THEORY AND DESIGN OF

AUTOMOTIVE ENGINES

Prof. B Dinesh Prabhu

PESCE

Mandya

Syllabus
I - Introduction
1. General - History, Types of Power Plant,
Principle of operation & Classification of
Engines
2. Two Stroke & Four Stroke Engines;
Principles of Engine Operation (SI & CI),
Scavenging - Systems, Theoretical
Processes, Valve/ Port Timing,
Merits & Demerits,scavenging pumps
Prof. B Dinesh Prabhu

PESCE

Mandya

Syllabus
II - Engine Components
Classification/Types,
Function,
Materials,
Constructional Details,
Design and
Manufacturing Processes
of The Engine Components
Prof. B Dinesh Prabhu

PESCE

Mandya

Syllabus
3. Cylinder Head, Cylinders & Liners
4. Piston, Rings & Pin
5. Connecting Rod
6. Crank Shaft
7. Flywheel, Camshaft
8. Valve & Valve Mechanism
9. Crank case
10. Manifolds
Prof. B Dinesh Prabhu

PESCE

Mandya

Chapter 1
General
Historical development of automobiles
Types Of Power Plant
Principle of Engine Operation
Classification Of Engines

Prof. B Dinesh Prabhu

PESCE

Mandya

Prof. B Dinesh Prabhu

PESCE

Mandya

Prof. B Dinesh Prabhu

PESCE

Mandya

History is very valuable,

because it is the combination of
the hard work & sacrifices that brilliant
people made to forge the
world that we live in.
- Anonymous

Prof. B Dinesh Prabhu

PESCE

Mandya

History
Automobiles Through the Years
Since originated on late 1800s,
Changed and Developed in response to
-Consumer Wishes,
-Economic Conditions, and
-Advancing Technology
Current designs continue to reflect economic
awareness, although many different markets
exists
Prof. B Dinesh Prabhu

PESCE

Mandya

History
4,000 Years ago
Used for Transportation in India
15th Century
Portuguese & Chinese Created Wheel
that Turned Under its Own Power
1600
Small Steam-Powered Engine Models
developed
Prof. B Dinesh Prabhu

PESCE

Mandya

Cugnot Steam Tractor

1769-First Automobile-By Nicolas Cugnot
Three-wheeled steam-powered vehicle
Speed 3.2 km/h (2mph)
Had to stop every 20min
to build up fresh head of steam

Prof. B Dinesh Prabhu

PESCE

Mandya

Few Records
1801

Heavy steam automobiles introduced in

England
1802
Steam powered coach journeyed 160km
(100mi)
Mid 1800-England-extensive network of steam
coach lines
1830
Steam carriages used for first omni bus
service in London
1906
Stanley steamer established world land
speed record 205.44km/h(121.573mph)
Prof. B Dinesh Prabhu

PESCE

Mandya

Internal - Combustion Engine

1860 One-cylinder engine, kerosene- fuel.
1864 Two-cylinder gasoline engine
1876 Otto built four-stroke gas engine
2-stroke engines accomplish the same steps, but
less efficiently & with more exhaust emissions.
1885 Gasoline-powered engine mounted
onto bicycle-motorcycle &
1887 First car- included steering tiller & 4speed gearbox - Daimler & Maybach
Prof. B Dinesh Prabhu

PESCE

Mandya

 In 1885 German engineer Gottlieb Daimler mounted an engine

of his own design into a wood-framed vehicle.
The vehicle had 4 wheels, including 2 round stabilizing wheels.
Worlds first
motorcycle.

Prof. B Dinesh Prabhu

PESCE

Mandya

Early Car
1885 First practical car (gasoline car)
By Karl Benz
Incorporating differential drive & other
components

Prof. B Dinesh Prabhu

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 1891

Design Improvements

Peugeot automobile paced 1,046-km

(650-mi)
1894 Instead of installing engine under
seats, front-mounted engine under hood
along with clutch, gears, & separate
construction of the chassis designed
1899 Fiat in Italy began building cars

Prof. B Dinesh Prabhu

PESCE

Mandya

Horseless Carriage

1893
-By Duryea brothers -Original Horseless Carriage - -Americas First Internal Combustion Motor Car

-Henry Ford built IC Engine

1896- Henry Ford used
engine power on bicycle
steered by tiller

Prof. B Dinesh Prabhu

PESCE

Mandya

Early Electric Cars

1800s Electric engines (quiet, slow speed
& not scaring to horse & people),
enjoyed great popularity
1899 Electric car designed & driven to set
a record of 105.8810 km/h
(65.79 mph)
Most electric cars-top speed 48km/h
(30mph), could go only 80km
(50mi)
before recharging
Prof. B Dinesh Prabhu

PESCE

Mandya

20

th

Century

For many years commonly used power sources

- steam engines, gasoline engines and
electric motors.
Gasoline powered engines became universal
choice to have longer trips & faster speeds
1902
First American car (Locomobile)
had 4-cyinder,water cooled, front
mounted gasoline engine very
similar in design to most cars today
Prof. B Dinesh Prabhu

PESCE

Mandya

Shaping Up!
1906
Gasoline powered cars had
- a hood covered front mounted engine
- two kerosene/acetylene lamps (head lights)
- fenders covering wheels & step up platforms
- passenger compartment-behind engine
1911
Electric self starter introduced
to replace hand crank to start engine
Electric head lights introduced
Prof. B Dinesh Prabhu

PESCE

Mandya

Ford
1903

First automobile Ford Model A

each year new Ford models B, C...
1908-1927 15 million cars of Model T
adopting innovative
assembly line
method
Affordable for an
average wage earner!
Prof. B Dinesh Prabhu

PESCE

Mandya

Assembly of a Model T
Two workers
mount an engine
into the chassis
of a Ford Model T
that was put
together at earlier
points on the
assembly line.

Prof. B Dinesh Prabhu

PESCE

Mandya

Luxury Automobiles
(For comfort & style rather than speed)
1909
Rolls-Royce Silver Ghost
-quiet 6-cylinder engine, leather interior,
folding windscreens & aluminum body.

Prof. B Dinesh Prabhu

PESCE

Mandya

Desgin Improvements
1920 Synchromesh Transmission
(for easy gear shifting),
improved
carburetors,
shatterproof glass,
heaters, balloon tires,
4 - wheel hydraulic brake systems,
pressed-steel wheels, and
mechanically operated wind shield
wipers
incorporated
Prof. B Dinesh Prabhu

PESCE

Mandya

Vintage Models
Made to individual specifications
1929 Graham Paige DC Phaeton
8-cylinder engine & aluminum body

Prof. B Dinesh Prabhu

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Improvements
1930 -1937
Large Engines (12-16 cylinder) &
large -luxurious Bodies
Independent front suspension, (made big cars
more comfortable )
more reliable braking systems,
higher-compression engines (for more hp)
1936 - Mercedes introduced Worlds first
Diesel Car
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PESCE

Mandya

Convenient, Reliable& Inexpensive

1937
Pontiac De Luxe Sedan
roomy interior rear hinged back door
suited to the needs of families

Prof. B Dinesh Prabhu

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Improvements
1940

Automatic transmission, sealed-beam

headlights, and tubeless tires
Studebaker Champion two-door sedan

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Car For The People

1949 A combination of look and economy that
remained popular for more than four decades.
VW Beetle

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Car For The People

Volkswagen Beetle
With a rear-mounted engine and
rounded, bug like shape, appealed to
buyers seeking utilitarian good looks,
easy serviceability, and fuel efficiency.
The classic Beetle became the bestselling car of all time, with more than 21
million sold.
Prof. B Dinesh Prabhu

VW New Beetle
In early 1998 Volkswagen put the first
New Beetle on the American market

PESCE

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New Features
1950 Air conditioning
electrically operated car windows
seat adjusters.
change over from the 6-volt to the12- volt
ignition system, for better engine performance
and more reliable operation of electrical
accessories.
Power steering & Power Brakes!
Prof. B Dinesh Prabhu

PESCE

Mandya

Powerful
High-performance Cars
1957 Mercedes-Benz 300SL-Gullwing
compact & stylized
230kmh(144mph)
-Door opens upward
Like gulls wings

Prof. B Dinesh Prabhu

PESCE

Mandya

Consumers Loved The Look

1957 Cadillac El Dorado convertible
consumers loved the look, demanded fins
of increasing size
until 1960s

Prof. B Dinesh Prabhu

PESCE

Mandya

Improvements
1960

1970

American cars-built Small, Increased

Engine Size & Horse Power
Heating and ventilating systems
became standard equipment.
Automatic transmissions, power
brakes & power steering-widespread.
Styling prevailed over practicality!
Catalytic converters introduced to
reduce exhaust emissions.
Prof. B Dinesh Prabhu

PESCE

Mandya

Muscle Car
1964 - Mustang Fords best early sales
success since introduction of Model T.
popular characteristics
small, fast design,
excellent handling,
powerful engine &
distinctive look.
Prof. B Dinesh Prabhu

PESCE

Mandya

Advances in Technology

1980
Digital speedometer & electronic
prompts to service parts
-Sporty cars & family mini vans
-Better engine control & use of
innovative
types of fuel
1981
On-board computer to monitor engine
performance
-A solar-powered vehicle, traveled 3,000
km (1,864 mi) in Australia in six days.
Prof. B Dinesh Prabhu

PESCE

Mandya

Modern Cars
1992 MR-2 Turbo T-bar Toyota
aerodynamically shaped, light & compact

Prof. B Dinesh Prabhu

PESCE

Mandya

New Technologies
1997 Gas-Electric Hybrids-Toyota Prius
four-seat hybrid electric vehicle (HEV)
first HEV- Japan

Prof. B Dinesh Prabhu

PESCE

Mandya

Better-smarter
1990s
1996

Pollution control laws adopted

EV1 all electric car first sold by GM
- Redesigned, quieter Diesel engines by
Volkswagon used in passenger cars!
- Engines run on Hydrogen tested

Expanded use of computer technology,

development of stronger & lighter materials & research
on pollution produce better-smarter
automobiles

Prof. B Dinesh Prabhu

PESCE

Mandya

Computer control!
1990s
Computer control of automobile systems
In modern cars, CPU -manages overall engine
performance.
Microprocessors regulating other systems share
data with the CPU
Computers manage F/A mixture ratios, ign.timing, &
emission levels, adjust antilock braking &
traction control systems, control air conditioning,
heating, sound system & information displayed
in
dash board
Prof. B Dinesh Prabhu

PESCE

Mandya

New Technologies
1980s

1990s

The notion that a car would talk to

its driver was science fiction; by the
1990s it had become reality.
Onboard navigation - By using the
satellite-aided global positioning
system (GPS), a computer in the
automobile can pinpoint the vehicles
location within a few meters
Prof. B Dinesh Prabhu

PESCE

Mandya

New Technologies
The onboard navigation system uses -electric
compass, digitized maps, a display screen
showing location of vehicle relative to intended
destination
After mentioning, computer locates destination
& directs driver, offering alternative routes if
needed
Also GPS system helps in emergency
situations to locate & direct the concerned
Prof. B Dinesh Prabhu

PESCE

Mandya

New Technologies
Cars equipped with computers and cellular
phones can link to Internet to obtain constantly
updated traffic reports, weather information,
route directions and other data
Built-in computer systems may be used to
automatically obtain business information over
Internet and manage personal affairs while
driving
Prof. B Dinesh Prabhu

PESCE

Mandya

Looking Ahead

Devises to
-reduce driver errors and poor driving habits.
-prevent intoxicated drivers from starting their
vehicles.
-Anti-collision systems with sensors and
warning signals
-slow the vehicle if it is following another vehicle
too closely
-warn drivers when another vehicle is in their
blind spot. Courtesy Microsoft Encarta
Prof. B Dinesh Prabhu

PESCE

Mandya

Types Of Power Plant

An Engine is a device which transforms one
form of energy into another form.
Most Engines convert thermal energy into
mechanical work &therefore they are called
Heat Engines.
Heat Engine is a device which transforms the
chemical energy of a fuel into thermal energy
& utilizes this thermal energy to perform useful
work.
Thus thermal energy is converted to
mechanical energy in a Heat Engine.
Prof. B Dinesh Prabhu

PESCE

Mandya

Heat Engines

Prof. B Dinesh Prabhu

PESCE

Mandya

Classification of Heat Engines

Prof. B Dinesh Prabhu

PESCE

Mandya

Heat Engines
Of the various types of heat engines,
the most widely used ones are

Reciprocating internal combustion engine,

Gas turbine and
Steam turbine

Prof. B Dinesh Prabhu

PESCE

Mandya

Advantages Reciprocating I C Engine

Mechanical simplicity and improved power plant
efficiency (absence of heat exchangers)
All its components work at an average temp. which
is much below the maximum temp. of the working
fluid in the cycle. Therefore, very high working fluid
temperatures can be employed resulting in higher
thermal efficiency.

Prof. B Dinesh Prabhu

PESCE

Mandya

Advantages
Higher thermal efficiency can be obtained with
moderate maximum working pressure of the
fluid in the cycle
Weight of power ratio is less than that of the
steam turbine plant
It has been possible to develop reciprocating
internal combustion engines of very small
power output with reasonable thermal
efficiency and cost.
Prof. B Dinesh Prabhu

PESCE

Mandya

Disadvantages
Problem of vibration caused by the
reciprocating components.
Considering all the above factors the
reciprocating internal combustion engines
have been found suitable for use in
automobiles, motor-cycles and scooters,
power boats, ships, slow speed aircraft,
locomotives and power units of relatively
small output.
Prof. B Dinesh Prabhu

PESCE

Mandya

Cross Section of a SI Engine

Prof. B Dinesh Prabhu

PESCE

Mandya

Basic geometry of
reciprocating IC Engine
Vc Clearance,
Vd Displaced, and
Vt Total cylinder volumes
TC (TDC) top dead centre
BC (BDC) bottom dead centre

Prof. B Dinesh Prabhu

PESCE

Mandya

Prof. B Dinesh Prabhu

PESCE

Mandya

2-Stroke Operating Cycle

Prof. B Dinesh Prabhu

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Engine Classifications

Prof. B Dinesh Prabhu

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Mandya

Engine Classifications

1.Application.
2.Basic engine design

Prof. B Dinesh Prabhu

PESCE

Mandya

Engine Classifications
3. Working cycle
4. Valve or port
design & location.

(c)
(a) Cross, (b) Loop, (c) Uniflow Scavenging

Prof. B Dinesh Prabhu

PESCE

Mandya

Engine Classifications
5. Fuel
6. Method of mixture preparation.
7. Method of ignition
8. Combustion chamber design.
9. Method of load control.
10. Method of cooling.

Prof. B Dinesh Prabhu

PESCE

Mandya

References:
Microsoft Encarta
Britanica Encyclopedia
Theory & Practice in IC Engines By C F Taylor
Fundamentals of I C Engines-J B Heywood
Internal Combustion Engines-Ganesan
Internal Combustion Engines-M L Mathur & S P
Sharma
Prof. B Dinesh Prabhu

PESCE

Mandya