Practical -1

Aim: To study parts of Internal Combustion (IC) Engines.

Apparatus: A working model of Internal Combustion (IC) Engine.

Theory: As a matter of fact, an Internal Combustion (IC) Engine consists of

hundreds of different parts, which are important for its proper working .

Diagram:

Internal Combustion Engines

Fig. 1 parts of IC engine

An IC Engine is a machine that transforms the energy released from the
combustion of fuel into mechanical energy. The combustion of fuel occurs inside
the engine's cylinders, where a mixture of fuel and air is ignited, creating high-
pressure gases that push a piston. The motion of the piston is then converted into
rotary motion by at crankshaft, which can be used to drive a wide range of
machines and vehicles. IC engines come in different types, including reciprocating
engines, such as spark ignition engines and diesel engines, and rotary engines,
such as the wankel engines.

Parts of IC Engines:
1.Cylinder : It is one of the most important part of the engine, in which the
piston moves to and fro in order to develop power. Generally, the engine cylinder
has to withstand a high pressure (more than 50 bar) and temperature (more than
2000 degree Celsius). Thus, the materials for an engine cylinder should be such
that it can retain sufficient strength at such a high pressure and temperature. For
ordinary engines, the cylinder is made of ordinary cast iron. But for heavy duty
engines, it is made of steel alloys or aluminium alloys. In case of multiple cylinder
engines, the cylinders are cast in one block known as cylinder block.
 Fig. 1.1 parts of Cylinder

2. Cylinder Head: It is fitted on one end of the cylinder, and act as a cover to
close the cylinder bore. Generally, the cylinder head contains inlet and exit valves
for admitting fresh charge and exhausting the burnt gases. In petrol engines, the
cylinder head also contains a spark plug for igniting fuel-air mixture, towards the
end of the compression stroke. But in diesel engines, the cylinder head contains
nozzle( i.e. fuel valve) for injecting the fuel into the cylinder .
 Fig. 1.2 Parts of cylinder head

3. Piston: It is considered as the heart of an L.C. engine, whose main function is

to transmit the force exerted by the burning of charge to the connecting rod. The
pistons are generally made of aluminium alloys which are light in weight. They
have good heat conducting property and also greater strength at higher
temperatures.
 Fig. 1.3 parts of piston

4. Piston rings: These are circular rings and made of special steel alloys which
retain elastic properties at higher temperatures. The piston rings are housed in
the circumferential grooves provided on the outer surface of the piston.
Generally, these are two sets to provide air tight seal to prevent leakage of the
burnt gases into the lower portion. Similarly, the function of the lower rings to
provide effective seal to prevent leakage of the oil into the engine cylinder.
 Fig. 1.4 parts of piston rings

5. connecting Rods: It is the link between the piston and crank shaft, whose
main function is to transmit force from the piston to crankshaft. Moreover, it
converts reciprocating motion of the piston into circular motion of the crankshaft,
in the working stroke. The upper end (smaller) of the connecting rod is fitted to
the piston and lower end (bigger) to the crank.
 Fig 1.5 connecting rod

6. Crankshaft: It is considered as the backbone of an I.C. engine whose function

is to convert the reciprocating motion of the piston into rotary motion with the
help of connecting rod. This shaft contains one or more eccentric portions called
cranks. That part of the crank, to which bigger end of the connecting rod is fitted,
is called crank pin.
 Fig. 1.6 parts of crankshaft

7. Crank Case: It is a cast iron case, which holds the cylinder and crankshaft of
an I.C. engine. It also serves as a sump for the lubricating oil. The lower portion of
the crank case is known as bed plate, which is fixed with the help of bolts.

Fig 1.7 Crank case

8. Flywheel: It is a big wheel, mounted on the crank shaft, whose function is to
maintain its speed constant. It is done by storing excess energy during the power
stroke, which is returned during other strokes.

Fig. 1.8 parts of flywheel

9. Spark Plug: The main function of a sparkplug is to conduct the high potential
from the ignition system into the combustion chamber It provides the proper gap
across which spark is produced by applying high voltage, to ignite the mixture in
the ignition chamber.
 Fig. 1.9 parts of spark plug
10. Carburetor: The function of a carburetor is to atomize and meter the liquid
fuel and mix it with the air as it enters the induction system of the engine and
also. maintaining fuel-air proportion under all conditions of operation appropriate
to the conditions.
 Fig. 1.10 Carburetor

11. Governer: A device for regulating automatically output of a machine by

regulating the supply of working fluid. When the speed decreases due to increase
in load the supply valve is opened by mechanism operated by governor and the
engine therefore speeds up again to its original speed. Thus the function of a
governor is to control the fluctuations of engine speed due to changes of load.
Fig. 1.11 Governor
 Materials Lists Of I.C. Engines Parts

Sr. Name of I.C . Name of Materials Manufacturing

No. Engine Parts Process
1. Cylinder Block Cast Iron/Low Casing/Forging
Carbon Steel after heat transfer,
Machining
2. Cylinder Head Aluminium Alloys Casting
3. Piston Aluminium Alloy Casting
4562, due to low
specific gravity
4. Piston Rings Cast Iron of fine Pot Casting
grains and high
elastic material
5. Connecting Rods Low Carbon Steel Forging after heat
transfer
6. Crankshaft Alloy Steel Casting
7. Fly Wheel Cast Iron Casting
8. Carburetor Cast Die Die Casting
9. Piston Pin Plain Carbon Steel Casting
10. Rocker Arm Medium Carbon Forging
Steel
11. Cam Shaft Plain Carbon Steel Grinding, Case
Hardening
12. Crank Case Cast Iron/Cast Sand Casting
Aluminium

Fig. 1.12 material lists

Result: The parts of an Internal combustion Engine has been thoroughly studied.
 Practical -2

Aim: Draw the valve timing diagram of a diesel engine-single cylinder.

Apparatus: A working model of valve timing

Theory: A valve timing diagram is a graphical representation of the exact

moments, in the sequence of operations, at which the two valves (ie, inlet and
exhaust valves) open and close as well as firing of the fuel. It is, generally,
expressed in terms of angular position of the crankshaft

 Theoretical Valve timing diagram for four stroke diesel cycle

engine

Fig 2.1--The theoretical valve timing diagram for a four-stroke cycle engine is
shown in figure T.

In this diagram, the inlet valve opens at A and the takes place from A to B. The
crankshaft revolves through 180 and the piston moves from T.D.C. to B.D.C. At B,
the inlet valve closes and the compression takes place from B to C. the crankshaft
revolves through 180 and the piston moves from B.D.C. to T.D.C. At C, the fuel is
fired and the expansion takes place from C to D. The crankshaft revolves through
180 and the piston again moves from T.D.C. to B.D.C. At D, the exhaust valve
opens and the exhaust takes place from D to E. The crankshaft again revolves
through 180 and the piston moves back to T.D.C.

• Actual Valve timing diagram for four stoke diesel cycle engine

VALVE TIMING DIAGRAM FOR A FOUR-STROKE CYCLE DIESEL ENGINE

Fig 2.2 valve timing diagram

The actual valve timing of a diesel engine four-stroke cycle can vary depending on
the specific engine design and application. However, generally, the valve timing
for a four-stroke diesel engine can be described as follows:

Intake valve timing: The intake valve opens a few degrees before the piston
reaches top dead center (TDC) on the exhaust stroke. This timing allows the
intake air to enter the cylinder while the exhaust gases are still leaving, which
helps to prevent mixing of the two.

Compression valve timing: Once the piston reaches TDC on the exhaust
stroke, the intake valve closes, and the piston begins moving back down the
cylinder. As the piston moves down, it compresses the air that was drawn in
during the intake stroke. The compression stroke lasts until the piston reaches
TDC on the compression stroke.
Power valve timing: As the piston reaches TDC on the compression stroke, the
fuel injector injects fuel into the cylinder, which ignites due to the high pressure
and temperature created by the compression. The expanding gases push the
piston down the cylinder, generating power. The power stroke lasts until the
piston reaches BDC.

Exhaust valve timing: As the piston reaches BDC, the exhaust valve opens,
allowing the exhaust gases to be expelled from the cylinder as the piston moves
back up the cylinder during the exhaust stroke. The exhaust valve timing is usually
set to keep the exhaust valve open for a few degrees after the piston reaches
TDC, which helps to ensure that all of the exhaust gases are expelled from the
cylinder.

Result: The valve timing diagram for four stroke cycle diesel engine have been
thoroughly studied.

Practical -3

Aim: Study the working of a carburetor used in scootor/motor cycle.

Apparatus: A model of carburetor

Theory:

Carburetor:
A carburetor is a mechanical device on an internal combustion engine, for the
purpose of mixing air and gasoline into a combustible fine vapor, in automatically
changing proportions, depending on the operating conditions of the engine.
Construction, Working Principle and Operation of Carburetors
In the part of the carburetor known as the body is located the float bowl or
chamber. This chamber is used for the storage of a certain quantity of gasoline. It
serves two purposes, namely, to keep all the other circuits of the carburetor
supplied with the amount of fuel they need and to absorb the pulsation of the
fuel pump, as it delivers the gasoline to the carburetor. Though its construction is
simple, it plays a very important part in the proper functioning of the engine.

Figure 2.1 Simple carburetor

To provide a means to adjust maximum fuel flow, a needle valve was added to the
orifice in the emulsion tube. A carburetor with this design would function well
under varying loads and speeds. Starting is a different condition; an engine needs
a richer fuel-air mixture. This was accomplished by adding a choke. Closing the
choke increases the pressure difference the fuel bowel and the venturi. Once
engine starts the choke must be opened to prevent the engine from running too
rich. The addition of choke improved enginestarting, but this carburetor still has a
problem if the engine needs to idle. When the throttle is in the idle position,
almost closed, the area with greatest restriction, and greatest pressure difference,
moves from the venturi to the area hetween the throttle plate and the wall of the
tube. This problem was solved with the addition of an idle circuit and idle needle
valve. To have constant fuel flow with constant pressure difference the lift,
distance from the top of the fuel to the top of the main nozzle, must remain
constant. A constant level of fuel is maintained in the fuel bowel by the float, float
needle valve and float needle valve seat.
 Practical -4

Aim: Study of fuel injection pump, injector by dismanting it.

Apparatus: A working model of Fuel Pump and Fuel Injector.

Theory:

*Fuel Pump
Fuel pump is widely used to supply fuel under high pressure in diesel engines. In
this pump, the plunger stroke remains constant but the effective stroke is
reduced by the changing the position of helix on the plunger with respect to the
fuel inlet port.

Fig 4.1 Fuel pump

The fuel pump is shown in the figure. It has a cylindrical plunger which is closely
fitted into the barrel by lapping The plunger has a constant stroke and
reciprocating motion of the Plunger is given by the cam. The vertical hole extends
from the top of the plunger to another helical groove. When the inlet and spill
port or the bypass ports are closed by the upper edge of the plunger during its
ascending motion, the oil above the plunger gets compressed and the delivery
valve gets lifted of its seat due to the high pressure developed. Then the fuel is
forced through the pipe to the injector. The supply of the fuel to the injector is
continued until the helical groove reaches the inlet port. The pump space in this
position of the plunger communicates with the spill port through the spiral slot
and the vertical groove is thus connected to the atmosphere. The pressure on the
spring side is released. The delivery valve falls back to its seat and the supply of
the fuel to the atomizer is stopped. At this time, the fuel barrel escapes from the
spill port or the bypass port. During the downward stroke of the plunger, the
section is seated and fuel is drawn in to the barrel through the supply port. The
quantity of fuel being supplied to the injector depends upon the position of
helical groove. The plunger can be rotated by means of tooth rack. By tuning the
plunger to the right, the effective pumping stroke can be increased i.e. the
instant, at which the space ger to the right, the communication with the spill port
can be delayed and so, more fuel can be supplied to the engine at higher loads.
The rack is operated by governor.

Fig 4.2 fuel pump

Fuel Injector
The fuel from the fuel pump is supplied to the fuel injector. The fuel injector has
to perform the following functions:

a) To atomize the fuel the required degree.

b) To distribute the fuel in such a way that there is complete mixing of fuel andair.

c) It must prevent the injection on the walls of the cylinder and piston top surface.
d) It must start and stop the fuel injection instantaneously.
 Fig 4.3 fuel injector
Fuel Injector is typical spring loaded Bosch fuel injector is shown in figure. The
spring loaded valve is lifted by the high pressure oil supplied by the pump and the
fuel is injected in to the combustion chamber of the engine cylinder. As the
pressure of oil falls, the valve is automatically closed by the spring force. The
amount of fuel injected is regulated by the duration of the open period of the
valve.
 Practical -5
Aim: Draw the layout of the cooling circuit of a multi-cylinder engine to study the
function of each component.

Apparatus: Model diagram of cooling system

Theory: The cooling system in a multi-cylinder engine is responsible for

dissipating the heat generated by the combustion process. It consists of several
components, including a radiator, water pump, thermostat, hoses, and a fan. The
coolant, typically a mixture of water and antifreeze, circulates through the engine
block and cylinder head, absorbing heat and carrying it to the radiator where it is
cooled by air passing through the fins. The water pump circulates the coolant
throughout the system, while the thermostat regulates the temperature by
controlling the flow of coolant. The fan helps to draw air over the radiator to aid
in cooling. The cooling system is critical to the proper functioning of the engine, as
excessive heat can cause damage to internal components and reduce efficiency.

The two main requirements of an efficient cooling system are:

1. It must be capable of removing only about 30% of the heat generated in the
combustion chamber. Too much removal of heat lowers the thermal efficiency of
the engine.

2. It should remove heat at a fast rate when the engine is hot. During the starting
of the engine, the cooling should be very slow so that the different working parts
reach their operating temperatures in a short time.

TYPES OF COOLING SYSTEM

There are two types of cooling systems:

(i) Air cooling system

(ii) Water-cooling system.

1. Air cooling system: Air-cooled engines remove engine heat by using the air
that hits the engine when the bike is moving. This is why they have fins on the
outside to create more surface area for the air to pass over. This cooling method
is very simple, lightweight and requires no special devices. the advantages of the
air-cooled system:

i. The air cooled system has no radiator or pump so the system is light.

ii. In case of water cooling system there are leakages, but in this case, there are
no leakages.

iii. Coolant and antifreeze solutions are not required.

iv. This system can be used in cold climates, where if water is used it may freeze.

Components of Air Cooling System

1. Fins: The fins on the cylinder head and engine block increase the surface
area available for heat transfer. They allow air to flow over them, carrying
away the heat and cooling the engine.

Fig. no. 5.2 Fins

2. Fan: A fan is used to increase the airflow over the fins and improve the
cooling efficiency of the engine.

Fig.no. 5.3 Fans

 3. Water Cooling System: The cooling system is needed to keep the engine
from not getting so hot as to cause problems and yet to permit it to run hot
enough to ensure the maximum efficiency of the engine. Advantages of
water cooling system are:

(a) Uniform cooling of cylinder, cylinder head and valves.

(b) Specific fuel consumption of engine improves by using water cooling

system.

(c) Engine is less noisy as compared with air cooled engines, as it has water
for damping

Fig.no. 5.4 coolings system

Components of Water cooling system
A water cooling system in an engine typically consists of the following
components:

1. Radiator: A heat exchanger that cools the engine coolant as it flows through it.
2. Water Pump: A pump that circulates the coolant through the engine and
radiator.

3. Thermostat: A valve that regulates the flow of coolant to maintain a consistent

engine temperature.
4. Cooling Fan: A fan that draws air through the radiator to help dissipate heat.

5. Coolant Reservoir: A container that holds excess coolant and allows for
expansion and contraction of the coolant as it heats up and cools down.

6. Hoses: Flexible tubes that connect the various components of the cooling
system.