design a four cylinder internal combustion engine

Design a four-cylinder
Internal Combustion
Engine”
Submitted By:-
1. Siddharth Pratap Singh (301403717131)
2. Siddharth S Kashyap (301403717132)
3. Siddesh Atul nagle (301403717133)
4. Sohail Hussain (301403717134)
MAJOR PROJECT PRESENTATION ON

INTRODUCTION
We almost take our Internal Combustion Engines for granted don‟t we? All we do is buy our
vehicles, hop in and drive around. There is, however, a history of development to know about. The
compact, well-toned, powerful and surprisingly quiet engine that seems to be purr under your
vehicle‟s hood just wasn‟t the tame beast it seems to be now. An internal combustion engine is
defined as an engine in which the chemical energy of the fuel is released inside the engine and used
directly for mechanical work, as opposed to an external combustion engine in which a separate
combustor is used to burn the fuel. For example, consider how this type of engine has transformed
the transportation industry, allowing the invention and improvement of automobiles, trucks,
airplanes and trains. Internal combustion engines can deliver power in the range from 0.01 kW to
20x103 kW, depending on their displacement. The major applications are in the vehicle (automobile
and truck), railroad, marine, aircraft, home use and stationary areas. The vast majority of internal
combustion engines are produced for vehicular applications, requiring a power output on the order
of 102 kW. Next to that internal combustion engines have become the dominant prime mover
technology in several areas. Today gas turbines are the power plant used in large planes, and piston
engines continue to dominate the market in small planes. The adoption and continued use of the
internal combustion engine in different application areas has resulted from its relatively low cost,
favorable power to weight ratio, high efficiency, and relatively simple and robust operating
characteristics. The components of a reciprocating internal combustion engine, block, piston, valves,
crankshaft and connecting rod have remained basically unchanged since the late 1800s. The main
differences between a modern day engine and one built 100 years ago are the thermal efficiency and
the emission level. For many years, internal combustion engine research was aimed at improving
thermal efficiency and reducing noise and vibration. As a consequence, the thermal efficiency has
increased from about 10% to values as high as 50%. Since 1970, with recognition of the importance
of air quality, there has also been a great deal of work devoted to reducing emissions from engines.
Currently, emission control requirements are one of the major factors in the design and operation of
internal combustion engines.

GOALS AND OBJECTIVES
The aim of this Thesis is to introduce to the interesting world of
internal combustion engines and to describe what actually Internal
Combustion Engine is. What are its main components and structure.
How the engine indeed operates. Also to design a real engine, having
into account all necessary calculations concerning with kinematics,
dynamics and strength calculation of basic details. Another purpose
of the project is to define the proper materials for each part. Next to
that I will make 2D and 3D drawings on SOLID WORKS and animation
of working Internal Combustion Engine.

HISTORY & DEVELOPMENT
A brief outline of the history of the internal combustion engine includes the following highlights:
1680 - Dutch physicist, Christian Huygens designed (but never built) an internal combustion engine that was to be fueled
with gunpowder.
1807 - Francois Isaac de Rivaz of Switzerland invented an internal combustion engine that used a mixture of hydrogen
and oxygen for fuel. Rivaz designed a car for his engine - the first internal combustion powered automobile. However, his
was a very unsuccessful design.
1824 - English engineer, Samuel Brown adapted an old Newcomen steam engine to burn gas, and he used it to briefly
power a vehicle up Shooter's Hill in London.
1858 - Belgian-born engineer, Jean Joseph Étienne Lenoir invented and patented (1860) a double-acting, electric spark-
ignition internal combustion engine fueled by coal gas. In 1863, Lenoir attached an improved engine (using petroleum
and a primitive carburetor) to a three-wheeled wagon that managed to complete an historic fifty-mile road trip
1862 - Alphonse Beau de Rochas, a French civil engineer, patented but did not build a four-stroke engine (French patent
#52,593, January 16, 1862).
1864 - Austrian engineer, Siegfried Marcus, built a one-cylinder engine with a crude carburetor, and attached his engine
to a cart for a rocky 500-foot drive. Several years later, Marcus designed a vehicle that briefly ran at 10 mph that a few
historians have considered as the forerunner of the modern automobile by being the world's first gasoline-powered
vehicle

1873 - George Brayton, an American engineer, developed an unsuccessful two-stroke kerosene engine (it used two
external pumping cylinders). However, it was considered the first safe and practical oil engine.
1866 - German engineers, Eugen Langen and Nikolaus August Otto improved on Lenoir's and de Rochas' designs and
invented a more efficient gas engine.
1876 - Nikolaus August Otto invented and later patented a successful fourstroke engine, known as the "Otto cycle". 7
1876 - The first successful two-stroke engine was invented by Sir Dougald Clerk.
1883 - French engineer, Edouard Delamare-Debouteville, built a singlecylinder four-stroke engine that ran on stove gas.
It is not certain if he did indeed build a car, however, Delamare-Debouteville's designs were very advanced for the time -
ahead of both Daimler and Benz in some ways at least on paper.
1885 - Gottlieb Daimler invented what is often recognized as the prototype of the modern gas engine - with a vertical
cylinder, and with gasoline injected through a carburetor (patented in 1887). Daimler first built a two-wheeled vehicle
the "Reitwagen" (Riding Carriage) with this engine and a year later built the world's first four-wheeled motor vehicle.
1886 - On January 29, Karl Benz received the first patent (DRP No. 37435) for a gas-fueled car.
1889 - Daimler built an improved four-stroke engine with mushroom-shaped valves and two V-slant cylinders.
1890 - Wilhelm Maybach built the first four-cylinder, four-stroke engine.

TYPES OF ENGINE
There are two major cycles used in internal combustion engines: Otto and Diesel.
The Otto cycle is named after Nikolaus Otto (1832 – 1891) who developed a four
stroke engine in 1876. It is also called a spark ignition (SI) engine, since a spark is
needed to ignite the fuel-air mixture. The Diesel cycle engine is also called a
compression ignition (CI) engine, since the fuel will auto-ignite when injected into
the combustion chamber. The Otto and Diesel cycles operate on either a four- or
two stroke cycle. Since the invention of the internal combustion engine many
pistons-cylinder geometries have been designed. The choice of given arrangement
depends on a number of factors and constraints, such as engine balancing and
available volume:
1. In line
2. Horizontally opposed
3. Radial
4. V / Internal Combustion Engine

1. IN LINE
The inline-four engine or straight-four engine is an
internal combustion engine with all four cylinders
mounted in a straight line, or plane along the
crankcase. The single bank of cylinders may be
oriented in either a vertical or an inclined plane with
all the pistons driving a common crankshaft. Where
it is inclined, it is sometimes called a slant-four. In a
specification chart or when an abbreviation is used,
an inline-four engine is listed either as I4 or L4. The
inline-four layout is in perfect primary balance and
confers a degree of mechanical simplicity which
makes it popular for economy cars. However,
despite its simplicity, it suffers from a secondary
imbalance which causes minor vibrations in smaller
engines. These vibrations become worse as engine
size and power increase, 15 so the more powerful
engines used in larger cars generally are more
complex designs with more than four cylinders.

2. HORIZONTALLY
OPPOSED
A horizontally opposed engine is an engine in which
the two cylinder heads are on opposite side of the
crankshaft, resulting in a flat profile. Subaru and
Porsche are two automakers that use horizontally
opposed engine in their vehicles. Horizontally
opposed engines offer a low centre of gravity and
thereby may a drive configuration with better
stability and control. They are also wider than other
engine configurations, presenting complications
with the fitment of the engine within the engine bay
of a front-engine car. This kind of engine is wide
spread in the aircraft production. Typically, the
layout has cylinders arranged in two banks on the
either side of the single crankshaft and is generally
known as boxer.

3. RADIAL
The radial engine is a reciprocating type internal combustion
engine configuration in which the cylinders point outward from
a central crankshaft like the spokes on a wheel. This
configuration was very commonly used in large aircraft engines
before most large aircraft started using turbine engines. In a
radial engine, the pistons are connected to the crankshaft with
a master-andarticulating-rod assembly. One piston has a master
rod with a direct attachment to the crankshaft. The remaining
pistons pin their connecting rods` attachment to rings around
the edge of the master rod. Four-stroke radials always have an
odd number cylinders per row, so that a consistent every-other-
piston firing order can be maintained, providing smooth
operation. This achieved by the engine talking two revolution of
the crankshaft to complete the four stokes (intake,
compression, power, exhaust), which means the firing order is
1,3,5,2,4 and back to cylinder 1 again. This means that there is
always a two-piston gap between the piston on its power
stroke and the next piston on fire (piston compression). If an
even number of cylinders was uses, the firing order would be
something similar to 1,3,5,2,4,6 which leaves a threepiston gap
between firing piston on the first crank shaft revolution and
only onepiston gap on the second. This leads to an uneven
firing order within the engine, and is not ideal.

4. V / Internal Combustion Engine
V engine or Vee engine is a common configuration
for an internal combustion engine. The cylinders and
pistons are aligned in two separate planes or
“banks”, is that they appear to be in a “V” when
viewed along the axis of the crankshaft. The Vee
configuration generally reduces the overall engine
length, height and weight compared to the
equivalent inline configuration. Various cylinder
bank angles of Vee are used in different engines
depending on the number of the cylinders; there
may be angles that work better than others for
stability. Very narrow angles of V combine some of
the advantages of the straight and V engine. The
most common of V engines is V6. It is an engine with
six cylinders mounted on the crankcase in two banks
of three cylinders, usually set at either a right angle
or an accurate angle to each other, with all six
pistons driving a common crankshaft. It is second
common engine configuration in modern cars after
the inline-four

MAIN COMPONENTS OF THE ENGINE
1. PISTON - Piston is one of the main parts in the engine. Its purpose
is to transfer force from expanding gas in the cylinder to the
crankshaft via a connecting rod. Since the piston is the main
reciprocating part of an engine, its movement creates an imbalance.
This imbalance generally manifests itself as a vibration, which causes
the engine to be perceivably harsh. The friction between the walls of
the cylinder and the piston rings eventually results in wear, reducing
the effective life of the mechanism. To transmit the energy of the
piston to the crank, the piston is connected to a connecting rod which
is in turn connected to the crank. Because the linear movement of the
piston must be converted to a rotational movement of the crank,
mechanical loss is experienced as a consequence. Overall, this leads
to a decrease in the overall efficiency of the combustion process. The
motion of the crank shaft is not smooth, since energy supplied by the
piston is not continuous and it is impulsive in nature. To address this,
manufacturers fit heavy flywheels which supply constant inertia to
the crank. Balance shafts are also fitted to some engines, and
diminish the instability generated by the pistons movement. To
supply the fuel and remove the exhaust fumes from the cylinder
there is a need for valves and camshafts. During opening and closing
of the valves, mechanical noise and vibrations may be encountered.

2. PISTON RINGS - A ring groove is a recessed
area located around the perimeter of the piston that
is used to retain a piston ring. Ring lands are the two
parallel surfaces of the ring groove which function as
the sealing surface for the piston ring. A piston ring is
an expandable split ring used to provide a seal
between the piston an the cylinder wall. Piston rings
are commonly made from cast iron. Cast iron retains
the integrity of its original shape under heat, load, and
other dynamic forces. Piston rings seal the
combustion chamber, conduct heat from the piston
to the cylinder wall, and return oil to the crankcase.
Piston ring size and configuration vary depending on
engine design and cylinder material. Piston rings
commonly used on small engines include the
compression ring, wiper ring, and oil ring. A
compression ring is the piston ring located in the ring
groove closest to the piston head. The compression
ring seals the combustion chamber from any leakage
during the combustion process. When the air-fuel
mixture is ignited, pressure from combustion gases is
applied to the piston head, forcing the piston toward
the crankshaft. The pressurized gases travel through
the gap between the cylinder wall and the piston and
into the piston ring groove. Combustion gas pressure
forces the piston ring against the cylinder wall to form
a seal. Pressure applied to the piston ring is
approximately proportional to the combustion gas
pressure.

3. CONNECTING ROD - The connecting rod is a
major link inside of a combustion engine. It connects the
piston to the crankshaft and is responsible for
transferring power from the piston to the crankshaft and
sending it to the transmission. There are different types
of materials and production methods used in the
creation of connecting rods. The most common types of
connecting rods are steel and aluminum. The most
common type of manufacturing processes are casting,
forging and powdered metallurgy. The connecting rod is
the most common cause of catastrophic engine failure. It
is under an enormous amount of load pressure and is
often the recipient of special care to ensure that it does
not fail prematurely. The sharp edges are sanded smooth
in an attempt to reduce stress risers on the rod. The
connecting rod is also shot-peened, or hardened, to
increase its strength against cracking. In most high-
performance applications, the connecting rod is
balanced to prevent unwanted harmonics from creating
excessive wear.

4. CRANKSHAFT - The crankshaft is the part
of an engine which translates reciprocating
linear piston motion into rotation. To convert
the reciprocating motion into rotation, the
crankshaft has crankpins, additional bearing
surfaces whose axis is offset from that of the
crank, to which the “big ends” of the
connecting rod from each cylinder attach. It
typically connects to a flywheel, to reduce the
pulsation characteristic of the four stroke cycle,
and sometimes a torsional or vibrational
damper at the opposite end, to reduce the
torsion vibrations often caused along the
length of the crankshaft by the cylinders
farthest from the output end acting on the
torsion elasticity of the metal.

USED MATERIALS
The choice of material for any machine part can be said to depend on
the following consideration:
- general function: structural, bearing, sealing, heat-conducting,
space-filling;
- environment: loading, temperature and temperature range,
exposure to corrosive condition or to abrasive, wear
- life expectancy
- space and weight limitations
- cost of the finished part and of its maintenance and replacement
- special considerations, such as appearance, customer prejudices
Material whose essential function is to carry relatively high stresses
will here be classed as structural. The heavily stressed materials
include those that carry and transmit the forces and torques
developed by cylinder pressure and by the inertia of the moving parts
in the power train and valve gear. The success of the structural
materials is measured by their resistance to structural failure. When
choosing the material for the parts of the engine, it will be taken
those materials that have as high as possible resistance to structural
failure due to fatigue.

CONCLUSION
Internal Combustion engine is one of the most important inventions of the last century. It has been
developed in the late 1800s and from there on it has had a significant impact on our society. It has
been and will remain for foreseeable future a vital and active area of engineer research. The aim of this
project is to design a four-cylinder internal combustion engine taking into consideration all necessary
calculations concerning its basic components. In addition the most proper materials which have to be
used have been determined. It has been taken into consideration that the chosen materials must resist
on the maximum forces, moments and stresses that occur when the engine is operating. Another goal
is to make drawings on CATIA that clearly display the engine structure, connection and location of all
parts. And last but not least, to make a simulation and animation of the design engine. The project
begins with short description of the history of engines and how they have developed through the years,
because despite of the fact that everyday new and new engines are invented, the main components
piston, block, crankshaft, valves and connecting rod have remained basically unchanged. Next to that,
the project continues with an explanation of the functions of these parts and the used materials for
their production. The next point of consideration is the different types of engines and what their major
differences are. Next step of the assignment is kinematics of the engine - determination of piston
motion, acceleration and velocity and creating graphs, which show the changes of values depending on
the angle between crank and connecting rod. After that gas and inertia forces acting on the connecting
rod are determined. Another very important step, achieved in the project is determining equilibrium of
the engine. This is essential because if the engine is not in equilibrium condition, it will cause vibration
and noise.

Next step made is the calculation of tensile stress and temperature of the cylinder. Another
thing that is taken into consideration is the forces acting on strength stud bolts. This is
important because strength stud bolts provide density between the cylinder and cylinder head
at all mode of operation. The project continues with 80 calculation of piston group. These
calculations are made very precisely, because the piston is the main reciprocating part of an
engine and its movement creates an imbalance. To transmit the energy of the piston to the
crank, the piston is connected to a connecting rod. Calculation of the connecting rod is of vital
importance as it should be done very precisely because when the engine is running the rod is
under varying in size and direction gas and inertia forces. For this reason it has been made by
stainless steel with high resistance to fatigue. Next step that is taken is calculation of
crankshaft mechanism, considering that it is subject to the action of gas forces, inertia forces
and moments which are periodical functional angle of knee. In designing the crankshaft,
parameters of already existing engines are being used. After making all mentioned calculation
the necessary part dimensions are achieved and the project continues with drawings on
CATIA. First of all, 3D drawings of all calculate parts have been made. In addition 2D drawings
based on 3D are made. After that ready 3D parts are connected in a product. Having a whole
product is just the beginning of the simulation. One of the most difficult things in the project is
to make necessary joints in order to have 0 degree of freedom. Achieving 0 degree of freedom
means that the mechanism can be simulated. Having calculated all forces, moments and
stresses in an allowable range and animation of operating engine, the main design question
have been answered and the objectives of the project achieved.

DRAWINGS
SOLIDWORKS 2016
SOLIDWORKS was developed by MIT graduate Jon Hirschtick and was bought by Dassault Systems in
1997. The software now encompasses a number of programs that can be used for both 2D and 3D
design.
SOLIDWORKS is used to develop mechatronics systems from beginning to end. At the initial stage, the
software is used for planning, visual ideation, modeling, feasibility assessment, prototyping, and project
management. The software is then used for design and building of mechanical, electrical, and software
elements. Finally, the software can be used for management, including device management, analytics,
data automation, and cloud services.
The SOLIDWORKS software solutions are used by mechanical, electrical, and electronics engineers to
form a connected design. The suite of programs is aimed at keeping all engineers in communication and
able to respond to design needs or changes.
SolidWorks is the only solution capable of addressing the complete product development process,
from product concept specifications through product-in-service to a fully integrated and associative
manner.
I have chosen Solidworks to design my final project, because it is used in every corner of the globe and
only by mastering the software will give me the opportunity to succeed, no matter which career path I
would take.

design a four cylinder internal combustion engine

More Related Content

Similar to design a four cylinder internal combustion engine (20)

Recently uploaded (20)

design a four cylinder internal combustion engine