I.C Engines Part-2

PISTON SCUFFING
Metal-metal contact after spoiling of oil filmdue to excessive expansion welded like structures formed due to overheating.
REASONS
Less lubrication of walls
Overloading the engine---driving habits
Knocking
Insufficient cooling system
Leakage of water in the cylinderwashing of oil film.
Copyright 2017, Dept. of Aeronautical & Automobile

6-Sep-17 1
Engineering, MIT, Manipal University
PISTON RINGS
Functions
Seals H P gases blow-by is minimized
Heat flow-crown-rings-walls-cooling systems
Maintains oil film thickness----
Too thinruptures---scuffing
Too thick----viscous friction pumping losses more- less mech efficiency
COMPRESSION RINGS-2-3
OIL CONTROL/ scraper RINGS-1
Centrifugally casted

6-Sep-17 2
Materials
FINE GRAINED GREY C I+ Si+ Mn, good heat and wear resistant
Cr PLATED top rings high T & corrosive actionlonger cyl. LifeCr is hardmay wear the cyl rapidly. very fine finish given.
Phosphate coated by a bath of phosphoric acidoffers a porous surfaceoil reservoir==friction between rings and wall is reduced.
MOLYBDENUM FILLED FACE- better oil holding capacitylonger engine life.higher M P(26200c) of MOLY-m allows the
ring to stand High Temperature.
ALLOY STEEL, STAINLESS STEEL-oil ringsanti corrosive, remain clean, do not clog with C

6-Sep-17 3
CENTRIFUGAL CASTING PROCESS
Centrifugal casting --in which the centrifugal force set up by the rotation of a part of the
casting installation is utilized to-
shape the casting,
Fill the mould, and help solidify and strengthen the metal.
It produces---
good filling of the mould,
high dimensional accuracy, and
a high strength dense structure of the casting metal.
This method is used for casting of components that are too difficult to produce
satisfactorily by static casting methods because their sections are too thin
e.g., gears, piston rings, impellers, propellers, bushings and railway wheels.

6-Sep-17 4
Piston ring manufacture
An advantage of the centrifugal process is that it produces a sound and more uniform casting
than static means.
The mould is usually made of ------------- steel or cast iron.

6-Sep-17 5
End gap
0.25-0.35 mm desirable.
Easy fit on to grooves
Circumferential expansion is accommodated.
Excessive gapblow by loses,

Less gap high T, scuffing

6-Sep-17 6
Shapes of end gaps
BUTT TYPE- Most commonly used,cheaper
TAPER TYPE-effective in preventing leakages, costly, for low speed, high C R engines,
gases have more time to leak.
SEAL CUT TYPE.- low speed diesel engines.

6-Sep-17 7
Compression sealing-due to high P, ring is hard pressed on the base of the ring groove.
some leakage past the Iast ring is needed, provides P for the sealing action of second piston ring.

6-Sep-17 8
Oil ring
Function of oil rings
:- to maintain oil film
:- provide lubricant to cylinder walls
:- clean the cylinder wall

6-Sep-17 9
PISTON PIN/GUDGEON PIN
Connects piston connecting rod
Solidsmall engines;
Tubularlight, rigid
Low C, case hardened steel0.15% C, 0.3% Si, 0.5% Mn, rest iron
0.1m run out permitted. check with dial gauge and V-blocks

6-Sep-17 10
6-Sep-17 11
1> by SET SCREWS t/h piston bossessemi floatingC R small end can float in bearing. Pin
is rigid with piston.
2> PIN-C R BOLTED=pin slotted C R split eyes at small end-pin can float in bosses

6-Sep-17 12
3>FULLY FLOATING PIN most common typecirclips/end pads(Al,Br) used to prevent end
movementspin floating in the bosses & small end -- seizure is mostly prevented

6-Sep-17 13
Piston Assembly
Piston: aluminum, cast steel or cast iron
Wrist pin: machined steel
Connecting rod: forged-steel or cast iron

6-Sep-17 14
CRANK SHAFT
O/P SHAFT. receives power from connecting rods in the designated sequence and transmits to clutch.
MAIN JOURNALS supported in main bearings in crank caseforms axis of rotation of crank shaft based on number of cylinders.
CRANK PINS: room for big end of con. Rodsupported in shell/split bearings; crank throw-distance b/w pin axis and journal axis-decides
torque.
OIL HOLES: main journal-web-pin-big end of con rod
WEB: links pins and journal

6-Sep-17 15
CRANKSHAFT
steel forged;
However, crankshafts with relatively low

stresses -- cast iron may be substituted ----
reduced cost.

6-Sep-17 16
6-Sep-17 17
6-Sep-17 18
Crank shaft-making
INTERGAL-----UNIVERSALLY USED- rigid- multi-cylinder engines
BUILT-UP- small enginespin & journal are bolted to crank arms which act as flywheels.
FORGING drop forgingheat treated to relieve residual stresses
turning-grinding
SAE 1045 & 3140, STEELS

6-Sep-17 19
CASTING: spheroidal graphite iron---SHELL MOULDING PROCESS. Shell Like Mould Is Made
From the sand and synthetic resin.
this mould is then used for casting small/medium parts
high accuracyless machining reqduniform and random structure throughout-less
densecheaper.[+/-]

6-Sep-17 20
TREATMENTS GIVEN
The case-hardening, is the process of carburising the surface layer of a suitable low
carbon steel to obtain a high carbon case.
The carburising or carbon supplying agent may be solid, liquid, or gaseous.
Subsequent quenching and heat treatment is applied with the object of producing a high
degree of hardness in the case while maintaining strength and toughness in the core.
The time required ranges from a minimum of about a quarter of an hour in the cyanide bath
to several hours in box hardening with solid carburising agents.

6-Sep-17 21
Nitriding
A process in that the chemical composition of the surface layer is altered, ------- by the
production of very hard nitrides of iron and certain alloying metals,
The nitriding agent is ammonia gas, which decomposes into hydrogen and nitrogen at the
furnace temperature of about 500C.
The great advantage compared with carburising is the -----
exceptional degree of hardness obtainable and
the relatively low temperature necessary,

6-Sep-17 22
MAIN BEARINGS
Supports journals of crank shaft.
Number is one more/less than the number of cylinders
2 types1)PRECISION INSERT TYPE
2) CAST TYPE---

6-Sep-17 23
6-Sep-17 24
Classification of main bearings
STANDARD DUTY
Babbit lining with steel/bronze back.
Babbit metals (white metals)antimony+tin/ antimony+lead alloys---
good embeddability, corrosion resistance, ---- low fatigue strength.
MEDIUM DUTY-
Cu alloy lining with steel backgood fatigue strength(+)---low corrosion resistance(-), embeddability(-)
HEAVY DUTY
Tin flash coating-babbit over plate, brass barrier plate, Cu-alloy lining, steel back
EXTRA HEAVY DUTY

tin flash platebabbit over plate, Al-alloy lining( 11% Si, 1% Cu, remaining Al),-steel back---(+) no corrosion.

6-Sep-17 25
CONNECTING ROD
To convert reciprocating motion of the piston into rotary motion of crank shaft.
Small end , big end, shank-I sectionto reduce wtmax rigidity
Axial ( tensile/compressive) stresses due to gas pre.

And inertia forces due to reciprocating masses and
bending stresses due to centrifugal effects act on con rod
To be tested for bending and twisting
Small endsolid/split eye(secured with a bolt)

Big end-split
Passage from big end-small end---for lubrication.
1)Drop forgedsteel, compact, strong(+)

2)casted---spheroidal graphite cast iron, lighter, cheaper(+), less strength(-)

6-Sep-17 26
Nomenclature of Con Rods
Shank
Bush
Bolt and nut
Small end Bearing (Babbitt) Big end
Oil hole
Sectional view
6-Sep-17 27
Different cross sections
I - Section
Round and Tubular Sections
I & H Sections
6-Sep-17 28
Forced Lubrication of con rods

6-Sep-17 29
Splash Lubrication of con rods

6-Sep-17 30
Manufacture of connecting rods
Manufactured by forging process
Surfaces are finished by broaching
Milling of both end bosses
Grinding on both faces
Drilling of pin hole
Both ends are bored
Bolt holes are drilled and reamed
Cap is split off by milling
Drilling of oil hole

6-Sep-17 31
VALVES
INLET VALVEto admit A/F
EXHAUST VALVE---to let out gases
TYPES- 1] POPPET VALVES
2] SLEEVE
3] ROTARY

6-Sep-17 32
POPPET VALVES
simple in construction
self centering
free to rotate
sealing eff high
Inlet valves larger than exhaust valve

6-Sep-17 33
valves
INLET VALVE:
larger, as speed of A/F mix is less, to improve vol effi.face angle-30/450
EXHAUST VALVE-
smaller== 0.38Dto reduce hot surface, gases leave under Higher pressure.
stem dia is 10-15% greaterto improve HT of head., strength and hardness to resist tensile fore and wear(properties
desirable)

6-Sep-17 34
MATERIALS
properties
fatigue strength,
corrosion resistance,
resistance to oxidation due to HT,
small coeff of thermal expansion,
high thermal conductivity
SILICO-CHROME STEEL
0.4% C,0.5% Ni, 0.5% Mn, 3.5% Si,8% Cr,+Molybdenum
AUSTINITIC STEEL (EV)
0.25% C, 1.5% Mn, 1% Si, 12% Ni, 21 %Cr

6-Sep-17 35
Valves
Intake valve: a chromium-nickel alloy
Exhaust valve: a silicon-chrome alloy since

it operates at higher temperatures (about
1200oF)

6-Sep-17 36
For heavy duty applications
E V may be made in 2 pieces and welded together---
valve HEADShigh strength, corrosion resistant, --welded to wear resistant alloy STEM
AL- coated to make anti corrosivestems, Cr-plated to make wear resistant.
Na-cooled valves
Na-high conductive metalmelts above 1050cfilled upto 40% volume in hollow stems
when valve goes up, absorbs heat and when back gives it to stem>valve guide>cyl
head- >-coolant

6-Sep-17 37
Heat flow paths

6-Sep-17 38
Production
Drop forging
Extruding
Electric gathering
For heavy duty, exhaust valves are made in two parts weld together
Valve head special, high strength, corrosion resistance alloy
Valve stem wear resistant alloy
Copyright 2014,
2017, Dept. of Aeronautical & Automobile
6-Sep-17 39
SLEEVE VALVES
Cylindrical in shape
Types single and double sleeve
Simple in design
Silent operation
Long life
Reduce the tendency of detonation less hot spot
o High oil consumption to lubricate sleeve
o Gumming formation of semi solid oil

6-Sep-17 40
ROTARY VALVES
operated with rotary disc with port
Drive given from crank
Uniform motion
Noise-free motion
o Poor pressure sealing
o Lubrication

6-Sep-17 41
VALVE ACTUATING MECHANISMS
Over head valve mechanism - : Side camshaft
: Over head camshaft
Side valve mechanism
Over head inlet and side exhaust valve mechanism

6-Sep-17 42
VALVE ACTUATING MECHANISMS
OVER HEAD VALVE MECHANISM (side camshaft)
Parts:
Cam-follower(tappet) :- b/w stem and cam
- slightly eccentric wrt cam- rotates- even wear
- clearance must be given b/w cam and tappet
- adjusting screws to adjust the length
push rod :- transmits the lift force to rocker arm
- made of steel
- either solid or hollow
rocker arm :- reverse the upward motion of push rod to downward

motion of valve and vice versa.
- either solid or hollow
- made of steel (forged / stamped) or iron (cast)

6-Sep-17 43
6-Sep-17 44
6-Sep-17 45
Features
Higher vol effi, (I head & V head)
higher COMP. RATIO,
smaller cam lobes be used due to ROCKER ARM leverage.
Noisy lower mech effi

6-Sep-17 46
OVER HEAD CAMSHAFTS
INVERTED BUCKET FOLLOWER -cam shaft is directly over the valve stem
direct and rigid valve movement, follows precisely the designed cam profile lift
valve stem are not subjected to side thrustless wear
tappet clearance is small
freq adjustment is not necessary(+)
Large cam size---(-)

6-Sep-17 47
Poppet Valve Actuation with Overhead Camshaft
Camshaft
Spring
Spark
plug Guide
Stem
Air manifold
Valve head
Valve seat
Piston

6-Sep-17 48
6-Sep-17 49

I.C Engines Part-2

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

I.C Engines Part-2

Uploaded by

Copyright:

Available Formats

PISTON SCUFFING

Less lubrication of walls

Overloading the engine---driving habits

Insufficient cooling system

Leakage of water in the cylinderwashing of oil film.

Copyright 2017, Dept. of Aeronautical & Automobile

Seals H P gases blow-by is minimized

Heat flow-crown-rings-walls-cooling systems

Maintains oil film thickness----

Too thick----viscous friction pumping losses more- less mech efficiency

OIL CONTROL/ scraper RINGS-1

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Easy fit on to grooves

Circumferential expansion is accommodated.

Excessive gapblow by loses,

Copyright 2017, Dept. of Aeronautical & Automobile

SEAL CUT TYPE.- low speed diesel engines.

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Function of oil rings

:- to maintain oil film

:- provide lubricant to cylinder walls

:- clean the cylinder wall

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Piston: aluminum, cast steel or cast iron

Wrist pin: machined steel

Connecting rod: forged-steel or cast iron

Copyright 2017, Dept. of Aeronautical & Automobile

OIL HOLES: main journal-web-pin-big end of con rod

WEB: links pins and journal

Copyright 2017, Dept. of Aeronautical & Automobile

However, crankshafts with relatively low

Copyright 2017, Dept. of Aeronautical & Automobile

FORGING drop forgingheat treated to relieve residual stresses

SAE 1045 & 3140, STEELS

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

The carburising or carbon supplying agent may be solid, liquid, or gaseous.

Copyright 2017, Dept. of Aeronautical & Automobile

The great advantage compared with carburising is the -----

exceptional degree of hardness obtainable and

the relatively low temperature necessary,

Copyright 2017, Dept. of Aeronautical & Automobile

Number is one more/less than the number of cylinders

2 types1)PRECISION INSERT TYPE

Copyright 2017, Dept. of Aeronautical & Automobile

EXTRA HEAVY DUTY

Copyright 2017, Dept. of Aeronautical & Automobile

Axial ( tensile/compressive) stresses due to gas pre.

Small endsolid/split eye(secured with a bolt)

1)Drop forgedsteel, compact, strong(+)

Copyright 2017, Dept. of Aeronautical & Automobile

Small end Bearing (Babbitt) Big end

Round and Tubular Sections

Copyright 2017, Dept. of Aeronautical & Automobile

Copyright 2017, Dept. of Aeronautical & Automobile

Manufactured by forging process