Lab session No.

3:-

Study of Components, Systems & working of Diesel Engine Model

Preliminaries:A diesel engine or a compression ignition engine is an internal
combustion engine that uses the heat of compression to initiate ignition and burn the fuel
that has been injected into the combustion chamber.

Working:In compression-ignition engines, air alone is inducted into the cylinder. The fuel
is injected directly into the engine cylinder just before the combustion process is required
to start. Load control is achieved by varying the amount of fuel injected each cycle, the air
flow at a given engine speed is essentially unchanged. The liquid fuel, usually injected at
high velocity as one or more jets through small orifices or nozzles in the injector tip,
atomizes into small drops and penetrates into the combustion chamber. The fuel vaporizes
and mixes with the high-temperature high-pressure cylinder air. Since the air temperature
and pressure are above the fuel's ignition point, spontaneous ignition of portions of the
already-mixed fuel and air occurs after a delay period of a few crank angle degrees. The
cylinder pressure increases as combustion of the fuel-air mixture occurs. The compression
ratio of diesels is much higher than typical SI engine values, and is in the range 12 to 24,
depending on the type of diesel engine and whether the engine is naturally aspirated or
turbocharged. The valve timings used are similar to those of SI engines. Processes involve
in the operation of 4-Stroke Diesel Engine are:

1. Induction stroke: With the inlet valve open and the exhaust valve closed, the
piston moves away from the cylinder head. The outward movement of the piston will
establish a depression in the cylinder, its magnitude depending on the ratio of the crosssectional areas of the cylinder and the inlet port and on the speed at which the piston is
moving. The pressure difference established between the inside and outside of the cylinder
will induce air at atmospheric pressure to enter and fill up the cylinder. A maximum
depression of maybe 0.15 bar below atmospheric pressure will occur at about one-third of
the distance along the piston's outward stroke, while the overall average pressure in the
cylinder might be 0.1 bar or even less.
2. Compression stroke: With both the inlet and the exhaust valves closed, the piston
moves towards the cylinder head. During the compression stroke, the air charge initially at
atmospheric pressure and temperature is reduced in volume until the cylinder pressure is
raised to between 30 and 50 bar. This compression of the air generates heat which will
increase the charge temperature to at least 600 C under normal running conditions.
3. Power stroke: With both the inlet and the exhaust valves closed and the piston
almost at the end of the compression stroke, diesel fuel oil is injected into the dense and
heated air as a high-pressure spray of fine particles. Provided that they are properly
atomized and distributed throughout the air charge, the heat of compression will then
quickly vaporize and ignite the tiny droplets of liquid fuel. Within a very short time, the
piston will have reached its innermost position and extensive burning then releases heat
energy which is rapidly converted into pressure energy. Piston gets pushed away from the
TDC & power is transmitted through connecting rod to the crankshaft which in turn
develops the rotation energy.
4. Exhaust stroke: When the burning of the charge is near completion and the piston
has reached the outermost position, the exhaust valve is opened. The piston then reverses
its direction of motion and moves towards the cylinder head. The sudden opening of the
exhaust valve towards the end of the power stroke will release the still burning products of
combustion to the atmosphere. The pressure energy of the gases at this point will
accelerate their expulsion from the cylinder.

Components of Diesel Model:Following are the components of Diesel engine model:

1.

Block: Body of engine containing the cylinders, made of cast iron or aluminum.

2.

Overhead Camshaft: Rotating shaft

used to push open valves at the proper
time in the engine cycle, either directly
or through mechanical or hydraulic.

3.

Combustion chamber: The end of the cylinder between the head and the piston face
where combustion occurs. The size of the combustion chamber continuously changes
from a minimum volume when the piston is at TDC to a
maximum when the piston is at BDC.

4.

Connecting rod: Rod connecting the piston with the

rotating crankshaft, usually made of steel or alloy forging
in most engines but may be aluminum in some small
engines.

5.

Connecting rod bearing: Bearing where connecting rod

fastens to crankshaft.

6.

Cooling Fan: It is a on the outside surfaces of cylinders and

head of Diesel engine model. It cools the cylinders by
conduction and convection.

7.

Crankcase: Part of the engine block surrounding the

rotating crankshaft. In many engines, the oil pan makes up
part of the crankcase housing.

8.

Crankshaft: Rotating shaft through which engine work

output is supplied to external systems. The crankshaft is
connected to the engine block with the main bearings. It is
rotated by the reciprocating pistons through connecting rods connected to the
crankshaft.

9.

Cylinders: The circular cylinders in the engine

block in which the pistons reciprocate back and
forth.

10. Exhaust manifold: Piping system which carries

exhaust gases away from the engine cylinders,
usually made of cast iron.
11. Exhaust system: Flow system for removing
exhaust gases from the cylinders.

12. Flywheel: Rotating mass with a large moment of inertia connected to the crankshaft of
the engine. The purpose of the flywheel is to store energy and furnish a large angular
momentum.
13. Fuel injector: A pressurized nozzle that sprays fuel
into the cylinder of model.

14. Fuel pump: Mechanically driven pump to supply fuel

from the fuel tank (reservoir) to the engine. It takes
power from the crankshaft through the belt drives.

15. Glow plug: Small electrical resistance heater

mounted inside the combustion chamber of diesel
engine model, used to preheat the chamber enough so
that combustion will occur when first starting a cold
engine.

16. Head: The piece which closes the end of the cylinders,
usually containing part of the clearance volume of the
combustion chamber. The head is usually cast iron or
aluminum, and bolts to the engine block.

17. Head Gasket: Gasket which serves as a sealant

between the engine block and head where they bolt
together.

18. Intake Manifold: Piping system which delivers

incoming air to the cylinders usually made of cast
metal.

19. Pulleys & Belt drives: They are used to transmit

power to camshaft, fuel pump, water pump & oil
pump.

20. Main Bearing: The bearings connected to the engine

block in which the crankshaft rotates.

21. Oil Pan: Oil reservoir usually bolted to the bottom of

the engine block, making up part of the crankcase. Acts
as the oil sump for the engine.

22. Oil Pump: Rotary Pump used to distribute oil from

the oil sump to required lubrication points. It is driven
by the crankshaft through belt drives.

23. Piston: The cylindrical-shaped mass that reciprocates

back and forth in the cylinder, transmitting the
pressure forces in the combustion chamber to the
rotating crankshaft.
24. Piston Rings: Metal rings that fit into circumferential
grooves around the piston and form a sliding surface
against the cylinder walls.

25. Wrist Pin: Pin fastening the connecting rod to the piston (also called the gudgeon pin).

26. Radiator: Liquid-to-air heat exchanger of honeycomb construction used to remove

heat from the engine coolant after the engine has been cooled. An engine-driven fan is
used to increase air flow through the radiator.

27. Starter: An electrical motor used to crank the engine in the start. Electrical power is
provided by the battery.

28. Turbocharger: Turbine-compressor is used to

compress incoming air into the engine. The
turbine is powered by the exhaust flow of the
engine and thus takes very little useful work
from the engine.
29. Valves: Used to allow flow into and out of the
cylinder at the proper time in the cycle.

30. Water jacket: System of liquid flow passages

surrounding the cylinders, usually constructed as part of the engine block and head.

31. Water Pump: Pump used to circulate engine coolant through the engine and radiator.
It is mechanically run off of the engine.

32. Air Filter: It cleans the incoming air by restricting the

particles present in air.

33. Injection Lines: They are used to transport the fuel to the
fuel injectors.

Systems of Diesel engine Model

Indirect injection (IDI) system:Indirect injection systems have a divided
combustion chamber, with some form of pre-chamber in which the fuel is injected, and a
main chamber with the piston and valves.
The purpose of a divided combustion
chamber is to speed up the combustion
process, in order to increase the engine
output by increasing engine speed. There
are two principal classes of this
combustion
system;
pre-combustion
chamber and swirl chamber. Precombustion chambers rely on turbulence
to increase combustion speed and swirl
chambers rely on an ordered air motion to
raise combustion speed. Combustion
chamber use heat-resistant inserts with a
low thermal conductivity. The insert is
quickly heated up by the combustion
process, and then helps to reduce ignition
delay. These combustion chambers are
much less demanding on the fuel injection equipment. The fuel is injected and impinges on
the combustion chamber insert, the jet breaks up and the fuel evaporates. During initial
combustion the burning air/fuel mixture is ejected into the main chamber, so generating a
lot of turbulence. This ensures rapid combustion in the main chamber without having to
provide an ordered air motion during the induction stroke. Since these systems are very
effective at mixing air and fuel, a large fraction of the air can be utilized, so giving a high
bmep with low emissions of smoke.
Glow Plugs: A glow plug is a heating device used to aid
starting diesel engines. In cold weather, high speed diesel
engines can be difficult to start because the mass of the
cylinder block and cylinder head absorb the heat of
compression, preventing ignition due to the higher
surface-to-volume ratio. Pre-chambered engines make use
of small electric heaters inside the pre-chambers called
glow plug. The glow plug is a pencil-shaped piece of metal with a heating element at the tip.
This heating element, when electrified, heats due to its electrical resistance and begins to
emit light in the visible spectrum, hence the term glow plug.

Fuel Injectors: The most important part of the fuel injector is the nozzle. All nozzles have
a needle that closes under a spring load when they are not spraying. Open nozzles are used
much less than closed nozzles since, although they are less prone to blockage, they dribble.
When an injector dribbles, combustion deposits build up on the injector, and the engine
exhaust is likely to become smoky. In closed nozzles the needle-opening and needle-closing
pressures are determined by the spring load and the projected area of the needle. The
pressure to open the needle is greater than that required to maintain it open, since in the
closed position the projected area of the needle is reduced by the seat contact area. The
differential pressures are controlled by the relative needle diameter and seat diameter. A
high needle-closing pressure is desirable since it maintains a high seat pressure, so giving a
better seal. This is also desirable, since it keeps the nozzle holes free from blockages caused
by decomposition of leaked fuel.

Fuel Pump
Strainer

Fuel Tank

Fuel
Injector

Air Intake System:It consists of fresh air induction system into the cylinders. It
includes Turbo-Charger, Air Filter, Intake manifold & intake valves. Because a diesel engine
requires close tolerances to achieve its compression ratio, and because most diesel engines
are either turbo charged or supercharged, the air entering the engine must be clean, free of
debris, and as cool as possible.
Turbo-charger: A turbocharger is a turbine driven forced induction device that makes an
engine more efficient and produce more power for its size by forcing extra air into the
combustion chamber. A turbocharged engine is more powerful and efficient than a
naturally aspirated engine because the turbine forces more air, and proportionately more
fuel, into the combustion chamber than atmospheric pressure alone. The key difference
between a turbocharger and a conventional supercharger is that the latter is mechanically
driven from the engine, often from a belt connected to the crankshaft, whereas a
turbocharger is powered by a turbine that is driven by the engine's exhaust gas. Compared
to a mechanically-driven supercharger, turbochargers tend to be more efficient but less
responsive.

Cooling System:Diesel
engine model has a liquid
cooling system. The cooling
system consists of the engine's
water jacket, a thermostat, a
water pump, a radiator and
radiator cap, a cooling fan
(belt-driven), hoses, the heater
core, and usually an expansion
(overflow) tank.
Coolant Jackets: The water
jacket is a collection of
passages within the block and
head. These passages let the
coolant circulate around the
"hot spots" (valve seats and
guides, cylinder walls, combustion chamber, etc.) in order to cool them off. Liquid cooled
engines have passages for the liquid, or coolant, through the cylinder block and head. The
coolant has to have indirect contact with such engine parts as the combustion chamber, the
cylinder walls, and the valve seats and guides. Running through the passages in the engine
heats the coolant (it absorbs the heat from the engine parts), and going through the
radiator cools it. After getting "cool" again in the radiator, the coolant comes back through
the engine. This business continues as long as the engine is running, with the coolant
absorbing and removing the engine's heat, and the radiator cooling the coolant.
Thermostat*: The thermostat provides control for your engine's warm-up period.
Expansion Tank*: Cooling systems make use of a clear plastic container, which is
connected to the overflow tube from the radiator. This container provides extra storage
space for the coolant when it expands and is called the expansion, or overflow tank. It is
also known as the coolant reservoir, or overflow canister.
Radiator cap*: The radiator cap acts as more than just a "lid" for your radiator; it keeps
engine cool by sealing and pressurizing the coolant inside it.
Belt powered Cooling Fan: The reason the coolant goes into the radiator is to allow air to
pass through it and cool the coolant. This is done by an external forcing medium i.e. Fan.

Radiator Shroud*: The radiator shroud prevents the recirculation of air around the fan. It
is usually a plastic hood that encloses the fan to guide the air through the core, and stop it
from coming back around and through the fan again. It also protects you from the fan
blades.

Lubrication System:When two solid surfaces are in contact in an engine, they will
touch each other at the roughness high spots of the surfaces. The smoother the surfaces are
machined (on a macroscopic level), the lower will be the surface high points (microscopic)
and the less will be the average distance separating them. If one surface is moved relative
to the other, the high points will come into contact and will resist motion (friction). Points
of contact will become hot, sometimes to the point of trying to weld together. To greatly
reduce resistance of surface-to-surface motion, lubricating oil is added to the space
between the surfaces. Lubricating oil adheres to the solid surfaces, and when one surface
moves relative to the other, oil is dragged along with the surface. The oil holds the surfaces
apart and one surface hydraulically floats on the other surface. The only resistance to
relative motion is the shearing of fluid layers between the surfaces, which is orders of
magnitude less than that of dry surface motion. Three important characteristics are needed
in a lubricating fluid:
It must adhere to the solid surfaces.
2. It must resist being squeezed out from between the surfaces, even under the
extreme forces experienced in an engine between some components.
3. It should not require excessive force to shear adjacent liquid layers. The property
that determines this is called viscosity

Oil Pump

Oil sump
&
Strainer

Oil Filter

Lubrication
*Not included in Model