I C Engine

INTERNAL COMBUSTION ENGINES (I C ENGINES)
Dept. of Mech & Mfg. Engg.
Heat Engine
Heat Engine is a prime mover which derives the heat energy from combustion of fuel or any other source and converts this energy into mechanical work.
Mechanical work produced in Heat Engines is Linear Work (Motion) which is converted into Rotary Work (Motion) by elements such as cylinder, piston, connecting rod, crank, etc.
Note: Prime Mover is a device which utilizes a natural source of energy to produce rotary mechanical energy.
Dept. of Mech & Mfg. Engg. 2
Classification of Heat Engines

Heat Engines may be classified as:
1. External Combustion Engines (E.C. Engines) Combustion of fuel takes place outside the engine cylinder. Example: Steam Engine, Steam turbine, etc.
2. Internal Combustion Engines (I.C. Engines) Combustion of fuel takes place inside the engine cylinder. Example: Petrol Engine, Diesel Engine, etc.
Comparing between E.C. & I.C. Engines

I.C. Engine
1. Combustion of fuel takes place inside the engine cylinder. 2. The temperature inside the combustion chamber is much higher.
E.C. Engine
1. Combustion of fuel takes place outside the engine cylinder. 2. The working temperature and pressure inside the combustion chamber is low. 3. The cylinder must be insulated to prevent the loss of heat to the surroundings.
3. Cooling arrangement is necessary to prevent overheating of the cylinder.
Comparing between E.C. & I.C. Engines contd.

I.C. Engine
4. Thermal efficiency is higher (35 to 40%) 5. It can be started instantaneously. 6. I.C. Engines are of single acting type. 7. Used for transport vehicles
E.C. Engine
4. Thermal efficiency is lower (15 to 20%) 5. It cannot be started instantaneously. 6. Reciprocating steam engines generally are of double acting type. 7. Used for electric power generation
Classification of IC Engines
According to: (i) Nature of Thermodynamic Cycle:
Otto cycle engine Diesel cycle engine Dual combustion cycle engine
(ii) Type of the Fuel used:

Petrol engine Diesel engine Gas engine Bio-fuel engine Dual fuel engine
Classification of IC EnginesContd.
(iii) Number of Strokes:
2 - Stroke Engine 4 - Stroke Engine
(iv) Method of Ignition:

Spark Ignition Engine (S.I. Engine) Compression Ignition Engine (C.I. Engine)
Single Cylinder Engine Multi-Cylinder Engine
(v) Number of Cylinders:
(vi) Position of the Cylinder:
Horizontal engine Vertical engine V- engine In-line engine Opposed cylinder engine Radial engine Air cooled engine Water cooled engine
(vii) Method of Cooling:
(viii) Speed of the Engine:
Low Speed Engine Medium Speed Engine High Speed Engine
Inlet Valve Inlet Port
Exhaust Valve Exhaust Port
Cylinder Head
Spark Plug or Injector

Piston Rings
Cylinder Block Coolant
Gudgeon Pin Piston Connecting Rod
Crank Pin PARTS OF I. C. ENGINE Crank
Lubricant Crank Shaft Crank Case

I. C. Engine terms & Definitions

1. Dead Centers:
These are two positions of the piston when the crank and connecting rod are in line. (a) Top Dead Center (TDC): It is the top most position of the piston towards head side of the cylinder. It is also known as the Cover End
(b) Bottom Dead Center (BDC): It is the lowermost position of the piston towards the crank end side of the cylinder. It is also known as the Crank End
2. Stroke (L):
It is the linear distance travelled by the piston when it moves from one end of the cylinder to the other end. (TDC to BDC or BDC to TDC)
3. Bore (d):
It is the inside diameter of the cylinder.
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4. Swept volume or Displacement volume (vd):

It is the volume swept through by the piston in moving between TDC and BDC
5. Clearance volume (vc):

It is the volume contained in the cylinder above the top of the piston, when the piston is at TDC.
Total volume = Swept volume + Clearance volume. vtot = vd + vc
vtot
d 2
4 4 d 2 ( L Lc ) 4
d 2
Lc
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6. Compression ratio r :
It is defined as the ratio of total cylinder volume (vtot) to clearance volume (vc).
( vd vc ) Total Volume Compression Ratio (r ) ClearanceVolume vc

Value of r for,
Petrol engine lies between Diesel engine lies between 7 and 12 16 and 20
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Working of 4-S Petrol Engine
The petrol engines work on the principle of OTTO CYCLE also known as Constant Volume Cycle. The engines operating on this cycle use either petrol or other spirit fuels or the gases such as LPG / CNG as their fuels..
D
Reversible Adiabatic Compression Reversible Adiabatic Expansion
Pressure
C
E
v1
Volume
v2
Theoretical Otto cycle
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Cylinder cover at other end
Cylinder
Spark Plug Inlet valve operates in the inlet port Exhaust valve operates Piston in the exhaust port
Crank
Connecting Rod at Open one end Crank Shaft

The piston performs four strokes to complete one working cycle.

1. Suction stroke
2. Compression stroke
3. Working or power stroke, and
4. Exhaust stroke
A spark plug is used to produce a spark so as to ignite the charge inside the cylinder. Since ignition in these engines is due to a spark, they are also called Spark Ignition Engines (S.I. Engines).
In a 4-Stroke petrol engine, the charge admitted into the engine cylinder is a homogeneous mixture of petrol and air.
Depending on the load on the engine, petrol and air is mixed in proper proportions and sent into the cylinder by a popular device known as carburettor.
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Schematic of 4-S Petrol Engine
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Suction Stroke: During the suction stroke, inlet valve is

open and exhaust valve closed. The piston moves from TDC to BDC, drawing a fresh charge of vaporized fuel-air mixture. Crank shaft rotates by half a rotation. This stroke is represented by the line AB on the P-V diagram.
Pressure, P A BDC I.V. Open E.V. Close
TDC
B Volume, V
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Compression Stroke: During compression stroke, both

inlet & exhaust valves are closed. The piston moves from BDC to TDC, thus compressing air petrol mixture. Crank shaft rotates by half a rotation. Due to compression, the pressure and temperature of the charge are increased. This is shown by the line BC on the P- V diagram which is Adiabatic Compression. Just before the end of this stroke the spark - plug initiates a spark which ignites the compressed charge and combustion takes place at constant volume as shown by the line CD.
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I.V. Close
E.V. Close TDC Pressure, P
Constant Volume Combustion

Reversible Adiabatic Compression
BDC
B Volume, V
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Working Stroke: During working stroke, both inlet &

exhaust valves are closed. The burnt gases expand and cause the piston to move from TDC to BDC. Crank shaft rotates by half a rotation. The high pressure burnt gases exert pressure on the piston and force it to move from TDC to BDC producing Linear Work. Connecting rod and crank convert this linear work into Rotary Work of the crank shaft. The burnt gases expand as the piston moves. Expansion of gases is an Adiabatic Expansion process which is shown by the line DE on the P-V diagram. Just before the piston reaches BDC, the exhaust valve opens causing sudden release of gases to atmosphere. There is sudden drop in pressure at constant volume inside cylinder as shown by line EB on the P-V diagram.
D I.V. Close E.V. Close TDC Pressure, P C
Reversible Adiabatic Expansion Constant volume expansion
E A
BDC
B
Volume, V
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Exhaust Stroke: During the exhaust stroke the exhaust

valve is open and inlet remains closed. During this stroke the piston moves from BDC to TDC and pushes the remaining gases to the atmosphere. This stroke is represented the line BA on the P-V diagram.
I.V. Close E.V. Open
TDC Pressure, P C
E A Volume, V B
BDC
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Concluding Remarks on working of 4S Petrol Engine

This engine requires 4 strokes to complete one working cycle. The crank shaft makes two revolutions to complete one cycle (half revolution per stroke). Power is developed in alternate revolutions of the crankshaft. Energy developed during power stroke is stored in the flywheel. Energy required to perform suction, compression and exhaust stroke is provided from the flywheel. At start of engine, energy required to perform the strokes is Flywheel is a heavy disc rigidly provided by cranking.
keyed to the crank shaft
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P V Diagram for SI Engine / Otto Cycle Engine

D
Pressure
TDC
C E A Volume Theoretical Otto cycle
BDC
28
Working of 4S Diesel Engine
The basic construction of a four stroke diesel

engine is same as that of four stroke petrol engine. Instead of a spark plug, a Fuel Injector is mounted in its place. Instead of a carburettor, a fuel pump supplies the fuel oil to the fuel injector at higher pressure. The fuel injector injects the fuel into the cylinder as a fine spray at very high pressure at the beginning of power stroke.
In case of diesel engine, only air enters the cylinder during
suction stroke, i.e., charge is only air. So, only air is compressed during the compression stroke. At the end of the compression stroke, the fuel injector injects diesel into the cylinder in the form of fine spray. When this fine spray of diesel comes in contact with hot compressed air in the cylinder, it auto ignites and results in the combustion of injected diesel fuel. Since ignition in these engines is due to the high temperature of the compressed air, they are called as Compression Ignition Engines (C.I. Engines).
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31
The diesel engines work on the principle of DIESEL CYCLE also known as Constant Pressure Cycle. The engines operating on this cycle use either diesel fuel or other spirit fuels or bio-fuels..
Constant Pressure Combustion Reversible Adiabatic Expansion

C D
Pressure
E A
Volume
Theoretical Diesel cycle
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Suction Stroke: During the suction stroke, inlet valve is

open and exhaust valve closed. The piston moves from TDC to BDC, drawing a fresh charge of air only. Crank shaft rotates by half a rotation. This stroke is represented by the horizontal line AB on the P-V diagram.
Pressure, P A BDC Volume, V
33
I.V. Open
E.V. Close TDC
Compression Stroke: During compression stroke, both

inlet & exhaust valves are closed. The piston moves from BDC to TDC, thus compressing air. Crank shaft rotates by half a rotation. Due to compression, the pressure and temperature of air are increased. This is shown by the curved line BC on the P-V diagram which is Adiabatic Compression.
34
I.V. Close
E.V. Close TDC Pressure, P
BDC
Volume, V
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Working Stroke: During working stroke, both inlet &

exhaust valves are closed. The burnt gases expand and cause the piston to move from TDC to BDC. Crank shaft rotates by half a rotation. Just at the beginning of this stroke, the fuel injector continuously injects a metered quantity of diesel in the form of a fine spray into the hot compressed air. The temperature of compressed air is sufficient to ignite the diesel being sprayed. So, combustion takes place at constant pressure. Partial expansion of burnt gases at constant pressure causes the initial movement of the piston as shown by the horizontal line CD on the P-V diagram. The piston is forced further during the remaining part of this stroke only due to the expansion of burnt gases.
Expansion of gases is an Adiabatic Expansion process which is shown by the curved line DE on the P-V diagram. Connecting rod and crank converts the Linear Work of the piston into Rotary Work of the crank shaft. Just before the piston reaches BDC, the exhaust valve opens causing sudden release of gases to atmosphere. There is sudden drop in pressure at constant volume inside cylinder as shown by the vertical line EB on the P-V diagram.
37
I.V. Close
E.V. Close TDC
Reversible Adiabatic Expansion

D
Pressure
BDC
Volume
38
Exhaust Stroke: During the exhaust stroke the exhaust

valve is open and inlet remains closed. During this stroke the piston moves from BDC to TDC and pushes the remaining gases to the atmosphere. This stroke is represented the line horizontal BA on the P-V diagram.
I.V. Close E.V. Open TDC C
BDC
39
P V Diagram for C.I. Engine / Diesel Cycle Engine

C D
TDC
Pressure
E A
BDC
Volume Theoretical Diesel cycle
40
Concluding Remarks on working of 4S Diesel Engine

This engine requires 4 strokes to complete one working cycle. The crank shaft makes two revolutions to complete one cycle (half revolution per stroke). Power is developed in alternate revolutions of the crankshaft. Energy developed during power stroke is stored in the flywheel. Energy required to perform suction, compression and exhaust stroke is provided from the flywheel. At start of engine, energy required to perform the strokes is Flywheel is a heavy disc rigidly provided by cranking.
keyed to the crank shaft
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4S I.C. ENGINE ANIMATION
42
Comparison between Petrol & Diesel Engine

Petrol engine Diesel engine It works on Otto cycle. It works on Diesel cycle. Air and petrol are mixed in the carburetor before they enter into the cylinder. It compresses a mixture of air and petrol and is ignited by an electric spark. (Spark Ignition) Diesel is fed into the cylinder by fuel injection and is mixed with air inside the cylinder. It compresses only air and ignition is accomplished by the heat of compression. (Compression Ignition)
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1 2
4 5
Cylinder is fitted with a spark plug.
Cylinder is fitted with a fuel injector.
Less thermal efficiency More thermal efficiency and more fuel and less fuel consumption. consumption. Compression ratio ranges from 7:1to12:1 Less initial cost and more running cost. Light weight and occupies less space. Compression ratio ranges from 16:1 to 20:1 More initial cost and less running cost. Heavy and occupies more space.
44
10
11
12
Difficult to start in cold Easy to start even in weather and requires cold weather. heater plugs. They run for longer Requires frequent periods between overhauling. overhauls. Fuel (diesel) is cheaper Fuel (petrol) is costlier and more and less volatile. volatile. Used in light Used in heavy duty vehicles like cars, vehicles like tractors, trucks, buses, motor cycle, scooters, etc. locomotives, etc.
Two Stroke Engine

In a two stroke engine, one cycle is completed by the two strokes of the piston. Out of the four strokes, the two strokes that are eliminated are, suction and exhaust strokes. Actually the suction and exhaust processes are performed while the power and compression strokes are in progress. In case of the two stroke engines instead of valves, ports are used. Ports in the cylinder liner are opened and closed by the piston motion itself.
46
Parts of a 2S Engine
Spark Plug or Fuel Injector Transfer Port
Exhaust Port
Piston
Reed Valve
Inlet Port
Connecting Rod
Crank
crank case
Crank Shaft
Flywheel
47
Working of 2S Petrol Engine

Exhaust port Transfer port
Inlet port
48
Working of 2S Petrol Engine
First stroke
Second stroke
49
First stroke (Downward)

As soon as the charge is ignited by the spark plug, the hot gases force the piston to move from TDC to BDC. Crankshaft rotates by half a rotation, thus doing the useful work. During this stroke the inlet port is covered by the piston and the new charge is compressed in the crank case as shown in the figure.
50
Further downward movement of the piston uncovers first the exhaust port and then the transfer port. The burnt gases escape through the exhaust port. As soon as the transfer port opens, the compressed charge from the crankcase flows into the cylinder. As the compressed charge enters into the cylinder, it pushes out the exhaust gases from the cylinder. The process of removal of exhaust gases by the fresh incoming charge is known as scavenging.
51
Second stroke: (upward)

Here the piston moves from BDC to TDC, during which the exhaust port and transfer port are covered and the charge in the cylinder is compressed. Simultaneously, vacuum is created in the crankcase, and a new charge is drawn into the crankcase through the uncovered inlet port.
52
The compressed charge is ignited in the combustion chamber by a spark provided by the spark plug and the cycle of events is then repeated.
53
Concluding Remarks on working of 2S Petrol Engine

This engine requires 2 strokes to complete one working cycle. The crank shaft makes one revolution to complete one cycle (half revolution per stroke). Power is developed in every revolution of the crankshaft. Energy developed during the first (power) stroke is stored in the flywheel. Energy required to perform the second stroke is provided from the flywheel. Smaller flywheel is required as power is developed in every revolution of crank shaft. At start of engine, energy required to perform the strokes is provided by cranking.
Working of 2S Diesel Engine
First stroke
Second stroke
55
First stroke (Downward)

When the fuel injector injects the diesel into the hot compressed air, combustion starts and the hot gases force the piston to move from TDC to BDC. Crankshaft rotates by half a rotation, thus doing the useful work. During this stroke the inlet port is covered by the piston and the new charge [air] is compressed in the crank case as shown in the figure.
56
Further downward movement of the piston uncovers first the exhaust port and then the transfer port. The burnt gases escape through the exhaust port. As soon as the transfer port opens, the compressed charge from the crankcase flows into the cylinder. As the compressed charge enters into the cylinder, it pushes out the exhaust gases from the cylinder. The process of removal of exhaust gases by the fresh incoming air is known as scavenging.
57
Second stroke: (upward)

Here the piston moves from BDC to TDC, during which the exhaust port and transfer port are covered and the fresh air in the cylinder is compressed. Simultaneously, vacuum is created in the crankcase, and a new charge [air] is drawn into the crankcase through the uncovered inlet port.
58
At the end of the compression diesel is injected to the compressed air which is at a temperature higher than the self ignition temperature of diesel. Hence, the injected diesel auto ignites when it comes in contact with hot air. The cycle of events are then repeated.
59
Comparison between 4S & 2S Engine

1
4S Engine One working stroke for every two revolution of the crank shaft Turning moment on the crank shaft is not even, hence heavier flywheel is required
2S Engine One working stroke for each revolution of the crank shaft Turning moment on the crank shaft is more even, hence lighter flywheel is required
Less fuel consumption More fuel consumption.
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More output due to full fresh charge intake and full burnt gases exhaust. Higher thermal efficiency Engine design is complicated
No. of cycles/min = Half the engine speed i.e., n = N/2 It has inlet and exhaust valves
Less output due to mixing of fresh charge with the burnt gases. Lower thermal efficiency Engine design is simple.
No. of cycles/min = engine speed i.e., n = N It has inlet and exhaust ports
61
Engine is heavy & bulky. It requires lesser cooling and lubrication More initial cost
10
11
For the same power, the engine is light and compact. It requires greater cooling and lubrication. (consumes more lubricating oil) Less initial cost.
12
13
More running noise due to Less running noise the sudden release of the burnt gases. Used in cars, Used in mopeds, motor trucks, buses, cycles, scooters, etc. tractors, etc.
Simple Calculations in IC Engines

(1) Mean Effective Pressure (pm):
It is the average pressure of the burnt gases acting on the piston during the power stroke. Its actual value is determined from the actual P-V diagram obtained from a device known as spring indicator. It is given by the expression:
sa pm N / m2 l
where, s = Spring constant value of the spring used in the indicator, N/m2/cm a = Area of the actual indicator diagram, cm2 l = Base length of the indicator diagram, cm
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Actual indicator (P-V) diagrams for Petrol & Diesel Engines
l Actual P-V diagram for petrol engine
l Actual P-V diagram for diesel engine
A1 = Positive loop area = the actual work developed A2 = Negative loop area = work used to discharge the exhaust gases to the atmosphere a = Net area = (A1 A2) = Net work done l = Base length of the indicator diagram
(2) Indicated Power: Let pm = Mean Effective pressure, N/m2 L = Stroke length, m A = Area of cross section of the cylinder, m2 N = Speed of the Crank shaft, rpm n = Number of cycles per minute Work done by the piston per cycle
Mean force acting on the piston
Piston displacement in one power stroke
= pm A L
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Work done by the piston per minute =
Work done by the piston per cycle
Number of cycles per minute N/min
i.e., Indicated Power (IP) = pm A L n
pm LAn IP Nm / sec 60
For 4S Engine, n = N/2 For 2S Engine, n = N
66
Important definitions
Brake Power [B.P]: It is the power developed by the engine at the output shaft.
2NT Brakepower, kw 60000
Where, N = Speed of the crank shaft in rpm.

T =Torque applied on the brake drum due to load W, (N-m) R = Radius of the brake drum (m)
T = W x R kg-m = 9.81 x W x R N-m

Indicated Power [I.P]: It is the power developed inside the IC engine cylinder
i Pm L A n Indicatedp ower , kW 60000

Where, n = No. of working cycles/ min.
,
n = N/2, for 4 stroke engine

= N, for 2 stroke engine L = Stroke length (m), D = Bore diameter (m) Pm = Indicated mean effective pressure (N/m2) 2 2 A = Area of the cylinder, A D , m
4
Frictional Power [F.P]: It is the difference between the indicated power and the brake power. F.P = [I.P B.P] kW
,
Mechanical Efficiency [mech ]: It is the ratio of the brake power and the indicated power.
Mechanical efficiency , mech
B.P 100% I .P
69
Brake thermal Efficiency [bth ]: It is the ratio of the brake power to the heat supplied by the fuel.
B. P 3600 bth *100% mf Cv

Indicated thermal Efficiency [ith ]: It is the ratio of the indicated power to the heat supplied by the fuel.
I. P 3600 ith *100% mf Cv
Where, mf = mass of the fuel supplied (kg/hr) CV = Calorific Value of the fuel (kJ/kg)
Working of a Simple Carburetor

The petrol enters the float chamber through the needle valve, Purpose of needle valve is to maintain the constant level of petrol in the float chamber. When engine runs, the air is sucked through the venturi tube. As a result pressure at throat reduces (-) and the petrol issues out of the main jet located at the throat. Thus amount of petrol issuing from jet proportional to the velocity of air through the venturi tube.
Working of a Diesel pump

Plunger of the fuel pump is operated by the cam roller mechanism, which derives the power from the engine. El. As plunger moves up, the fuel filled above the plunger is pressurized and pressurized fuel flow through the barrel. The outlet of from the fuel pump barrel is closed by a spring loaded delivery valve which opens only at prescribed pressure of the fuel. As the fuel pressure rises, the delivery valve and is forced out towards the injector.
72
Working of a Diesel injector

Fuel under pressure from the pump, passes down through passages in the injector body to an annular space in the nozzle and lifts the needle valve against pressure of the spring As a result fuel is forced through the holes of injector under high pressure resulting in finely atomized spray.

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INTERNAL COMBUSTION ENGINES (I C ENGINES)

Dept. of Mech & Mfg. Engg.

Classification of Heat Engines

Comparing between E.C. & I.C. Engines

3. Cooling arrangement is necessary to prevent overheating of the cylinder.

Dept. of Mech & Mfg. Engg.

Comparing between E.C. & I.C. Engines contd.

Dept. of Mech & Mfg. Engg.

(ii) Type of the Fuel used:

(iv) Method of Ignition:

(v) Number of Cylinders:

(vii) Method of Cooling:

Dept. of Mech & Mfg. Engg.

Inlet Valve Inlet Port

Exhaust Valve Exhaust Port

Spark Plug or Injector

Cylinder Block Coolant

Gudgeon Pin Piston Connecting Rod

Crank Pin PARTS OF I. C. ENGINE Crank

Lubricant Crank Shaft Crank Case

I. C. Engine terms & Definitions

Dept. of Mech & Mfg. Engg.

4. Swept volume or Displacement volume (vd):

5. Clearance volume (vc):

Total volume = Swept volume + Clearance volume. vtot = vd + vc

Dept. of Mech & Mfg. Engg.

( vd vc ) Total Volume Compression Ratio (r ) ClearanceVolume vc

Dept. of Mech & Mfg. Engg.

Working of 4-S Petrol Engine

Reversible Adiabatic Compression Reversible Adiabatic Expansion

Theoretical Otto cycle

Dept. of Mech & Mfg. Engg.

Cylinder cover at other end

Connecting Rod at Open one end Crank Shaft

The piston performs four strokes to complete one working cycle.

Dept. of Mech & Mfg. Engg.

Schematic of 4-S Petrol Engine

Dept. of Mech & Mfg. Engg.

Suction Stroke: During the suction stroke, inlet valve is

Dept. of Mech & Mfg. Engg.

Compression Stroke: During compression stroke, both

Dept. of Mech & Mfg. Engg.

E.V. Close TDC Pressure, P

Constant Volume Combustion

Dept. of Mech & Mfg. Engg.

Working Stroke: During working stroke, both inlet &

D I.V. Close E.V. Close TDC Pressure, P C

Reversible Adiabatic Expansion Constant volume expansion

Dept. of Mech & Mfg. Engg.

Exhaust Stroke: During the exhaust stroke the exhaust

Dept. of Mech & Mfg. Engg.

Concluding Remarks on working of 4S Petrol Engine

keyed to the crank shaft

Dept. of Mech & Mfg. Engg.

P V Diagram for SI Engine / Otto Cycle Engine

C E A Volume Theoretical Otto cycle

Dept. of Mech & Mfg. Engg.

Working of 4S Diesel Engine