DESIGN

CONSTRUCTION
1. SITI NUR JAMILAH ROSLIEN 53106121352
2. MUHAIMIN NAUFAL BIN MUSHANA AZAMI 53106121335
3. AHMAD ZAKWAN BIN AHMAD NARANG 53106121354
 INTRODUCTION
◦ 1860 – Etienne Lenoir of France built the first practical piston engine
- The engine called Lenoir’s engine. Used battery ignition system and natural gas
as fuel.
- The engine used to operate industrial machinery such as latest machine and
printing presses.
◦ 1876 – Dr. August Otto and Eugene Langen of Germany developed four stroke, five-
event cycle engine and called Otto cycle.
- The engine used on most modern reciprocating engine.
- They also built two-stroke cycle engine.
◦ 1885 – Gottlieb Daimler associated with Otto and Langen built the first successful
gasoline engine.
◦ 17 Dec. 1903, Wright Brothers flew the first airplane.
 DESIGN AND CONSTRUCTION

◦ Purpose is to convert heat energy into mechanical energy to drive the propeller…
◦ How? By specific volume of air and fuel mixture and burned it to provide combustion.
◦ Combustion provide heated air than expands and creating a force that converted into mechanical energy.
◦ Reciprocating engines derive their name from back-and-forth motion. Then from linear motion to rotary
motion.
 ROTARY TYPE RADIAL ENGINES.

●1a. Rotary type radial engine.

- Cylinder mounted around the

crankcase.

- Cylinder and propeller rotate

together and crankshaft
stationary.

- Most popular rotating engine

was the Bently, Gnome and LeRhone.
 ROTARY TYPE RADIAL ENGINE.
● Disadvantages:-

- The torque effect produced by the

large rotating mass of the
propeller and cylinders made
aircraft difficult to control.

- Coupled with carburetor,

lubrication and exhaust problem.

- Large frontal area.

- Have some cooling problem.

 Static type radial engine
- Engine is stationary and bolted to the airframe.

- Crankshaft rotates and turns the propeller.

- No. of cylinders from 3 to 28 cylinders.

- Consist of a single row and multiple rows,

max. of 4 rows with 7 cylinders in a row
and total of 28 cylinders.

- Produce higher horsepower and high

power to weight ratio, mostly used on
military and civilian transport aircraft.
CRANKSHAFT

PURPOSE:-

Is to transform the reciprocating motion of the

pistons and connecting rod to rotary motion to
turn a propeller.

Typically have one or more cranks or throws

located at specific points along its length.
Crankshaft.

 Formed by forging off sets into crankshaft then machined.

 To withstand high stress, it is made from strong alloy such as chromium-nickel molybdenum
steel.

 Made from single piece of steel which consist of several components.

 Crankshaft have one throw or as many as eight throws depending on the engine types.

 Parts include the main bearing

◦ journal, crankpin and crank cheek.

 In addition counterweight and dampers are installed to reduce vibration.

 Bearings

Three difference types of

bearing typically use in
aircraft piston engine:
1) Plain bearing.
2) Ball bearing.
3) Roller bearing.
 CONNECTING RODS
 Purpose:-
- To transmit the force exerted on piston to the crankshaft.

 Material:
- Made of a durable steel alloy.
- aluminum can be used on low horsepower engine.

 The lighter a connecting rod is, the less inertia it

produces when the rod and piston stop and accelerate.
 It is forged and cross sectional of
“H” or “I” and few are tubular.

 Crankshaft end is called crankpin

(big) end and the other end is
piston end (small).

 Three types of connecting rod

assemblies generally in used:-

i) Plain-type.
ii) Master and articulated rod type.
iii) Fork and blade type.
Piston Rings
When properly lubricate form an effective seal.

Made of high grade grey cast iron.

Some are chrome plated mild steel

to withstand high temperature.

After it is made, it is ground to desired cross-section and then

split.
This allow the ring to slip over the
piston and seat into the grooves.

Split is called piston ring gap.

Piston ring gap are of butt, angle

or step joint.

Specific clearance and correct

stagger to ensure effective sealing during all operating
temperature to prevent blow-by thus loosing power.
 CYLINDERS
PURPOSE:
- Provides a combustion chamber where the burning and expansion of gases takes place
to produce power.
- Cylinder houses the piston and connecting rod as well as the
valves and spark plugs.

REQUIREMENT:
- Strong enough to withstand internal pressure during engine operation yet lightweight
to minimize engine weight.
- Must have good heat conducting properties for efficient cooling.
- Cylinder assembly must be comparatively easy and inexpensive to manufacture,
inspect and maintain.
An air-cooled engine cylinder consists of cylinder head, barrel, mounting
flange, skirt, cooling fins and valve assembly.

To form a cylinder, cylinder head is heated up and chilled barrel is screwed
together.
 Valves
PURPOSE:
- Regulates the flow of gases into and out of the cylinder
at predetermined times.

Intake valve control the amount of fuel/air mixture that

enter the cylinder through intake port.

Exhaust valve allows the exhaust gas exit through the

exhaust port.
> Subject to high temperature, corrosion and extreme stress.

> Made from metals that are able to resist this factors.

Normally each cylinder must have one intake and exhaust valve. But some
high power engine have two intake and exhaust valve for each cylinder.

Most common type of valve in used is the poppet valve which gets its name
from the popping action of the valve.
 Opposed Type Engine
● Advantages.

- High power to weight ratio because of small and light

weight crankcase.

- Small frontal areas, more

streamline and less drag.

- Less vibration because

the power impulses
tend to cancel each
other.
 V-Type Engine
 Advantages of V-type engine.

- Producing higher horsepower than in-line engine.

- Small frontal area with higher power to weight ratio.

- Better pilot visibility as

shorter/lower main
landing gear.
 In-Line Engine
● Advantages of in-line engine.
- Small frontal area, less drag
- Greater propeller clearance
as for inverted engine.
- Shorter main landing gear and
provide better visibility.

● Disadvantages of in-line engine.

- Relatively low power to weight ratio
- The rearmost cylinder receives less cooling air
- Low and medium horsepower output to engine fitted to light
aircraft only.
 Engine Identification
 Series of letters and numbers that identified the type and size of
◦ the engine.

◦ O - Horizontally opposed engine.

◦ R - Radial engine.
◦ I - In-line engine.
◦ V - V-type engine.
◦ T - Turbocharged
◦ I - Fuel injection.
◦ S - Supercharged.
◦ G - Geared nose section ( propeller reduction gearing )
◦ L - Left hand rotation.
◦ H - Horizontal mounting (helicopter)
◦ V - Vertical mounting (helicopter)
◦ A - Modified for aerobatics.
 The numbers in an engine identification code indicate
◦ an engine displacement in cubic inches.

 Eg.
◦ - O-320 horizontally opposed engine with a
◦ displacement of 320 inches.
◦ - LIO-360 – left rotation, fuel injection and
◦ horizontally engine with displaces of 360 cubic
◦ inches.
◦ - GSTIO-520-F – engine is geared, turbo-
◦ supercharged, fuel injection, horizontal opposed,
◦ displaces 520 cubic inches and F model.
◦ iii) Flanged shaft.
◦ - widely used on oppose engine.
◦ - use bolt or bolt and nut to secure propeller to the shaft.
◦ ii) Splined shaft.
◦ - rectangular groove is machined into the propeller shaft with master
spline.
◦ - master spline assures a propeller is attached a shaft a specified way and
kept vibration to a minimum.
PROPELLER
SHAFTS
 Three type common in use:-
i) Tapered
ii) Splined
iii) Flanged shaft.

i) Tapered propeller shafts.

- used on low-power engines.
- shaft gets smaller in diameter toward the end of the shaft.
- one or more key slots are
milled into the shaft to lock propeller to the shaft.
- end of the shaft is treaded to receive a propeller retaining nut.
Valve Clearance

 Due to relative mass, the push rod expand less than the cylinder
resulting in increases in valve clearance.

 Cold clearance - set when the engine cold.

 Running clearance – set when the engine is hot.

 The clearance is set or adjusted at beginning of

power stroke using a thickness or feeler gauge.
Rocker Arm

 Purpose:-

 Change lifting movement of the pushrod into downward motion

needed to open the valve.

 Made of forged steel.

 Has a cup shape socket to hold push rod end.

Push Rod.

 Transmit lifting action to the rocker arm.

 Is a hollow steel or aluminum alloy tube with polished end.

 One end rides in valve lifter while other end fit into socket in
rocker arm.

 Typically have hole on each end to allow oil flow from lifter to
valve component.
Valve Lifter.

 Valve lifter or tappet transmit the lifting force of the cam to pushrod.

 Valve lifter can be either solid or hydraulic.

 The camshaft end of a solid lifter is flat with polished surface while the
pushrod end contains spherical cavity that house the pushrod.

 Holes drilled to allow lubricating oil flow through the lifter to lubricate the
push rod.

 Most opposed engine used hydraulic lifters.