Internal Combustion Engines

Introduction:
Any machine, which converts heat energy in to useful mechanical energy,
is known as an engine.
The machines may be a gas turbine, steam turbine and an engine.
All the engines comes under two classifications, they are
i) Internal combustion engine
ii) External combustion engine
Internal combustion engine:
If the combustion of fuel takes in a cylinder and the heat is converted in to
mechanical energy, is known as internal combustion engine, Ex. Engines of moped,
scooter, bikes, cars, bus, trucks etc;

External combustion engine:

If the combustion of fuel takes place in a combustion chamber and the heat
energy is taken to a machine through pipe line there the heat energy is converted in to
mechanical energy is known as external combustion engines. Ex, gas turbine and steam
engine.

Classification of internal combustion engines

Internal combustion engines are classified according to
1) According to thermodynamic cycle
i) Otto cycle ii) Diesel cycle iii) Dual combustion cycle
2) According to number of strokes
i) Two stroke ii) Four stroke
3) According to number of cylinders
i) Single cylinder engine ii) Multi cylinder engine
4) According to method of ignition i)Spark
ignition (petrol, gas engine)
ii) Compression ignition (diesel, vegetable oil)
5) According to type of fuel used
i) Petrol ii) Diesel iii) Gas
iv) Bio fuel (peanut oil, sunflower oil, linseed oil)
6) According to position of cylinder
i) Horizontal engine (hero Honda)
ii) Vertical engine (car, bus, truck engines)
iii) Vee engine
iv) Radial engine (old aeroplane engine)
v) Opposed cylinder engine
7) According to method of cooling
i) Air cooling ii) Water cooling iii) oil cooling
8) According to speed of engine
i) Slow speed engine ii) Medium speed engine iii) High speed engine
Parts of internal combustion engine
The parts of internal combustion engines are Cylinder, head, piston, piston rings
(compression rings and oil control ring), connecting rod and crankshaft.

Parts of internal combustion engine

Function of IC engine parts:

Cylinder: (cylinder block) The cylinder is the main part of an engine. The
combustion takes place in the combustion chamber and these gases exert pressure on the
piston, due to high gas pressures the piston reciprocates in the cylinder block. The cylinder
is designed to with stand high gas pressure. The temperature in the combustion
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chamber (cylinder block) will reach up to 2800 C. The cylinder has to be cooled
properly either by air cooling or water cooling. In case of air cooled engines fins are
provided around the cylinder block (Scooter and bikes) in water cooled engines water
jackets are provided for the circulation of water to carry away the heat around the cylinder
block. The cylinder block material; is aluminium alloy
 Head: (cylinder head) The head is fitted on the top of the cylinder block. In two
stroke engines only spark plug is fitted in the cylinder head.
In four stroke engine inlet valve , exhaust valve and spark is fitted in the cylinder head.-
The head is built with two ports, one port, which allows the charge in to the cylinder block,
is known as inlet port and the second port that allows the exhaust gases to leave the
cylinder block is known as exhaust port. In case of petrol engine spark plug is fitted in
the head, in diesel engines fuel injector is fitted to inject the diesel into the cylinder block.
The cylinder head material; is aluminium alloy
Piston: The piston is a cylindrical plug, which converts heat energy in to
mechanical energy. A two stroke piston is fitted with only compression ring. In four-
stroke engine both compression ring and oil control rings are fitted. The piston is
connecting to the small end of the connecting rod. The piston is made of aluminium
alloy. Functions of piston are
i) The piston will act as a seal
ii) To provide the passage for heat flow from piston to cylinder block through
rings.
iv) It transmits the force of explosion to the crankshaft through connecting
rod.
Piston rings: Near the top of the piston, a few grooves are provided to
accommodate the piston rings. There are two types of piston rings- compression
ring and oil ring.

compression rings press hard with the cylinder walls maintaining a tight seal
between the piston and the cylinder. This is required to prevent the high pressure
gases from escaping into the crankcase.

Oil rings are used to extract the excess lubricating oil from the cylinder walls and
send it back to the oil sump through the holes provided on the piston.

Connecting rod: The small end of the connecting rod is connected to the piston
and the big end of the connecting rod is connecting to the crankshaft. The connecting rod
converts the reciprocating motion of piston in to rotary motion of crankshaft. The
connecting rod is made of I-beam cross section to provide maximum rigidity with
minimum weight.
Crankshaft: The big end of the connecting rod is connected to the crankshaft. The
power transmission starts from the crankshaft. The crankshaft is rigidly fixed in the
crankcase. The other end of the crankshaft is connected to a clutch.
Crankcase: Crankcase is fitted at the bottom of the cylinder block. Two-stroke
engine crankcase is properly sealed and made airtight. Four stroke engine crankcase will
serve as a reservoir, filled with sufficient quantity of lubricating oil. This oil lubricates
the main bearings of crankshaft, big end bearings of connecting rod, lubricates the
cylinder liner, piston and piston rings.
Valves: The valves are the devices which controls the flow of the intake and the
exhaust gas to and from the cylinder. They are also called poppet valves. These
valves are operated by means of cams driven by crankshaft through a timing gear
and chain.
Fly wheel: It is a heavy wheel mounted on the crankshaft of the engine to maintain
uniform rotation of the crankshaft.
IC ENGINE TERMINOLOGY
Top dead center (TDC): The top most position of the piston at the cover end is
known as top dead center.
Bottom dead center (BDC): The
lower most position of the piston at the
crank end is known as bottom dead center.
Rotate the crankshaft slowly, the
piston starts moving slowly towards the
top dead center, Further rotation of crank
shaft moves the piston towards the top
and suddenly it changes its direction (it
starts moving in down ward direction),
The momentary stopping of the piston
indicates the position of TDC.
Rotate the crankshaft further; the
piston starts moving in down ward
direction, this movement continues till
the piston reaches the bottom dead
center. Here also the piston reaches the
Bottom and suddenly it changes its direction, the point at which it stops is known as
BDC.
Bore: The diameter of the cylinder is called bore.
Stroke length (L): It is the distance travelled by the piston from TDC to BDC. It
is denoted by L.

Clearance volume: When the piston is at TDC position the cylinder volume above it,
it is known as clearance volume and it is denoted by Vc

Swept volume: The volume swept by piston while traveling from TDC to BDC
in known as swept volume and is denoted by Vs.

Compression ratio: It is the ratio of total volume of cylinder (Vs.+ Vc) to the
clearance volume (Vc). it is denoted ‘ r’.
r = (Vs.+ Vc) / Vc
The compression ratio of petrol engine varies from 7 to 10.
The compression ratio of diesel engine varies from 15 to 24.

Piston speed: The total linear distance travelled by the piston per unit time is
called piston speed. It is expressed in m/min and is given by,

Piston speed = 2LN ……………m/min

L= length of stroke in m
N= speed of the engine in rpm.
 Four stroke engines:
The cycle of operation is completed in four strokes of the piston or two revolution of the
crank shaft. Each stroke consists of 180˚of crank shaft rotation. The series of operations
are shown in figure:

Fig: Four stroke Petrol engines

Working of four stroke petrol engine :

The four-stroke petrol engine works on the principle of Otto (constant volume) cycle. The parts of
four-stroke petrol engine are cylinder, piston, head, crankcase, connecting rod, crankshaft, spark
plug, inlet and exhaust valve. The four-stroke petrol engine may be air-cooled or water-cooled.
The piston performs four strokes to complete one cycle. The four different strokes are i) Suction
stroke ii) Compression stroke iii) Power or Expansion stroke iv) Exhaust stroke.
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Suction stroke: The suction stroke is completed by rotating the crankshaft from 0 to
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180 . During suction stroke the inlet valve opens and exhaust valve should kept in
closed condition. When the piston starts moving from TDC to BDC, The volume above
the piston increases, results in decrease in pressure (vacuum), This decrease in pressure
draws the petrol and air mixture from the carburetor and delivered it to the cylinder, this
process is continuous till the pressure inside the cylinder becomes equal to atmosphere. At
the end of suction stroke the cylinder is completely filled with petrol and air mixture. At
the end of suction stroke the inlet valve closes. The line AB in the PV diagram represents
suction stroke (volume of mixture filled in the cylinder).

Fig:four stroke petrol engine

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Compression stroke: Rotation of crankshaft from 180 to 360 completes The
compression stroke. During compression stroke both inlet and exhaust valves are closed.
In this stroke the piston travels from BDC to TDC. When the piston starts moving from
BDC to TDC the mixture is compressed, and the pressure increases in the cylinder. The
line BC represents the compression stroke.
At or near the before the end of the compression stroke, the spark occurs, this spark ignites
the petrol and air mix. The combustion of mixture releases hot gases, which will increase
pressure at constant volume. The line CD represents increase in the pressure at constant
volume.
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Power stroke: Rotation of crankshaft from 360 to 540 completes the power stroke.
During power stroke (expansion stroke) both inlet valve and exhaust valve are in closed
position. The high-pressure gases produced due to combustion, will exert pressure on the
top face of the piston, the piston moves rapidly in the down ward direction performs power
stroke.
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Exhaust stroke: Rotation of crankshaft from 540 to 720 completes the exhaust stroke.
At the beginning of exhaust stroke, the exhaust valve opens, and the upward movement
of the piston pushes the exhaust gases out the cylinder. At the end of the exhaust stroke
the exhaust valve closes.
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Thus one cycle completes by rotating the crankshaft from 0 to 720 .
 four stroke petrol engine

Four stroke Diesel engines:

Working of four stroke diesel engine
The four-stroke diesel engine works on the principle of diesel (constant pressure)
cycle. The parts of four-stroke diesel engine are cylinder, piston, head, crankcase,
connecting rod, crankshaft, fuel injector, inlet and exhaust valve. The four- stroke diesel
engine may be air-cooled or water-cooled. The piston performs four strokes to complete
one cycle. The four different strokes are i) Suction stroke ii) Compression stroke iii) Power
or Expansion stroke iv) Exhaust stroke.

i) Suction stroke: The suction stroke is completed by rotating the crankshaft 0 0 TO1800 .
During suction stroke the inlet valve opens and exhaust valve should kept in
closed position. When the piston starts moving from TDC to BDC, The volume
above the piston increases, results in decrease in pressure (vacuum), This decrease in
pressure draws the air from atmosphere and fills the air in to the cylinder, this process
is continuous till the pressure inside the cylinder becomes equal to atmosphere. At the
end of suction stroke the cylinder is completely filled with air. At the end of suction
stroke the inlet valve closes. The line AB in the PV diagram represents suction stroke
(Volume of air filled in the cylinder).
o o
ii) Compression stroke: Rotation of crankshaft from 180 to 360 completes the
compression stroke. During compression stroke both inlet and exhaust valves are closed.
In this stroke the piston travels from BDC to TDC. When the piston starts moving from
BDC to TDC the air is compressed, both pressure and temperature of the air increases.
At the end of the compression stroke the temperature of the air reaches the ignition
temperature of diesel. The line BC represents the compression stroke.
Before the end of the compression stroke, the fuel injector starts injecting the diesel into
the combustion chamber. The heat of the compressed air burns the injected diesel. The
combustion takes place at constant pressure. The line CD represents increase in the
pressure at constant pressure.
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iii) Power stroke: Rotation of crankshaft from 360 to 540 completes the power
stroke. During power stroke (expansion stroke) both inlet valve and exhaust valve are in
closed position. The high-pressure gases produced during combustion, will exert
pressure on the top face of the piston, the piston moves rapidly in the down ward direction
performs power stroke. The energy is supplied to the flywheel during power stroke. This
energy propels the vehicle.
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iv) Exhaust stroke: Rotation of crankshaft from 540 to 720 completes the exhaust
stroke. At the beginning of exhaust stroke, the exhaust valve opens, and the upward
movement of the piston pushes the exhaust gases out the cylinder. At the end of the exhaust
stroke the exhaust valve closes.
Thus one cycle completes by rotating the crankshaft from i.e., in two, revolutions
of the crank shaft.
Two stroke engines
Two strokes engine: In two-stroke engine the cycle is completed in two strokes, i.e. one
revolution of the crank shaft. The difference between two-stroke and four-stroke engines
is in the method of filling the cylinder with the fresh charge and removing the products
of combustion.

Two stroke petrol engine.

The parts of two-stroke petrol engine are
Cylinder: The cylinder liner is made in the form of barrel (hollow cylinder).
The head is connected at the top of the cylinder. A crankcase is connected at the bottom
of the cylinder. The cylinder liner is provided with cooling fins for cooling purpose; an
exhaust port is located opposite to the transfer port. One end of the transfer port is
connected to the cylinder and the other end is connected to the crankcase through which
the charge enters.
Head: A spark plug is fitted at the top of the head. Fins are provided in the head
for cooling purpose.
Crankcase: The crankcase is fitted at the bottom of the cylinder. An inlet port is
provided in the crankcase to allow the charge from carburetor to the crankcase, another
port is known as transfer port, which transfers the charge from transfer port to the cylinder.
The crankcase of two-stroke engine should be an airtight chamber, which prevents the
leakage of air in or out of the cylinder.

Piston: The opening and blocking of the ports are done by the movement of the
piston in the cylinder. The piston is fitted with only compression rings (2 or 3 rings)
The two-stroke petrol engine works on the principle of Otto cycle. The parts of
two-stroke petrol engine are cylinder, piston, head, crankcase, connecting rod,
crankshaft, spark plug, inlet port, transfer port and exhaust port. The piston performs two
strokes to complete one cycle. The two strokes are i) First stroke or down ward ii)
Second stroke or upward stroke.

Upward stroke or working stroke: In two-stroke petrol engine some charge is present
either in the cylinder block or in the crankcase. To start a two-stroke engine, power is
supplied either by using a kicker or by electric start.
During upward stroke, the piston reciprocates from top dead center to bottom
dead center. As the piston moves upward volume below the piston increases results in
decrease in pressure in the crankcase. Due to pressure difference charge (petrol & air) is
drawn from the carburetor. As the piston moves further upwards covers both exhaust and
transfer port, now the charge is subjected to compression. Before the end of the
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compression stroke the spark (crank angle 20 before TDC) occurs in the combustion
chamber. Due to combustion of charge, the pressure increase, which pushes the piston
downwards i.e. the working stroke of the piston. As the piston moves rapidly in the
down ward direction compress the charge present in the crankcase.

Down ward stroke or exhaust stroke: As the piston moves further down wards, first it
uncovers the exhaust port. Due to pressure difference the high-pressure gases leaves the
combustion chamber. As the piston moves further down wards, it uncovers transfer port,
which allows the compressed charge in the crankcase to the cylinder. The fresh charge is
deflected upwards by the deflector provided on the top of the piston and pushes the
remaining exhaust gases present in the cylinder. The process of removal of exhaust gases
from the cylinder is known as scavenging.
Fig: First stroke or down ward
Two stroke diesel engine
Construction:
Head- Only fuel injector is fitted in the head. In air-cooled engine fins are
provided in the head for cooling purpose. The head is fitted above the cylinder block.
Cylinder block- it consists of 3 ports namely exhaust port, inlet port and
transfer port. The piston reciprocates in the cylinder block. The exhaust port is
located opposite to transfer port. The piston is fitted with only compression rings.
Around the cylinder block fins are provided for cooling purpose.
Crankcase- The crankcase is fitted below the cylinder block. The crankshaft
is fitted inside the crankcase. The crankshaft is supported by two bearings (ball or
roller bearings) on either side of crankshaft.
Working Upward stroke or working stroke: In two-stroke diesel engine some
charge is present either in the cylinder block or in the crankcase. To start a two-stroke
engine, power is supplied either by using a kicker or by electric start.
During upward stroke, the piston reciprocates from bottom dead center to
top dead center. As the piston moves upward volume below the piston increases
results in decrease in pressure in the crankcase. Due to pressure difference air is drawn
from the atmosphere. As the piston moves further upwards covers both exhaust and
transfer port, now the air is subjected to compression. The temperature of the air
during compression increases just above the ignition temperature of the diesel. Before
the end of the compression stroke the fuel is injected and begins to burn. Due to
combustion of charge, the pressure increases, which pushes the piston downwards i.e.
the working stroke of the piston. As the piston moves rapidly in the down ward
direction compress the air present in the crankcase.

Downward stroke or exhaust stroke: As the piston moves further down wards, first
it uncovers the exhaust port. Due to pressure difference the high-pressure gases leaves
the combustion chamber. As the piston moves further down wards, it uncovers transfer
port, which allows the compressed air in the crankcase to the cylinder. The
fresh air is deflected upwards by the deflector provided on the top of the piston and
pushes the remaining exhaust gases present in the cylinder. The process of removal of
exhaust gases from the cylinder is known as scavenging. As the piston reaches BDC
pushes all the air present in the crankcase, thus completes the down ward stroke.
In the next cycle again the piston moves from TDC to BDC.

Difference between petrol and diesel engine.

i) The petrol engine works on the principle of Otto cycle and the diesel engine works on
the principle of diesel cycle.
ii) In petrol engine during suction stroke petrol and air mixture is fed in to the cylinder,
where as in diesel engine only air is fed in to the cylinder.
iii) In petrol engine, the carburetor prepares correct air fuel mix and is delivered to the
cylinder, In case of diesel engine fuel injector injects diesel directly in to the cylinder.
iv) In petrol engine the air fuel mix is ignited by the spark given by the spark plug. In
case of diesel engine, the heat of the compressed air burns the injected diesel in
cylinder.
v) The compression ratio of petrol engine varies from 6 to 9, whereas in case of diesel
engine the compression ratio varies from 15 to 24.
vi) The petrol engine is cheaper than a diesel engine.
vii) The maintenance cost of diesel engine is more than a petrol engine. viii) The petrol
engine gives more pollutants then a diesel engine.
ix) The petrol engine runs smoother than a diesel engine.
x) The petrol engine produces less vibration than a diesel engine.
xi) The diesel engine gives more mileage than a petrol engine.
 Difference between two stroke and four stroke engines.
ii) In 4 - stroke engine, the suction and exhaust ports are opened by valves, whereas in
2 - stroke engine the piston itself opens and blocks the ports during reciprocation.

iii) The crankcase of a 4 - stroke engine is a closed chamber, where as in 2 - stroke

engine the crankcase is closed pressure tight chamber.

iv)In 4 - stroke engine the turning moment is not uniform, so a heavy flywheel is required.
Whereas in 2 – stroke turning moment is uniform, so a lighter flywheel is required.
v) In 4 - stroke engine During exhaust stroke the movement of the piston pushes all the gases
out of cylinder, whereas in 2 - stroke engine removal of exhaust gases is partly due to pressure
difference and partly due to scavenging.
vi) In 4 - stroke engine wear & tear is less because of one power stroke in two
revolutions of crankshaft, whereas in 2 - stroke engine wear & tear is more because of one
power stroke in one revolution of crankshaft.
vi) In 4 - stroke engine the volumetric efficiency is better, whereas in 2 - stroke engine the
volumetric efficiency is poor.
vii) In 4 - stroke engine the thermal efficiency is better, whereas in 2 - stroke engine the
thermal efficiency poor.
viii) In 4 - stroke engine due to one power stroke in two revolutions lesser cooling is needed,
whereas in 2 - stroke engine due to one power stroke one revolution of crankshaft
more cooling is needed.
ix) In 4 - stroke engine the charge directly enters into the cylinder, whereas in 2 - stroke
engine first the charge enters into crankcase then through transfer port it enters in to the
cylinder.
x) In 4 - stroke engine the oil consumption is less, whereas In 2 - stroke engine oil
consumption is more.
xi) In 4 - stroke engine number of components are more hence it is costly, whereas in
2 - stroke engine number of components are less hence it is cheap.
xii) The 4 - stroke engine needs more maintenance than a 2 – stroke engine.
xiii) The 4 – stroke engine needs more space than a 2 – stroke engine.