ENGINE CONSTRUCTION

Basic parts of Internal Combustion Engine

a) Cylinder head
top of the engine which contain a hole for valves
valves, intake and exhaust passages, cooling
passages
b) Valves
open and close to let fuel air mixture (petrol
engine) or air only (diesel engine)
exhaust gases out of each cylinder
c) Camshaft
rotates to open and close the valves by cam action
d) Cylinder block
Main housing of the engine and supports other main parts
Contain cylindrical vessels in which combustion takes place
and piston makes a reciprocating motion
e) Cylinders
Hollow tubes, piston moves back and forth
f) Pistons
Move in the cylinders and apply the force of combustion to
crankshaft
g) Piston rings
A component that fitted into the slot around the piston which
seal the combustion chamber and help transfer heat
h) Connecting rods
A rod that interconnect the piston and the crankshaft
and transmit the forces from the piston to crankshaft
i) Crankshaft
Receives the force from pistons and transmit as rotary
driving power
j) Main bearings
Support crankshaft in cylinder block
k) Flywheel
Attach to crankshaft at rear, provides momentum and
help return pistons to the top of cylinders
l) Timing drives
Link the crankshaft, camshaft and other parts
together to assure each is doing its job at the right
time
m) Cams
Integral part of camshaft design to open the valve
at the correct timing and to keep them open for the
necessary duration
n) Gudgeon pin
Forms the link between the small end of the
connecting rod and the piston
Classification of Tractors
According to the Power of Engine (horse power)
Small < 25 hp
Medium 25 50 hp
Large > 50 hp
Comparison Between Petrol and
Diesel Engine
a. Fuel Supply and Ignition
b. Compression Ratio
c. Design of Engine Parts
d. Grade and Type of Fuel Used
a) Fuel Supply and Ignition
Petrol Engine
Fuel and air mixed outside the cylinders in the carburetor and
intakemanifold
Mixture is forced into cylinders by partial vacuum created by
intakestrokeof piston
Useselectricsparktoignitefuel air mixture
Compressionratio8to1(8:1)
Diesel Engine
Nopremixingof air andfuel
Air takenintocylindersthroughintakemanifoldandcompressed
Fuel is sprayed into cylinders and mixed with air as the piston
nearsthetopof itscompressionstroke
Useheat andcompressedair for ignition
Compressionratio16to1(16:1)
b) Compression Ratio
Compression ratio is a characteristic of an engine
i.e. relatedtoengineefficiency i.e. theability of the
engineto convert in thefuel to useful mechanical
energy
The greater the compression ratio, the greater the
potential efficiencyof theengine
Compares volume in cylinder before compression
with volumeafter compression
High compression ratio of diesel cause high
temperatureof air toignitefuel without aspark
Therefore diesel engine more efficient because
higher compression i.e greater expansion of gases
incylinder thereforemorepowerful stroke
c) Design of Engine Parts
Engineofdieselmoresturdierpartsto
withstandgreaterforces
d) Grade and Type of Fuel Used
Diesel fuel -- more heat units (joule) per
gallon
Thereforeproducesmorepower per gallonof
fuel
fuel lowcost but fuel injection equipment is more
expensivethanpetrol equipment
Comparison between Engines
Diesel Petrol
1. Fuel efficiency Best Fair
2. Time before maintenance Good Fair
3. Weight per horse power High Low
4. Cold weather starting Fair Good
5. Acceleration Good Good
6. Continuous Duty Good Fair
7. Lubricating oil contamination Moderate Moderate
DIESEL ENGINE PETROL ENGINE
1. Fuel System
Use diesel
No carburetor
Uses heat & compressed air
for ignition
1. Fuel System
Use petrol
Have carburetor
Uses electric spark to ignite
airfuel mixture
2. Higher compression ratio
14 16 : 1
2.Lower compression ratio
7 10 : 1
3. Operation
No premixing of air and fuel
Air taken into cylinder
through intake manifold and
compressed
Fuel is sprayed into cylinders
and mixed with air as the
piston nears the top of its
compression stroke
3.Operation
Fuel and air mixed outside the
cylinders in the carburetor
and intake manifold
Mixture is forced into
cylinders by partial vacuum
created by intake stroke of
piston
Engine Construction
1. Valves - Intake and Exhaust Valves
The valves allow fuel-air in and exhaust gases out of each
cylinder during combustion cycle by opening and closing the
intakeandexhaust partsof thecylinder.
Intake Stroke
Intake valve opens allowing fuel air mixture to enter
combustionchamber
CompressionandPower Stroke
Bothvalvesareclosedtoseal incombustiblemixture
Exhaust Stroke
Exhaust valveopensallowinggasestobeexhausted
End of Exhaust Stroke
Intake valves opens, beginning another cycle
Functions
2. Camshaft
isturnedbytheenginecrankshaft.
A lobe (cam) on the camshaft causes the cam
follower andpushtherodtopushthevalveopen
Thespring closes thevalvewhen thecamallows
the push rod and camfollower to return to low
sideof thecam
Cammovementsaredesignedtoopenor closethe
valvesat theright moment
3. Engine Crankcase and Cylinder Block
Made of iron casting and is an integral with
cylinder blockwhichhousescylinder liners
Liners are said to be wet or dry according to
whether they are or not in contact with cooling
water that circulatethroughengineblock
Crankcasehousesthecrankgear andvalvegear
4. Engine Block
Houses theinjectionpump, oil pump, water pump
andpower generator
The front part carries the timing cover, rear end
carries clutch bell housing on which the starter
motor ismounted
Provided with oil filler cap and breather, oil
dipstickandwater connectiontotheradiator
5. Cylinder Head
Consists of fuel injectors , inlet and outlet valves, the rockers
Cylinder head is in a single piece for engines up to 4 cylinders
Between cylinder head and engine block cylinder head
gasket; to prevent gas, coolants and lubricating oil from
escaping
Also connected the inlet and exhaust manifolds water pipe from
radiator
6. Oil Sump
Made of iron casting
Seals the crankcase at the bottom
Functions as a reservoir for the lubricating oil
7. Piston, Connecting Rod & Cylinder Liners
Piston
move in the cylinders and apply the force of combustion to
the crankshaft
Combustion chamber machined in upper part known as
piston head or crown ; lower part known as piston skirt
Connecting rods
Transmit the motion of the pistons to the crankshaft
Cylinder Liners
made of cast iron
may be wet or dry; wet liners can be inserted and removed
by hand; dry liner removal and installation with the use of a
press (of a few tons capacity)
8. Crankshaft
Receivetheforcefromthepistonsandtransmitsit asrotarydriving
force
Rear endcarriestheflywheel incorporatingstarter ringgear
Front end carries crankshaft gear used to drive valve timing
mechanism, oil pump
9. Flywheel
Attachestocrankshaft at rear & providesmomentumtohelpreturn
thepistonstothetopof cylindersafter eachdownwardthrust
10. Timing Drives
Link thecrankshaft, camshaft andother parts together sothat each
isdoingitsjobat theright time
What is Internal and External
Combustion Engines
Internal Combustion Engine
Form of heat engine because heat engine produced
by the burning of fuel within the engine is changed
into mechanical energy
External Combustion Engine
Heat energy is supplied from external source in the
form of steam from boiler outside the engine
Adjusting Valve Clearance
Proper valvemaintenanceis necessary so that engine
worksefficientlyandnot bedamaged
When valves are properly adjusted, there is a small
clearancebetweenvalvestemandendof rocker arm
This clearance is referred to as Valve Clearance or
tappet clearance
Valve Clearance
Allows for heat expansion of valve operating
parts
Without clearance, tehe heated parts would
cause the valves to stay partly open during
operation & engine would lose compression &
power
The valve clearance is small, approx: 0.15-0.75
mm. Valve clearance varies with different engine
model; whether the engine should be hot or cold
duringadjustment
Effects of Too Small Valve Clearance
Causedthevalveout of timing
Valvesopentooearly& closetoolate
Valves stems may lengthen fromheating & prevent
valvesfromseatingcompletely.
Hot combustion gases rushing past the valves cause
overheating because the valves seat so poorly that
normal heat transfer into thecoolingsystemdoes not
havetimetotakeplace
ThiscausesBurned Valves
Effect of Too Big Valve Clearance
Causes alag in valvetiming which madetheengine
out of balance
Fuel air mixtureislateinenteringthecylinder during
theintakestroke
Exhaust valve closes early & prevents waste gases
frombeingcompletelyremoved
ThiscausesValve Damaged
Why Proper Valve Adjustment is
Important
Engine will use fuel more efficiently
Engine will start more easily
Maximum power will be achieved
Valves will give longer service
Overheating of engine is less likely to occur
Adjusting Valve Tappet Clearance
Check valve tappet clearance every 500 hours
of operation or at interval indicated in
operators manual
Valve Timing
Opening and closing of both inlet and exhaust
valves when the piston is at the exact top
(TDC) or bottom (BDC) of its stroke
Valve Overlap
Both valves are open at once at the same period
WHAT IS ENGINE
Is a structure that converts chemical energy
(fuel) to mechanical energy.
Usually made available on a rotating output
shaft.
Normal engine that been used on road is
known as Internal Combustion Engine (IC)
Is a reciprocating engines that have pistons
that move back and forth in cylinders within
the engine.
ENGINE CLASSIFICATIONS
1. Types of ignition
a) Spark Ignition (SI)
An engine starts the combustion process in each cycle
by using spark plug.
The spark plug gives high-voltage electrical discharge
between two electrodes which ignites the air-fuel
mixture.
Before spark plug been used torch holes been used
(external flame)
b)Compression ignition (CI)
CI engine starts when the air-fuel mixture self-ignites
due to high temperature in the combustion chamber
due to high compression.
2. Engine cycle
a) Four stroke cycle
A four-stroke cycle experiences four cycle movement
over two engine revolutions for each cycle.
b) Two stroke cycle
A two-stroke cycle has two cycle movement over one
revolution for each cycle.
3. Valve location
a) Valves in head (overhead valve), known as I
head engine.
b) Valves in block (flat head), known as L head
engine.
c) One valve in head (intake) and one in block,
known as F head engine.
4. Basic design
a) Reciprocating
Engine has one or more cylinders in which pistons
move back and forth.
The combustion chamber is located in the closed end of
each cylinder.
b) Rotary
Engine is made of a block built around a large non-
concentric rotor and crankshaft.
Combustion chambers are built into the nonrotating
block.
5. Position and number of cylinders of reciprocating
engines
a) Single cylinder
Engine has one cylinder and piston connected to the
crankshaft.
b) In-line
Cylinders are positioned in a straight line.
One behind the other along the length of the crankshaft.
They can consist of 2 to 11 cylinders or more
Common are four cylinders engine
c) V engine
Two banks of cylinder at an angle with each other along
a single crankshaft.
The angle are 15 to 120, common are 60 to 90
2 to 20 cylinders, normally V6s and V8s
V12s and V16s for luxury and high performances
vehicles.
d) Opposed cylinder engine (crankshaft at
middle)
Two banks of cylinders opposite each other on a single
crankshaft (a V engine with a 180 V).
Used for small aircraft, known as flat engine.
e) W engine
Same as V engine except with three banks of cylinders on the
same crankshaft.
Normally developed for racing automobiles.
f) Opposed piston engine
Two pistons in each cylinder with the combustion chamber in
the center between the piston.
A single-combustion process causes two power strokes at the
same time. Each piston pushed away from the center and
delivering power to a separate crankshaft at each end of the
cylinder.
g) Radial engine
Engine with pistons positioned in a circular plane around the
central crankshaft.
The connecting rods of the pistons are connected to a master
rod which, in turn, is connected to the crankshaft.
ENGINE COMPONENTS
LAB 2
1. Block
2. Camshaft
3. Carburetor
4. Catalytic converter
5. Combustion chamber
6. Connecting rod
7. Crankcase
8. Crankshaft
9. cylinders
10. exhaust manifold
11. exhaust system
12. fan
13. flywheel
14. fuel injector
15. Fuel pump
16. Glow plug
17. Cylinder head
18. Head gasket
19. Intake manifold
20. Main bearing
21. Oil pump
22. Piston
23. Piston rings
24. Push rods
25. Radiator
26. Spark plug
27. Speed control-cruise control
28. Starter motor
29. Throttle
30. turbocharger
31. Water jacket
32. Water pump
BASIC ENGINE CYCLES
A) Four Stroke SI Engine Cycle
B) Two Stroke SI Engine Cycle
Four Stroke SI Engine Cycle
Intake Stroke
Intake valve opens,
admitting fuel and air.
Exhaust valve closed
for most of stroke
Compression Stroke
Both valves closed,
Fuel/air mixture is
compressed by rising
piston. Spark ignites
mixture near end of
stroke.
Intake
Manifold
Spark
Plug
Cylinder
Piston
Connecting
Rod
Crank
Power Stroke
Fuel-air mixture burns,
increasing temperature
and pressure, expansion
of combustion gases
drives piston down. Both
valves closed - exhaust
valve opens near end
of stroke
1
2
3
4
Exhaust Stroke
Exhaust valve open,
exhaust products are
displaced from cylinder.
Intake valve opens
near end of stroke.
Crankcase
Exhaust
Manifold
Exhaust Valve
Intake Valve
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