by ______

a. Casting
b. Drop forging
c. Drawing
d. Extrusion

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● The main reasons for crankshaft wear are _______

a. Different loads at some points of rotation

b. Centrifugal forces due to crankshaft rotation
c. Misalignment in connecting rod
d. All of the mentioned

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● Exhaust valve face is generally

a. 20 deg
b. 30 deg
c. 40 deg
d. 45 deg

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● What is the inlet valve face angle that is generally kept?te
● d
a. 25°
b. 30°Piston pin boss
c. 45°
d. 30° or 45°

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● What is present inside the hollow stem of the valve?

a. Ethyl-glycol
b. Magnesium
c. Sodium
d. Mercury

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● Which material is generally used in valve springs?
● ted
a. Carbon steel
b. Chromium-vanadium steel
c. Nickel-chromium steel
d. Both carbon steel and chromium-vanadium steel

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● Engine valves are closed by

a. Crankshaft
b. Camshaft
c. Valve springs
d. Timing device

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● Which part of the valve surface comes in contact with the valve seat?
● ted
a. Head
b. Face
c. Stem
d. shank

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● Which feature does the conical surface of the valve gives?
● ted
a. hardness
b. Self-centering
c. strength
d. Increase in weight

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● The opening and closing of a valve is respectively done by

a. spring and a cam

b. A cam and a spring
c. Gas pressure and cam
d. Cylinder vacuum and spring

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● What happens to the spring when the valve is opened?
a. Elongate
b. Compress
c. Twist
d. both compress and elongate

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● Camshaft controls

a. Valve opening
b. Valve closing
c. Valve timing
d. All of these

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● In the cam, the distance between the base circle and the nose is called

a. Lift
b. Lobe
c. Flank
d. Pitch

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● In a four stroke cycle engine camshaft revolves at ______ the crank
speed.

a. Two times
b. Half
c. Four times
d. Three times

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● A rocker arm does which among the following?

a. Convert rotary to reciprocating motion

b. Convert reciprocating to rotary motion
c. Reverse reciprocating motion
d. None of these

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● The gears on camshaft and crankshaft are known as ________

a. Lining gears
b. Aligning gears
c. Timing gears
d. Tuning gears

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● Offset is provided to a cam follower mechanism to

a. Provide uniform wear

b. accelerate
c. avoid jerk
d. none of the mentioned

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● Clearance allowed between the cam and the tappet is known as

a. Cam profile
b. Valve lash
c. Cam lift
d. Tappet spacing

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