CHAPTER SIX

MAIN COMPONENT OF IC ENGINES

By Destaw B.
 CONTENTS

Cylinder block and head;

Piston and rings; Connecting rod; Crank shaft;

Main and crank pin bearing forces and moments on main components:

Cyclic variation of gas and inertia forces;

Turning effort
 Cylinder block and cylinder head
Cylinder is the main body of IC engine.

Cylinder is a part in which the intake of fuel, compression of fuel and

burning of fuel take place.

The main function of cylinder is to guide the piston. It is in direct

contact with the products of combustion so it must be cooled.

 For cooling of cylinder, a water jacket (for liquid cooling used in most

of cars) or fin (for air cooling used in most of bikes) are situated at the
outer side of cylinder.
 Cylinder block and cylinder head
At the upper end of cylinder, cylinder head and at the bottom end crank case
is bolted.
The upper side of cylinder is consisting a combustion chamber where fuel
burns.
To handle all this pressure and temperature generated by combustion of fuel,
cylinder material should have high compressive strength. So, it is made by
high grade cast iron.
It is made by casting and usually cast in one piece.
 Cylinder block and cylinder head
Blocks may be cast from different materials such as iron, aluminum,
magnesium, or possibly, in the future, plastic
Many engines have an aluminum block to reduce the vehicle’s overall
weight.
Certain materials are added to aluminum to make it stronger and less
likely to warp from the heat of combustion.
The cylinder walls of aluminum blocks may be treated with a special
coating or may have a sleeve or liner to serve as cylinder walls.
 Cylinder block and cylinder head
Cylinder Liners

Most aluminum blocks have cylinder liners.

The liners are normally made of a cast-iron alloy. On some engines, the
liners can be replaced
 Cylinder block and cylinder head
It consists of oil gallery and water jacket

The cylinder block houses the areas where combustion takes(combustion chamber) place It
is a place where piston, cylinder, crankshaft, camshaft (in block cam)found.
 cylinder head
The cylinder head is made of cast iron or aluminum.
 cylinder head
It consists of oil gallery and water jacket

On overhead valve engines, the cylinder head contains the valves,

valve seats, valve guides, valve springs, rocker arm supports, and a recessed
area that makes up the top portion of the combustion chamber Came shaft and
cam shaft bearing
 cylinder head
All cylinder heads contain passages that match passages in the cylinder block.
These passages allow coolant to circulate in the head and allow oil to drain back
into the oil pan.
Oil also moves through some of the passages to lube the camshaft and valve
train.
The cylinder head also contains tapped holes in the combustion chamber to
accept the spark plugs
 cylinder head
The sealing surface of the head must be flat and smooth.

To aid in the sealing, a gasket is placed between the head and block.

This gasket, called the head gasket, is made of special material that can
withstand high temperatures, high pressures, and the expansion of the metals
around it.
The head also serves as the mounting point for the intake and exhaust
manifolds and contains the intake and exhaust ports.
 cylinder head
Cylinder head design is one of the most influential factors that affects the overall
performance of an engine.
 The size and shape of the intake and exhaust ports affect the velocity and volume of the
mixture entering and leaving the cylinders.
Openings in the cylinder head allow coolant to pass through the head.

Coolant must circulate throughout the cylinder head to remove excess heat.

The coolant flows from passages in the cylinder block through the head gasket and into
the cylinder head.
The coolant then passes back to other parts of the cooling system
 cylinder head
• These ports are called Siamese ports.

• With Siamese ports, individual ports around each valve mesh together to form a
larger single port that is connected to a manifold.

• Cross-flow ports are used on some engines and have intake and exhaust ports
on opposite sides of the combustion chamber. Heads of this design are called
cross-flow heads.
 cylinder head
Intake and exhaust ports are cast into the cylinder head.

One port is normally used for each valve.

 However, on engines with more than two valves per cylinder, the ports for the
intake or exhaust valves may be combined.
 INTAKE AND EXHAUST VALVES
• The intake and exhaust valves are commonly called poppet valves

• They tend to pop open and close.

• When they open, they allow intake air to flow into the combustion chamber or allow the exhaust to leave
it.

• When closed, they must (along with the cylinder head gasket, piston rings, and spark plug) seal the
chamber. The heads of the intake and exhaust valves have different diameters.

• The intake valve is the larger of the two. An exhaust valve can be smaller because exhaust gases move
easier than intake air.

• Today, most valves are made from special hardened steel, steel alloys, or stainless steel. Other metals are
often used in high-performance valves.
 Piston
A piston is fitted to each cylinder as a face to receive gas pressure and transmit

the thrust to the connecting rod.

It is a prime mover in the engine.

The main function of piston is to give tight seal

to the cylinder through bore and slide freely inside the cylinder.

Piston should be light and sufficient strong to handle gas pressure generated by combustion
of fuel.
So the piston is made by aluminum alloy and sometimes

it is made by cast iron because light alloy piston expands more than cast iron so they need
more clearances to the bore.
 Piston
A piston is fitted to each cylinder as a face to receive gas pressure and
transmit
the thrust to the connecting rod.

It is a prime mover in the engine.

The main function of piston is to give tight seal

 Piston
to the cylinder through bore and slide freely inside the cylinder.

Piston should be light and sufficient strong to handle gas pressure generated
by combustion of fuel.
So the piston is made by aluminum alloy and sometimes

it is made by cast iron because light alloy piston expands more than cast iron
so they need more clearances to the bore.
 Piston rings
A piston must be a fairly loose fit in the cylinder so it can move freely inside
the cylinder.
If the piston is too tight fit, it would expand as it got hot and might stick tight
in the cylinder and if it is too loose it would leaks the vapor pressure.
To provide a good sealing fit and less friction resistance between the piston
and cylinder, pistons are equipped with piston rings.
 Piston rings
These rings are fitted in grooves which have been cut in the piston.

They are split at one end so they can expand or slipped over the end of
piston.
A small two stroke engine has two piston rings to provide good sealing but a
four-stroke engine has an extra ring which is known as oil ring.
 Piston rings
Piston rings are made of cast iron of fine grain and high elastic material
which is not affected by the working heat.
Sometimes it is made by alloy spring steel.
 connecting rod
A connecting rod is a vital engine component that connects the piston to the
crankshaft in internal combustion engines.
It transfers the reciprocating motion of the piston into rotational motion of
the crankshaft.
Typically made from steel or aluminum alloy, connecting rods are engineered
to withstand high forces and temperatures.
 connecting rod
They must maintain precise alignment to ensure smooth operation and
minimize frictional losses.
Connecting rods undergo rigorous design and manufacturing processes to
meet durability and performance requirements.
Their design and material composition directly impact engine efficiency,
reliability, and overall power output.
 Piston pin(gudgeon pin)
• A gudgeon pin, also known as a wrist pin, connects the piston to the
connecting rod in an internal combustion engine.

• It allows the piston to pivot as it moves up and down within the cylinder.

• Made from hardened steel,

 Piston pin(gudgeon pin)
• it withstands high temperatures and pressures.

• It is lubricated with engine oil, Proper lubrication is crucial for its longevity
and smooth operation.

• Its design impacts engine performance and durability significantly

 Crank shaft
The crankshaft is a crucial component in internal combustion engines and
other machinery that converts reciprocating motion into rotational motion:
It's typically a cylindrical shaft with offset crank webs or journals that
convert linear piston movement into rotational force.
 Crank shafts
Found in everything from car engines to industrial machines, the
crankshaft's design varies based on the engine type and application.
Made from hardened steel or alloy materials to withstand high stress and
torsional forces.
Precision-machined to ensure smooth rotation and minimize vibrations
during operation.
Advanced designs include counterweights and forged construction for
enhanced durability and performance in high-performance engines
 Crank shafts
The crankshaft consists of different portions portions

1. Crank pin .

2. Crank web(counter weight)

3. Shaft.

4. Fly wheel flange

 Main and pin bearing force and moment
In the engine block or crank shaft system there are three bearings.

1. Main bearing

2. Connecting rod bearing (pin bearings)

 Main and pin bearing force and moment
1. Main Bearings:
Main bearings are larger bearings that are located at the ends of the crankshaft, where it
connects to the engine block.
Main bearings support the weight of the crankshaft and help maintain its alignment
within the engine block.
Main bearings typically consist of two halves - an upper half and a lower half - that are
separated by an oil film. This oil film helps reduce friction between the bearing surfaces
and the crankshaft journal.
Handling Radial and Axial Loads: Main bearings are designed to withstand both radial
(perpendicular to the shaft) and axial (along the shaft) loads generated by the forces
 Crank shafts
2. Connecting rod bearings
Purpose: Connecting rod bearings specifically support the crankshaft within
the engine's bottom end.
Location: These bearings are situated at the connection points between the
crankshaft and the connecting rods.
Function: They endure both radial and axial loads generated by the
reciprocating motion of the pistons and the rotational forces of the
crankshaft. Connecting rod bearings must handle high dynamic loads and
provide a smooth surface for the crankshaft to rotate.
 Main and pin bearing force and moment
Pin Bearings (Connecting Rod Bearings)

Forces on main and pin bearings

• Radial Loads: These are forces acting perpendicular to the shaft, exerted by the weight of
the rotating components (like the crankshaft) and the inertial forces due to the reciprocating
motion of the pistons.

• Axial Loads: These forces act along the axis of the shaft (crankshaft). They are primarily
caused by combustion pressures pushing the pistons downwards (towards the crankshaft)
during the power stroke.
 Main and pin bearing force and moment
Pin Bearings (Connecting Rod Bearings)

Moments on main and pin bearings

• Bending Moment: This refers to the moment created by the forces acting perpendicular to
the crankshaft's axis, causing it to bend. Main bearings must withstand these bending
moments to maintain the crankshaft's alignment and prevent structural damage.

• Torsional Moment: Torsional moments result from the twisting forces applied to the
crankshaft, primarily due to the combustion cycles and the inertial forces of rotating
masses.
 Main and pin bearing force and moment
Design Considerations:

• Material Selection: Main and pin bearings are typically made from
materials like steel or aluminum alloys with bearing surfaces coated with
materials like tin, copper, or even polymers to reduce wear and friction.

• Clearance and Lubrication: Proper clearance between the bearings and

the crankshaft is crucial for effective lubrication, which reduces friction and
wear. Lubrication systems ensure that adequate oil is supplied to the
bearings to maintain their functionality. Or else the bearing will cease and
engine become stall.
 Cyclic variation of gas and inertia forces
In an internal combustion (IC) engine, cyclic variation of gas and inertia forces refers to the
fluctuations in forces acting on the engine components during each engine cycle.
Gas Forces:

The pressure varies significantly during each cycle. This pressure is generated by the

combustion of the air-fuel mixture, creating high-pressure gases that exert force on the
piston.

Gas Inertia:

As the piston moves up and down, the mass of the gas inside the cylinder also moves. This

mass has inertia, which affects the dynamics of the piston movement.

Inertia Forces: Piston Motion: The piston moves up and down inside the cylinder due to the
 Cyclic variation of gas and inertia forces
 This movement creates inertia forces that act on the piston and the connecting rod.

Reciprocating Masses

 Inertia forces also arise from the reciprocating masses of the piston, connecting rod, and other moving components

such as the crankshaft.

Effects of Cyclic Variation

 Vibration and Noise: Cyclic variation of these forces can lead to vibrations and noise in the engine. The magnitude

and frequency of these vibrations depend on factors such as engine speed, load conditions, and engine design.

 Engine Smoothness reduction: Higher levels of cyclic variation can lead to rough engine operation and reduced

smoothness, affecting overall vehicle performance and comfort.

 Wear and Tear: Fluctuating forces can contribute to increased wear and tear on engine components over time,

affecting durability and reliability.

 Cyclic variation of gas and inertia forces
Managing Cyclic Variation:

Engine Design: Engineers use various design techniques to mitigate these

effects, such as optimizing combustion chamber shape, adjusting valve timing,
and balancing reciprocating masses.
Control Systems: Modern engines often incorporate advanced control
systems that adjust fuel injection timing, air-fuel mixture ratios, and ignition
timing dynamically to minimize cyclic variations and improve efficiency.
 Tuning effect

Tuning is adjustment or optimization of various engine parameters to achieve specific performance goals

Performance Optimization: Tuning involves adjusting parameters such as ignition timing, fuel-air

mixture ratio, valve timing, and turbocharger or supercharger boost levels to maximize engine

performance.

This optimization aims to increase power output, improve fuel efficiency, and enhance drivability.

Fuel Efficiency: By tuning the engine, engineers can optimize the combustion process to ensure that

the air-fuel mixture burns efficiently. This improves fuel efficiency, which is crucial for reducing fuel

consumption and emissions.

Power Output: Tuning can increase the engine’s power output by adjusting parameters that affect the

combustion process and airflow dynamics. This includes optimizing intake and exhaust systems,
 Tuning effect
Emission Control: Proper tuning can help reduce harmful emissions by

ensuring complete combustion and efficient exhaust gas treatment. This is

achieved through precise control of fuel injection timing, air-fuel ratio, and

exhaust gas recirculation (EGR) systems.

Durability and Reliability: Effective tuning not only enhances performance

but also ensures the engine operates within safe limits for longevity. This

involves considering factors like thermal management, stress on engine

components, and maintaining optimal operating temperatures.

, END
THANK YOU