ME-263

Fundamentals
of
Mechanical Engineering
 Syllabus

 Classification of IC Engine
 Diagram of main components of IC Engine
 Difference between two stroke and four stroke cycle Engine
 Difference between CI and SI engines
 Difference between petrol and diesel Engine
 Valve timing and Indicated diagram of four stroke Engine
 Detonation , Causes and Effects and Ways of reduction
 Scavenging
 Block diagram of cooling, intake and exhaust, lubrication,
fuel, electric starting systems.
Internal Combustion
Engines
Engine

A machine that converts energy into mechanical force or

motion.
Heat Engine
 It can be defined as any engine that converts thermal
energy to mechanical work output. Examples of heat
engines include: steam engine, diesel engine, and gasoline
(petrol) engine.

 Heat engine can be classified as an internal combustion

engine and external combustion engine.

4
Heat Engine

Heat Engine

External Combustion Internal Combustion

Engine Engine

5
DIFFERENCE BETWEEN STEAM
ENGINES AND I.C. ENGINES

6
Internal Combustion Engine (IC Engine)
 Internal combustion engines are those engines
in which the combustion of fuel takes place inside
the engine cylinder.
Examples: Petrol, Diesel, Gas Engine

External combustion engine

 Combustion of an air-fuel mixture transfers
heat to a second fluid which becomes the motive
(working) fluid that produces power.
Example: Steam driven engine.

7
Steam Engine I.C
Engine
8
 Classification of I.C. Engine
The internal combustion engine may be classified
in many ways:

1. According to the type of fuel used :

a. Petrol Engine
b. Diesel Engine
c. Gas Engine

2. According to the method of ignition of fuel:

a. Spark ignition engines (SI engine)
b. Compression ignition engines (CI engine)

9
 SI Engine

 Generally homogeneous air – fuel mixture is used.

 Ignition by external source such as a spark.

10
SI Engine

11
 CI Engine

 Generally Non-homogeneous mixture is used.

 Ignition due to high temp.

12
CI Engine

13
3. According to the number of strokes per cycle :
a. Four Stroke cycle engines
b. Two stroke cycle engines

14
Four Stroke Cycle Engines

15
Two Stroke Cycle Engines

16
4. According to the speed of the engine :
a. Slow speed engines
b. Medium speed engines
c. High speed engines
5. According to the cooling system:
a. Air-cooled engines
b. Water cooled engines

17
6. According to the method of fuel injection:
a. Carburetor engines
b. Air injection engines
c. Solid injection

18
7. According to the number of cylinders:
a. Single cylinder engines
b. Multi-cylinder engines

19
8. According to the arrangement of cylinders:

a. Vertical Engines
b. Horizontal Engines
c. Radial engines
d. V-type multi-cylinder engines
e. In-line multi-cylinder engines

20
Vertical Engines Horizontal Engines

21
In-line multi-cylinder engines V-type multi-cylinder engines

22
Radial engines

23
09. According to the type of lubricating
system:

a. Wet sump lubrication

b. Dry sump lubrication
c. Pressure lubrication
d. Splash lubrication

24
Construction details of IC Engine

25
26
Engine Terminologies
 Engine Terminologies

Top Dead Center (TDC):

Position of the piston when it stops at the furthest point away
from the crankshaft.
Top because this position is at the top of the engines, and
dead because the piston stops as this point.
Bottom Dead Center (BDC):
Position of the piston when it stops at the nearest point away
from the crankshaft.
 Engine Terminologies

Stroke: Distance traveled by the piston from one

extreme position to the other : TDC to BDC or BDC
to TDC.
Bore: It is defined as cylinder diameter or piston
face diameter; piston face diameter is same as
cylinder diameter (minus small clearance).
 Engine Terminologies

Swept volume/Displacement volume : Volume

displaced by the piston as it travels through one
stroke.
 Swept volume is defined as stroke times
bore.
 Displacement can be given for one
cylinder or entire engine (one cylinder times
number of cylinders).
 Engine Terminologies

Clearance volume: It is the minimum volume of the cylinder

available for the charge (air or air fuel mixture) when the piston
reaches at its outermost point (top dead center or outer dead
Center)during compression stroke of the cycle.Minimum volume
of combustion chamber with piston at TDC.
Compression ratio: The ratio of total volume to clearance
volume of the cylinder is the compression ratio of the engine.
Typically compression ratio for SI engines varies form 8 to 12
and for CI engines it varies from 12 to 24.
 Main Components of I.C. Engine

Cylinder block: The cylinder block is the foundation of

the engine. Usually made of cast iron; Contains
coolant passages.
 Main Components of I.C. Engine

Cylinder Liner: It is a hole inside the cylinder block.

Wet or dry liner (wet if liner touch the cooling water).
Made Gray cast iron.
 Main Components of I.C. Engine

Crankcase: Holds the cylinder and crankshaft of an IC

engine. Made of cast iron. Also serves as a sump for
the lubricating oil.
 Main Components of I.C. Engine

Connecting Rod: Connecting rod is

used to transmit the motion from the
piston to the crankshaft. Made of
forged-steel or cast iron.

Crankshaft: It is considered as
the backbone of an engine. Its function is to
Convert reciprocating motion of the piston into
rotary motion with the help of connecting rod. Made of
forged steel.
 Main Components of I.C. Engine

Cylinder Head: A detachable unit

of an engine bolted to the top of the
cylinder block. Contain valve
assemblies.

Piston: The piston is a cylindrical

plug that moves up and down in the
engine cylinder. Made of aluminum,
cast steel or cast iron. It contains
piston rings (oil & compression).
Main Components of I.C. Engine
Functions of piston rings:

The three main functions of piston rings in

reciprocating engines are :
Sealing the combustion chamber so that there is
no transfer of gases from the combustion chamber
to the crank.
Supporting heat transfer from the piston to the
cylinder wall.
Regulating engine oil consumption.

38
 Main Components of I.C. Engine

Flywheel: Mounted on the crankshaft. To maintain

its speed const. Storing excess energy during the
power stroke, which is returned during other stroke.
 Main Components of I.C. Engine

Intake and Exhaust Valve:

Intake valve usually made of a
chromium-nickel alloy and slightly
larger than exhaust valve for
higher volumetric efficiency and
also combustion. Exhaust valve
made of a silicon-chrome alloy
since it operates at higher temps
(about 1200oF).
41
Sequence of operation of 4 Stroke
Petrol (SI) Engine

42
43
Sequence of operation of 4 Stroke Petrol
(SI) Engine

44
45
4 Stroke Petrol Engine with Carburettor

46
4 Stroke Petrol Engine (Direct Injection)

47
Valve timing for 4 Stroke Petrol Engine

48
Valve timing for 4 Stroke Petrol Engine

49
Indicator diagram for 4 Stroke Petrol Engine

50
Sequence of operation of 4 Stroke
Diesel (CI)Engine

51
Sequence of operation of 4 Stroke
Diesel (CI)Engine

52
4 Stroke Diesel Engine

53
Valve timing for 4 Stroke Diesel Engine

54
Indicator diagram for 4 Stroke Diesel Engine

55
Comparison of Petrol and Diesel Engine

Four stroke SI Engine

Comparison of Petrol and Diesel Engines
Sl Petrol (SI)Engine Diesel (CI)Engine
no
1 A petrol engine draws a mixture A diesel engine draws only air
of petrol and air during suction during suction stroke.
stroke.
2 The carburetor is employed to The injector or atomizer is
mix air and petrol in the employed to inject the fuel at the
required proportion and to end of compression stroke.
supply it to the engine during
suction stroke.
3 Pressure at the end of Pressure at the end of
compression is low. compression is high.
4 The charge is ignited with the The fuel is injected in the form of
help of sparking plug. fine spray . The temperature of the
compressed air is sufficiently high
to ignite the fuel. 57
58
59
 Two Stoke Cycle
Please Follow:
http://www.animatedengines.com
/twostroke.html

60
Intake
The fuel/air mixture is first
drawn into the crankcase by
the vacuum that is created
during the upward stroke of
the piston. The illustrated
engine features a poppet
intake valve.

61
Crankcase
compression
During the downward stroke,
the poppet valve is forced
closed by the increased
crankcase pressure. The fuel
mixture is then compressed
in the crankcase during the
remainder of the stroke.

62
Transfer/Exhaust
Toward the end of the stroke,
the piston exposes the intake
port, allowing the
compressed fuel/air mixture
in the crankcase to escape
around the piston into the
main cylinder. This expels the
exhaust gasses out the
exhaust port, usually located
on the opposite side of the
cylinder. Unfortunately, some
of the fresh fuel mixture is
usually expelled as well.

63
Compression
The piston then rises,
driven by flywheel
momentum, and
compresses the fuel
mixture. (At the same
time, another intake
stroke is happening
beneath the piston).

64
Power
At the top of the
stroke, the spark plug
ignites the fuel
mixture. The burning
fuel expands, driving
the piston
downward, to
complete the cycle.
(At the same time,
another crankcase
compression stroke is
happening beneath
the piston.)
65
Construction of 4 and 2 Stroke Engine

66
67
68
69
Comparison of 4 Stroke and 2 Stroke Engine

70
 Firing Order
The firing order is the sequence of power
delivery of each cylinder in a multi-cylinder 
reciprocating engine.

71
 Firing Order
The firing orders for 4 stroke engines are 

1-3-4-2 - Most commonly used configuration.

1-2-4-3 - This order has its disadvantages but is still used in
some special cases.
1-3-2-4 - Yamaha has used this configuration in some of
their bikes.
1-4-3-2 - This is also being used.

72
73
74
 IC Engine Systems
Transmission System
Cooling System
Lubricating System
Fuel System
Transmission System
 Transmission System

Engine Clutch Transfer Universal Propeller Final drive Rear drive

Universal Rear
Joint shaft /drive and axel/ half
Joint Wheel
shaft differential shaft

Front
drive axel

Front
wheel
 Cooling System
Air Cooling
Water Cooling
Cooling System- Water Cooling
 Components used in Water Cooling system
Radiator
Radiator Cooling Fans
Pressure Cap & Reserve Tank
Water Pump
Thermostat
Bypass System
Water jacket
Head Gaskets & Intake Manifold Gaskets
Heater Core
Hoses
Cooling System- Water Cooling
Cooling System- Water Cooling

Water Oil Water

Water Thermostat Radiator
Jacket of Cooler Jacket of
Radiator Pump housing
Cylinder Cylinder
Block Head

Thermostat bypass
Radiators

A radiator is a heat
exchanger.
Tube and fin style the
most popular.
Made of copper and
brass or aluminum and
plastic.
3 (radiator, evaporator,
heater core)

83
Radiator Fans
Keeps air moving
through the radiator
when the car is not
moving.
Several types:
rigid,
flex (not used much
anymore),
viscous clutch and
electric.
84
Radiator Cap
The cap allows access to the
cooling system for filling and
testing.
The cap has two valves: a
pressure relief valve set at
around 15 PSI and a vacuum
valve which is needed when
the engine cools down.
Raises boiling point of fluid
Able to take on more heat

85
Water Pump

Non-positive displacement
pump which circulates
coolant around cooling
system.
Simple impeller design.
Usually driven by drive belt
from crankshaft.

86
Thermostat

Controls coolant
temperature.
Uses a temperature
sensor and a valve.
Usually opens around 195
degrees F.

87
Water Jackets

Surrounds the cylinders

with water passage.
Absorbs heat from the
cylinder wall.
Pump move water to
radiator where heat is
exchanged to the air.

88
Coolant Recovery Tank
Keeps the coolant level full in the
system at all times.
Works in conjunction with the
radiator cap.
When the engine heats up the
coolant expands and flows to the
recovery tank.
When the engine coolant the
coolant contracts and creates a
vacuum and draws the fluid back
into the radiator.
Reduces air in system
Reduces rust
Less need to open radiator

89
Coolant Temperature Sensor (CTS)

Reports to computer
Gauges
Location
◦ Block
◦ Head
◦ Radiator tank

90
Heater

The hot water in the cooling

system is used warm the
passenger compartment.
A small radiator called a
heater core is located in the
dash area.
Heater hoses direct the hot
water to and from it.

91
Cooling System- Water Cooling
 Cooling System
An automotive cooling system must perform
several functions
a. Remove excess heat from the engine
b. Maintain a consist engine temperature
c. Help a cold engine warm-up quickly
d. Provide a means of warming the passenger compartment
Lubricating System
95
 Lubricating System

Big end bearings ,

By Pass Crank connecting rod ,
Pressure
Valve shaft small end bearings ,
Relief
Valve Piston rings

Cam Rocker arm ,

Oil Filter Oil Main shaft valve and valve
Sump Strainer Pump Cooler oil spring
gallery

Timing gear
mechanism

Sump
 Lubricating System Parts
Oil pan/sump
Oil strainer
Pick-up screen
Oil pump
Pressure regulator
Oil filter
By-pass valve
Oil galleries
Dipstick
Oil Pressure sending unit
Pressure indicator
Positive Crankcase ventilation Valve 97
 Lubrication system

Six main functions of lubricating oil

Reduce friction
Reduce wear
Seal power
Absorb shock
Clean
Cool

98
 Properties of lubricating oil
•Corrosion and Rust Inhibitor: Displaces water from
metal surfaces, to prevent corrosion.
•Foaming Resistance: Rotating crankshaft tends to cause
bubbles (Foam) in the oil and bubbles in oil will reduce the
effectiveness of oil to lubricate.
•Synthetic Oils: Made by chemical process and do not
necessarily come from petroleum.
Fuel System
 Fuel System

Residual
diesel
Fuel feed
Fuel Primary Secondary Fuel HP Injector
pump/l low
Filter injection
Cylinder
tank Filter line
pressure
pump/ high
pump
pressure
pump

Excess fuel
Super Charger
Turbocharger
Engine Performance

Compression Ratio
Volume in the cylinder at the bottom of its travel as
compared to the top
Expressed as a ratio 10:1, 7:1, etc……..
Higher compression ratios produce more power
Compression ratio is limited by fuel octane and
engine strength
The higher the compression ratio, the more apt the
engine is to detonate or “knock”
Compression Ratio
Engine Power
Power = work / time
P= w/t
Hp = 33,000 ft-lb (work) / 1 minute (time)
Hp = 550 ft-lb / 1 second
Kinds of HP
Indicated Horsepower
Brake Horsepower
Frictional Horsepower
Rated Horsepower
Corrected Horsepower

106
Indicated  Horsepower. The power developed within a cylinder can
be calculated by measuring the imep and the engine speed. (The rpm
of the engine is converted to the number of power strokes per
minute.) With the bore and stroke know (available  in  engine
manufacturers’   technical   manuals),   the horsepower (hp) can be
computed. This power is called indicated horsepower (ihp) because it
is obtained from the pressure measured with an engine indicator.
Power loss due to friction is not con- sidered in computing ihp.
ihp  = P   ×   L   ×   A   ×   N /33,000
P  =  Mean  indicated  pressure,  in  psi
L = ength  of  stroke,  in  feet
A  =  Effective  area  of  the  piston,  in square  inches
N = Number of power strokes per minute
33,000 = Unit of power (one horsepower), or foot
pounds per minute.

107
Brake horsepower. Actual or useful horsepower of an
engine, usually determined from the force exerted on a
friction brake or Dynamometer connected to the drive
shaft.
Frictional horsepower. That part of the gross or indicated
horsepower developed in an engine cylinder which is
Absorbed in frictional losses; It is the difference between
the indicated and the brake horsepower.
Rated horsepower. Power of an engine or prime mover,
The maximum horsepower that can be provided under
normal, continuous operation.
Corrected horsepower. is the observed readings
"corrected" to standard temperature, humidity, and
barometer, conditions.

108
Efficiency of Engine

Brake thermal efficiency: brake power/rate of heat output for complete combustion
Brake thermal efficiency=indicated thermal efficiency* mechanical efficiency
the thermal efficiency () is a dimensionless performance measure of a device that uses
thermal energy, such as an internal combustion engine, a steam turbine or a
steam engine, a boiler, a furnace, or a refrigerator for example. In other words,
efficiency indicates how well an energy conversion or transfer process is accomplished.

Mechanical efficiency measures the effectiveness of a machine in transforming the

energy and power that is input to the device into an output force and movement.
Efficiency is measured as a ratio of the measured performance to the performance of
an ideal machine:
 Factors Affecting Engine Performance
Detonation. The explosion of the fuel/air mixture instead of a
steady burning. This explosion causes an abrupt rise in cylinder
temperatures and pressures that may cause engine damage .
Detonation may be caused by several factors:
low octane fuel (SI Engine)
high cylinder temperatures
lean/uneven mixture
high compression ratios
shape of combustion chamber and position of sparking plug
Preignition of the fuel/air mixture before the properly timed
injection /spark occurs
Effect of Detonation:
Fuel Rating
Octane number, also called Antiknock Rating,  measure of the
ability of a fuel to resist knocking when ignited in a mixture with
air in the cylinder of an internal-combustion engine.
The octane number is determined by comparing, the knock
intensity of the fuel with that of blends of two reference fuels:
iso-octane, which resists knocking, and heptane, which knocks
readily. Thus the octane number is the percentage by volume of
Iso-octane in the iso-octane–heptane mixture that matches the
Fuel being tested in a standard test engine.

111
Fuel Rating
cetane number. Measure of the ignition quality of
Diesel fuel; higher this number, the easier it is to start a
standard (direct-injection) diesel engine. It denotes the
percentage (by volume) of cetane (chemical name
Hexadecane) in a combustible mixture (containing
cetane and 1-methylnapthalene) whose ignition
characteristics match those of the diesel fuel being
tested.

112