Automobile Engineering

INTRODUCTION:
Components of four wheeler automobile – chassis and body –
power unit – power transmission – rear wheel drive, front wheel
drive, 4 wheel drive – types of automobile engines, engine
construction, turbo charging and super charging – engine
lubrication, splash and pressure lubrication systems, oil filters, oil
pumps – crank case ventilation – engine service, reboring,
de-carbonisation, Nitriding of crank shaft.
Unit-II:
TRANSMISSION SYSTEM: Clutches, principle, types, cone clutch,
single plate clutch, multi plate clutch, magnetic and centrifugal clutches,
fluid fly wheel – gear boxes, types, sliding mesh, construct mesh, synchro
mesh gear boxes, epicyclic gear box, over drive torque converter. propeller
shaft – Hotch – Kiss drive, Torque tube drive, universal joint, differential
rear axles – types – wheels and tyres.
Unit – III:
STEERING SYSTEM: Steering geometry – camber, castor, king pin rake, combined angle
toein, center point steering, types of steering mechanism – Ackerman steering mechanism,
Davis steering mechanism, steering gears – types, steering linkages.
SUSPENSION SYSTEM: Objects of suspension systems – rigid axle suspension system,
torsion bar, shock absorber, Independent suspension system.
BRAKING SYSTEM: Mechanical brake system, hydraulic brake system, master cylinder,
wheel cylinder tandem master cylinder requirement of brake fluid, pneumatic and vacuum
brakes.
Unit-IV:
ELECTRICAL SYSTEM: Charging circuit, generator, current – voltage regulator –
starting system, bendix drive mechanism solenoid switch, lighting systems, horn, wiper,
fuel gauge – oil pressure gauge, engine temperature indicator etc.

ENGINE SPECIFICATION AND SAFETY SYSTEMS: Introduction- engine

specifications with regard to power, speed, torque, no. of cylinders and arrangement,
lubrication and cooling etc.
Safety: Introduction, safety systems - seat belt, air bags, bumper, anti lock brake system
(ABS), wind shield, suspension sensors, traction control, mirrors, central locking and
electric windows, speed control.
Unit-V:
ENGINE EMISSION CONTROL: Introduction – types of pollutants,
mechanism of formation, concentration measurement, methods of controlling-
engine modification, exhaust gas treatment-thermal and catalytic converters-
use of alternative fuels for emission control – National and International
pollution standards
ENGINE SERVICE: Introduction, service details of engine cylinder head,
valves and valve mechanism, piston connecting rod assembly, cylinder block,
crank shaft and main bearings, engine reassembly-precautions.
Introduction Automobile engineering:
Automobile engineering is the one of the stream of mechanical engineering.
It deals with the
various types of
automobiles, their
mechanism of
transmission systems
and its applications.
Automobiles are the
different types of
vehicles used for
transportation of
passengers, goods, etc.
DEFINITION:
Automobile engineering is a branch of engineering which deals with everything about
automobiles and practices to propel them.
Automobile is a
vehicle driven by an
internal combustion
engine and it is used
for transportation of
passengers and goods
on the ground.
Automobile can also
be defined as a vehicle
which can move by
itself. Examples : Car,
jeep, bus, truck,
scooter, etc.
Chassis:
Chassis is a French term which is now denotes the whole vehicle except body in case
of heavy vehicles. In case of light vehicles of mono construction, it denotes the whole
vehicle except additional fittings in the body. "Chassis consists of engine, power train,
brakes, steering system and wheels mounted on a frame”.

Frame
The frame is the main part of the chassis on which remaining parts of chassis are
mounted. The frame should be extremely rigid and strong so that it can withstand
shocks, twists, stresses and vibrations to which it is subjected while vehicle is moving
on road. It is also called underbody.
The frame is supported on the wheels and tyre assemblies. The frame is narrow in the
front for providing short turning radius to front wheels. It widens out at the rear side to
provide larger space in the body.
Types of Frame
There are three types of frames :
(a) Conventional frame,
(b) Semi-integral frame, and
(c) Integral frame (or unit frame).

Conventional Frame: It is non-load carrying frame. The loads of the vehicle are
transferred to the suspensions by the frame. This suspension in the main skeleton of
the vehicle which is supported on the axles through springs. The body is made of
flexible material like wood and isolated frame by inserting rubber mountings in
between. The frame is made of channel section
or tubular section of box section.Example : This type of frame is used for trucks.
Semi-integral Frame:
In this case the rubber mountings used in conventional frame between frame and
suspension are replaced by more stiff mountings. Because of this some of the vehicle
load is shared by the frame also. This type of frame is heavier in construction.
Example : Popular in European and American car.

Integral Frame or Frame-less Construction:

In this type of construction, there is no frame. It is also called unitized frame-body
construction. In this case, the body shell and underbody are welded into single unit.
The underbody is made of floor plates and channel and box sections welded into
single unit. This assembly replaces the frame. This decreases the overall weight
compared to conventional separate frame and body construction.
Conventional Frame
Semi-integral Frame
Integral Frame or Frame-less Construction
Types of Sections Used in Frames
Three types of steel sections are most commonly used for making frames :
(a)Channel section,
(b)Tubular section, and
(c)Box section.
The cross-section of all the three types of section is shown in Figure 8.1.
(a) Channel
(b) Box
(c) Tubular
Frame and Chassis
The channel section is best suited for bending loads.
Box section is good for both bending and torsion and
Tubular section is good for torsion.
Power Unit :
An engine or motor is
a machine designed
to convert energy into
useful mechanical
motion. Engine is the
power unit of the
automobile.
Important types of power units are:
• Heat Engine
• Electric motor
 - Heat engines
Heat engines are those that convert the heat energy into mechanical work.

• Combustion heat engines: These type of engines use the heat produced during
combustion processes to do work.
• Non-Combustion heat engines: These type of engines convert heat from non
combustive processes into mechanical work(as in the case of a nuclear reactor)

• External combustion engine : Loco engines

• Internal combustion engine : Car, bus and truck engines etc..
• Gas turbine : Aero plane engines
• Air-breathing combustion engines : Jet engines
 ⦁ Internal combustion engines
The internal combustion engine is
an engine in which the combustion of
a fuel (normally a fossil fuel) occurs with an
oxidizer (usually air) in a combustion
chamber. In an internal combustion engine,
the expansion of the high-temperature and
high -pressure gases produced by combustion
apply direct force to some component of the
engine. This force is applied typically
to pistons, turbine blades, or a nozzle. This
force moves the component over a distance,
transforming chemical energy into useful
mechanical energy.
Power Transmission
Rear Wheel drive
Front wheel drive
Four wheel drive
Four wheel drive
Super charging
As we said, a supercharger is an air compressor and it requires a source of power to operate the
compressor mechanism. Most automotive superchargers are run by a drive belt (or occasionally
a train of gears) operated by the engine, much like a power steering pump or air conditioning
compressor. An alternative is to run the supercharger with a turbine wheel placed in the
engine’s exhaust manifold, turned by the flow of burned exhaust gases rushing of the engine.
An exhaust-driven supercharger is called a turbocharger. (Years ago, they were often called
turbo-superchargers, but that term has fallen out of common use, although it is occasionally
applied to combinations of engine-driven and exhaust-driven superchargers.).
What’s the advantage of supercharging (or Turbocharging)?
A: More power! The more you increase the pressure of the intake air above the local
atmospheric pressure (boost), the more power the engine produces. Automotive superchargers
for street use typically produce a maximum boost pressures between 5 and 15 psi (0.33 to 1.0
bars), providing a proportionate increase in power. This is particularly useful at high altitudes:
A supercharger can pressurize the intake charge to something close to sea level pressure,
compensating for the power lost to reduced air density at high altitude. (Superchargers are
popular for high-altitude aircraft piston engines for precisely that reason.)
Turbo charging

An internal combustion engine works by drawing a mixture of air and fuel (the intake charge)
into its cylinders, compressing that mixture, and then burning it. The more air/fuel mixture
that can be crammed into the cylinders to burn, the more power the engine produces. You can
increase power in three basic ways: you can improve the engine’s ability to draw more air and
fuel into the cylinders and expel its burned exhaust gases (its volumetric efficiency, or
‘breathing’); you can increase the swept volume of the cylinders (the engine’s displacement)
so you can fit more air and fuel into each cylinder; or you can pump the intake charge into the
cylinders under high pressure, squeezing more air and fuel into the available volume.

Forcing air (or air-fuel mixture) through an engine’s intake valves at higher than atmospheric
pressure is called supercharging. A supercharger, therefore, is a mechanical air compressor
that pressurizes the air going into the engine’s intake manifold. There are several types of
compressor used for car and truck engines, the most common being Roots-type, centrifugal,
and Lysholm-type compressors; each has pros and cons, but they have the same basic purpose.
Objects of lubrication

1. To reduce friction between the moving parts.

2. To reduce wear of the moving parts.
3. To act as cooling medium for removing heat.
4. To keep the engine parts clean, especially piston rings and ring grooves,
Oil ways and filters.
5. To absorb shock between bearings and other engine parts thus reducing
engine noises and extending engine life.
6. To form a good seal between piston rings and cylinder walls.
Engine Lubrication:
Functions are:
• Lubrication of the rotor bearings
• Lubrication of the gears and bearings of the gearboxes
• Cooling of the bearings especially in the turbine area
• Removal of the contaminants from the lubricant
• Support of the sealing of the carbon bearing seals
• Supplying of a squeeze film between the bearing outer races and their
housings for oil dampened bearings.
Properties of Engine Oil
The main characteristics of engine oil are:
Engine Lubrication System
• Viscosity
• Pour point
• Flash point
• Pressure resistance
• Oxidation resistance
• Thermal stability
S A E number: The society of automotive engineers (S A E) rates oil
viscosity in two different ways, for winter and for other than winter.
Winter grade oils are tested at 00and 2100 F. There are 3 grades, SAE SW,
SAE 10W and SAE 20W. The W indicates the oil is winter grade. For
other than winter the grades are SAE 20, SAE 30, SAE 40 and SAE 50,
all without the W suffix. Some oil had multiple ratings which mean they
are equivalent in viscosity, to several rating oils.
For example – SAE 30W oil is comparable to SAE 10W, SAE 20W and
SAE30W oil.
Types of lubrication system:
The various systems of lubrication adopted in automobiles are
1. Petroil lubricating system
2. Splash lubricating system
3. Forced feed lubricating system
4. Dry sump lubricating system.
Petroil lubricating system:
This system of lubrication is generally adopted in two stroke petrol engines like scooters, mopeds and motor cycles. It is
the simplest form of lubricating system. It does not consist of any separate part like oil pump for the purpose of
lubrication. The lubricating oil is mixed into the petrol itself while filling in the petrol tank of the vehicle, in a specified
ratio. When the fuel goes into the crank chamber during the engine operation, the oil particles go deep into the bearing
surfaces and lubricate them. The piston rings, cylinder walls, piston pin etc. are lubricated in the same way.
If the engine is allowed to remain unused for a considerable time, the lubricating oil separates off from petrol and leads
to clogging of passages in the carburetor, resulting in the engine starting trouble.
Splash Lubrication system:
In this system of lubrication, the lubricating oil is stored in an oil
trough or sump. A scoop or dipper is made in the lowest part of
connecting rod. When the engine runs, the dipper dips in the oil once
in every revolution of the crankshaft and causes the oil to splash in
the cylinder walls. This action effects the lubrication of the engine
walls, piston rings, crankshaft bearings and big end bearings. Splash
system mostly works in connection with the pressure system in an
engine, some ports being lubricated by splash system and other by
pressure system.
Splash Lubrication system
Pressure system
In this system of lubrication, the engine ports are lubricated under pressure feed. The lubricating oil is stored in a
separate tank on the sump, from where an oil pump takes the oil through a strainer and delivers it through a filter to
the main oil gallery at a pressure of 2-4 kg/cm2. The oil from the main gallery, goes to the main bearings, falls back
to the sump, some is splashed to lubricate the cylinder walls and the remaining goes through a hole to the crankpin.
From the crankpin it goes into the piston pin through a hole in the connecting rod web, where it lubricates the
piston rings.
For lubricating camshaft and timing gears, the oil is led through a separate oil line from the oil gallery. The valve
tappets are lubricated by connecting the main oil gallery to the tappet guide surfaces through drilled holes. An oil
pressure gauge at the instrument panel indicates the oil pressure in the system clear off the oil from dust metal
particles and other harmful particles.
Dry Sump Lubricating System:
The system in which the lubricating oil is stored in the oil sump is called
wet sump system, like the pressure system. But the system in which the
lubricating oil is not kept in the oil sump is known as dry sump system. In
this system the oil is carried and separate tank from where it is fed to the
engine. The oil which falls into the oil sump after lubrication is sent back to
the oil tank by a separate delivery pump. The system consists of two
pumps, one to feed the oil and the other to deliver it back to the oil tank.
This system is used in saturation where the vehicle has to change its
position continuously, like in air crafts. The main advantage of this system
is that there is no chance of break down the oil supply during up and down
movement of the vehicle.
Function of oil filters
The main function of the oil filters is to filter out the dirt or grit particles from the oil. The oil
filters clears the dust particles settled in the oil through the burning of the fuel. Thus the oil
filters are helpful to clean the various parts of an engine from dust and dirt.
Types of filtering systems
There are two types of filtering systems. They are
1. Full flow system
2. By pass flow system.
In Bypass filter system, the whole of the oil does not pass through the filter at the same time,
but some of the oil without being filtered goes to the bearings. Remaining oil passes through
the filter and then goes to bearings. When the engine is running continuously for a long period,
the whole oil is however filtered.
In full flow system, the whole oil passes first through the filters and then goes to the bearings.
If the filter is clogged due to any reason, the system fails completely and bearings would be
starved.
Types of filtering elements
Different types of filtering elements are used in automotive engines.
1. Cartridge type
2. Edge type
3. Centrifugal type.
The Cartridge type consists of a filtering element placed in a metallic casing. The casing has inlet and outlet oil pump
enters casing through the filtering element, which takes up all the impurities. The filtered oil then comes out from the
casing and goes to the oil gallery.
The filtering element may be cleared when clogged. The Edge type filtering element consists of a number of discs in
a casing through which the oil passes. The alternate discs are mounted over a spindle and discs, between these are
fixed to a separate square rod. The clearance between the discs is only a few thousand of centimeter. When the oil
flows through this small clearance, it leaves impurities on the disc peripherals.
The Centrifugal type consists of a stationary casing, rotor casing, central spindle and tubes with jets. The important
oil enters the hollow central spindle and through holes around its periphery, the oil goes to the rotor casing. From the
rotor casing the oil goes in the tubes, at the ends of which jets under pressure, the reaction of which gives the motion
to the rotor casing so that it starts rotating. The oil from the jets impinges on the walls of the stationary casing under
heavy pressure, where the impurities are retained and the clean oil falls below which is taken for use. The filter walls
are cleared periodically.
cartridge type oil filters
Centrifugal oil filter
Edge type oil filter
Pumps
The type of pump used varies. Gear pumps, trochoid pumps and vane pumps[a] are all commonly
used. Plunger pumps have been used in the past, but these are now only used rarely, for small
engines.

To avoid the need for priming, the pump is always mounted low-down, either submerged or around
the level of the oil in the sump. A short pick-up pipe with a simple wire-mesh strainer reaches to the
bottom of the sump.
Pump drive
For simplicity and reliability, mechanical pumps are used, driven by mechanical geartrains from the crankshaft.
Reducing pump speed is beneficial[b] and so it is usual to drive the pump from the cam (if this is mounted in the
cylinder block) or distributor shaft, which turns at half engine speed. Placing the oil pump low-down uses a near-
vertical drive shaft, driven by helical skew gears from the camshaft. Some engines, such as the Fiat Twin Cam
engine of 1964, began as OHV engines with an oil pump driven from a conventional camshaft in the cylinder
block. When the twin overhead cam engine was developed, the previous oil pump arrangement was retained
and the camshaft became a shortened stub shaft. Even when the distributor position was moved from the
previous block-mount to being mounted on the cylinder head camshafts, the oil pump drive remained in the
same position, the unused distributor position now covered by a blanking plate.[4] Small engines, or scooters
may have internal gear pumps mounted directly on their crankshaft.

For reliability, it is rare to use an external drive mechanism, either a separate belt drive or external gears,
although camshaft-driven pumps often rely on the same timing belt. Additional separate belts are sometimes
used where dry sump pumps have been added to engines during tuning.

Electric oil pumps are not used, again for reliability. Some 'turbo timer' electric auxiliary oil pumps are sometimes
fitted to turbocharged engines. These are a second oil pump that continues to run after the engine has stopped,
providing cooling oil to the hot bearings of a turbocharger for some minutes, whilst it cools down.[c] These are
supplementary pumps and do not replace the main, mechanical, oil pump.
Crank case ventilation: Crankcase blow-by is produced when combustion gases under high pressure are blown passed
the piston rings into the crankcase. As these blow-by gases pass though the crankcase, they become contaminated. The
Crankcase Ventilation System removes these contaminations. The exhaust can then be allowed to vent to the
atmosphere.
For applications requiring more stringent emissions requirements, a closed crankcase filter is recommended. In this
application, the exhaust from the crankcase filter is routed to the inlet side of the turbo. A regulator in the crankcase
filter controls the vacuum in the crankcase to ensure proper operation.
Tools and Equipments at specialist Repair Shop
At specialist repair shop, in addition to the Tools and equipments of a garage,
the following specialized equipments are also found available.

1.Engine Analyzer 7.Brake drum turning Lathe

2.Cylinder Reboring machine. 8.Brake shoe riveting machine
3.Crank shaft Turning Machine 9.Fuel Injection pump testing machine
4.Crank shaft grinder 10.Fuel Injector tester.
5.Valve refacing machine 11.Spark plug tester
6.Valve grinding machine 12.Ignition timing tester etc.,
Fluids checklist Lights checklist
1. Engine oil 1. Headlights
2. Radiator coolant 2. Indicators/hazard lights
3. Brake fluid 3. Brake lights
4. Power steering fluid 4. Reverse lights
5. Windscreen washer fluid 5. Park & Fog lights
6. Clutch fluid (manual cars) Other general things to check
7. Gearbox oil 1. Radiator hoses – check for leaks and cracking
8. Differential fluid 2. Engine air filter – check that it is clean
Tyres checklist 3. Battery – look for corrosion around terminals
1. Tyre pressures 4. Fan belts – ensure none are loose or squeaking
2. Treadwear and tread depth on start-up
3. Spare tyre 5. Unusual engine noises – hard to start, ticking,
4. Car jack and tools hissing or clunking
Decarbonisation
In simple terms, decarbonising an engine involves removal of carbon deposits
from the engine, using either mechanical (physical) or chemical methods.
Decarbonisation
Opening up the cylinder head of a two-stroke engine is a relatively simple
procedure. This isn't the case however, with modern 4-stroke engines and their
overhead camshaft(s), injectors, multiple sensors and electronics. There is a lot
that can go wrong in the hands of an incompetent mechanic. Therefore, the
perceived need for chemical decarbonisation.

The procedure of mechanically cleaning out carbon deposits entails removal of

the cylinder head and then, physically scraping off carbon deposits from the top
of the pistons, the combustion chamber and other components (e.g. valves).
Two-stroke engines of yore needed frequent decarbonising as the lubricating oil
(2-T oil, in common parlance) burnt in the combustion chamber, leaving behind
carbon residue.
Cylinder Reboring
Reboring is done by the reboring machine in which a single point cutter
which is set to exact diameter required with special micrometer. The cutter
blade shaft is mounted inside a column which moves up and down its
housing in the fixed part of the machine for tool feeding purpose.
The top surface of the cylinder block is thoroughly cleaned and the boring
bar set at one of the cylinder bores. After completing boring the cylinder
must be washed thoroughly to remove all abrasive particles.
Nitriding of Crank shaft:
Nitriding is a heat treating process that diffuses nitrogen into the
surface of a metal to create a case-hardened surface. These processes
are most commonly used on low-carbon, low-alloy steels. They are
also used on medium and high-carbon steels, titanium, aluminium and
molybdenum. In 2015, nitriding was used to generate unique duplex
microstructure (Martensite-Austenite, Austenite-ferrite), known to be
associated with strongly enhanced mechanical properties.