ME 459

Automobile Engineering

Engine Construction

Md. Mostaqur Rahman

Lecturer
Mechanical Engineering Department
Dhaka University of Engineering and Technology

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Essential Parts of the Engine
Cylinder Head or Engine Head
Cylinder Block or Engine Block
Crankcase
Cylinder
Piston
Connecting rod
Crankshaft
Valves
Camshaft
Flywheel
Spark Plug for SIE & Injector for CIE

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 Engine Head
The cylinder head encloses one end of the engine
cylinders and forms the upper end of the combustion
chambers.
It contains combustion chamber, spark plug for SI,
injector for CI and valve port, manifold port and
passages for the flow of cooling water.
Some cylinder heads have additional features that
help promote good combustion, like, Turbulence
Generating Pot (TGP), High Swirl Intake Port and
Pre-combustion Chamber.
Materials: Gray iron, iron alloy and Aluminum alloy

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Advantages of Aluminum Cylinder & Head
Higher heat conductivity which is about
three times that of cast iron.
Light in weight.
Better cooling while the engine running.
Greater power output and low fuel
consumption
Engine warms up more quickly and requires
a smaller radiator.

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Cylinder Block
The cylinder block is the foundation of the engine.
They serve as a support and enclosure for moving
parts.

A cylinder block consists of

The cylinder in which the pistons slide up and
down
The passages for the flow of cooling water

Materials: Gray cast iron, with nickel and

chromium, Aluminum

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 Cylinder Liners
Cylinder liners are in the form of barrels made of
special iron alloy containing silicon, manganese, nickel
and chromium.
The cylinder liners are of the two types:
Dry liners:

It is not in direct contact with the cooling water.

It is thinner than wet liners ( Thickness 1.5-3mm)
Wet liners.
The liner is in direct contact with the cooling water.
It is thicker than dry liner (Thickness 1.5-6mm)
It is free to expand
It can be replaced easily.

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 Piston
Piston is essentially a cylindrical plug that moves
up and down in the cylinder.
It helps to coverts the chemical energy obtain by
the combustion of fuel into mechanical power.
During the power stroke, up to 1.8 ton (4000 lb)
is suddenly applied to the piston head.
Temperature above the piston head reach 2800
0C.

Piston must be strong, but it must be light, too,

to reduce inertia lodes on the bearing.
Materials: Cast iron and Aluminum alloy

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Land

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Function of the Piston cont..
The piston perform the following functions:
To receive the thrust generated by the
explosion of the gas in the cylinder and transmit
it to the connecting rod.
To reciprocate in the cylinder as a gas tight plug

causing suction, compression, expansion and

exhaust stroke.
To form a guide and bearing to the small end of

the connecting rod and to take the side thrust

due to the obliquity of the rod.

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Piston Clearance
The space between the cylinder wall and the
piston. It is generally 0.025 mm to 0.102 mm.

This clearance is essential for the following

reasons:
It provides a space for a film of lubricant
between the piston and cylinder wall to
reduce friction.
It prevents piston seizure.
It allows piston to reciprocate in the
cylinder.
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Piston Head Shape
Flat Head
Cup Head
Dome Head
Hump Head
Contour Head
Fire-Dome Head

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Hump Head

Cup or Dish Head

Flat Head
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Contour Head
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Fire-Dome Head

Dome Head
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Expansion Control in Pistons
By cam grinding the piston
By keeping heat away from the lower part
of the piston as much as possible.
By making heat dam

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Piston (Wrist, Gudgeon) Pin

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Piston Pin Offset

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Piston Ring
Piston rings are fitted into the groves of the
piston to maintain good seal between the piston
and the cylinder wall.

Three functions of the piston rings:

To provide a pressure seal to prevent blow-by of
burnt gases.
To form the main path for conduction of heat
from the piston crown to the cylinder wall.
To control the flow of oil.

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Piston Ring
Two types of piston rings:
Compression rings

Compression rings seal in the air-fuel mixture as it

is compressed, and also the combustion pressure
as the mixture burns.
Oil control rings

Oil control rings scraps off excessive oil from the

cylinder wall and return it to the oil pan.

Why two compression rings?????????

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Connecting Rod
The connecting rod is
the connection between
the piston and the
crankshaft.
The function of the
connecting rod is to
convert linear motion of
the piston into rotary
motion of the
crankshaft.
Material: Forged steel
or aluminum.
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Crankshaft
Crankshaft
Combines work done by each piston

Drives camshafts, generator, pumps, cooling fan ,

etc.
Materials: Alloy Steel

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Flywheel
A flywheel is a fairly heavy steel wheel attached to the rear end of
the crankshaft.
Absorbs and releases kinetic energy of piston strokes -> smoothes
rotation of crankshaft.
It is also used as a part of clutch mechanism and fluid drive unit.
It has teeth on its outer edge to mesh with the electric cranking
motor driven pinion when the engine is being cranked to start it.
The size of the flywheel depends upon the number of cylinders and
the general construction of the engine.

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Firing Order
Firing order is the order in which the cylinder deliver their power
stroke.
Minimizes the strain on the crankshaft.

In in-line engines, the cylinders are numbered from front to back

Two possible firing orders in four-cylinder engines are

1-3-4-2 and 1-2-4-3
In V-6 engines, left bank numbered from front to back 1, 3 and 5.

The right bank is numbered 2, 4 and 6

Other V-type, the right bank is numbered 1, 2, 3,. And the left bank is

numbered as 4, 5, 6.
Two possible firing orders in four-cylinder engines are
1-5-3-6-2-4 and 1-4-2-6-3-5
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Engine Bearings
Sleeve Bearings
Thrust Bearing
Bearing Requirements:
Load-Carrying Capacity

Fatigue Resistance

Embeddability

Conformability

Corrosion Resistance

Wear Rate

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