Experiment # 02

Objective:
To familiarize with the different components four stroke diesel engine and study its working
principle
Introduction:
The diesel cycle is a thermodynamic cycle that describes the operation of diesel engines,
widely used in heavy-duty vehicles, industrial machinery, and power generation. Unlike
petrol engines that use spark ignition, diesel engines rely on compression ignition. The
cycle consists of four stages: intake, compression, power, and exhaust.
During the intake stroke, air is drawn into the cylinder. In the compression stroke, the
piston compresses the air to a high pressure, raising its temperature significantly. At the
end of this stroke, diesel fuel is injected directly into the hot compressed air, igniting
spontaneously due to the high temperature—a defining characteristic of the diesel cycle.
The power stroke follows, where the rapid combustion forces the piston down,
generating mechanical energy. Finally, the exhaust stroke expels spent gases from the
cylinder. The diesel cycle is known for its efficiency and high torque, making it suitable
for applications requiring durability and power, such as trucks, ships, and construction
equipment.
Apparatus:
Cut out model of four stroke diesel engine
Main Parts
 Cylinder Block
 Piston
 Cylinder head
 Connecting rod
 Crankshaft
 Oil sump
 Camshaft
 Valves
Labelled diagram of Diesel Engine

Labelled diagram of 4-stroke diesel engine

Internal Combustion Engine:
An internal combustion engine (ICE) is a type of engine where fuel is burned within a
combustion chamber, converting chemical energy into mechanical energy. This process
involves the intake of air and fuel, compression, ignition, and the expansion of gases, which
drives a piston. ICEs are commonly found in vehicles, generators, and machinery, and they
can operate on various fuels, including petrol, diesel, and natural gas, offering efficient
power generation and mobility.
Classifications of Internal Combustion Engine:
Internal combustion engines (ICEs) can be classified based on the number of strokes in their
operation:
1. 2-Stroke Engines: Complete a power cycle in two strokes of the piston (one
crankshaft revolution). They are typically lighter and have a simpler design but can
be less fuel-efficient and produce more emissions.
2. 4-Stroke Engines: Complete a power cycle in four strokes of the piston (two
crankshaft revolutions). They offer better fuel efficiency, lower emissions, and more
power consistency, making them common in automobiles and larger machinery.
Internal combustion engines convert the chemical energy in the fuel (gasoline, diesel fuel,
LPG, natural gas, etc.) into mechanical energy. The fuel produces heat energy by engaging
in a chemical reaction with the air in the engine's combustion chamber. The heat produced
increases the gas pressure in the combustion chamber, which causes the piston to move.
Engines can be further classified based on the following criteria:
 Fuel Type
 Cylinder Arrangement
 Operation Time
 Mixture Formation
 Type of Ignition (Spark-Ignition or Compression-Ignition)
 Cooling Technique (Air-Cooled or Water-Cooled)
 Cylinder Filling Method (Naturally Aspirated, Turbo-Charged or Supercharged)
 Valve Arrangement
 Number of Cylinders (single cylinder or multiple cylinder)

Types of ignitions
Internal combustion engines use two ignition types: Spark Ignition (SI), found in petrol
engines, uses a spark plug, while Compression Ignition (CI), in diesel engines, relies on heat
from compression.

Spark Ignition (SI):

Spark ignition (SI) is a method used in petrol
engines to ignite the air-fuel mixture within the
combustion chamber. In an SI engine, the fuel is
mixed with air and drawn into the cylinder
during the intake stroke. As the piston rises
during the compression stroke, the mixture is
compressed, increasing its temperature and
pressure. At the optimal moment, a spark plug
generates an electrical spark, igniting the
compressed mixture. This combustion rapidly
expands, pushing the piston down during the power stroke, converting chemical energy into
mechanical energy.
SI engines are characterized by their smooth operation, high RPM capabilities, and
responsiveness, making them ideal for light-duty vehicles. They generally produce lower
emissions compared to diesel engines but can be less fuel-efficient. The ignition timing and
air-fuel ratio are crucial for performance and efficiency, and modern SI engines often utilize
advanced technologies like fuel injection and electronic control systems to optimize these
parameters.
Compression Ignition (CI):
Compression ignition (CI) is the ignition method used primarily in diesel engines. In this
process, air is drawn into the cylinder and compressed to a very high pressure during the
compression stroke. This compression significantly raises the air temperature, reaching
levels sufficient to ignite fuel without the need for a spark plug. Once the piston reaches the
top of the stroke, diesel fuel is injected directly into the hot, compressed air. The heat from
the air ignites the fuel almost instantly, causing rapid combustion that forces the piston
downward during the power stroke.
CI engines are known for their fuel efficiency, durability, and high torque output, making
them ideal for heavy-duty applications such as trucks, buses, and industrial machinery.
However, they typically produce higher emissions of nitrogen oxides (NOx) and particulate
matter compared to spark ignition engines. Advances in fuel injection technology and after-
treatment systems are continually improving the environmental performance of CI engines.
Engine Working Cycle
The engine working cycle refers to the sequence of events in an internal combustion engine
that converts fuel into mechanical energy. In a typical 4-stroke engine, the cycle consists of
four stages: intake, compression, power, and exhaust.
1. Intake Stroke: The intake valve opens, and the piston moves down, drawing a fuel-
air mixture into the cylinder.
2. Compression Stroke: The intake valve closes, and the piston moves up,
compressing the mixture, which raises its temperature and pressure.
3. Power Stroke: At the peak of compression, a spark plug ignites the mixture (in
spark ignition engines) or fuel is injected into hot air (in diesel engines). The rapid
expansion of gases forces the piston down, generating power.
4. Exhaust Stroke: The exhaust valve opens, and the piston moves up again, expelling
the burnt gases from the cylinder.
This cycle repeats continuously, enabling the engine to produce power efficiently and
effectively.
Four-stroke cycle:
A 4-stroke engine is a type of internal combustion engine that completes a power cycle in
four distinct strokes of the piston, resulting in two revolutions of the crankshaft. This design
is widely used in various applications, from automobiles to industrial machinery, due to its
efficiency and reliability.
The cycle begins with the intake stroke. During this phase, the intake valve opens, and the
piston moves down the cylinder, drawing in a mixture of air and fuel. This mixture is
crucial for the combustion process.
Next is the compression stroke. The intake valve closes, and the piston moves back up the
cylinder, compressing the air-fuel mixture. This compression raises the mixture’s
temperature and pressure, making it more volatile and ready for ignition.
The third phase is the power stroke. At the peak of compression, a spark plug ignites the
compressed mixture in petrol engines (or fuel is injected in diesel engines). The rapid
expansion of gases from this combustion forces the piston down, generating mechanical
work that powers the vehicle or machinery.
Finally, the exhaust stroke occurs. The exhaust valve opens, and the piston moves back up
the cylinder, pushing out the spent gases from the combustion process. Once this stroke is
complete, the cycle starts again with the intake stroke.
Number of cylinders
The number of cylinders in an internal combustion engine (ICE) significantly affects its
performance and characteristics. More cylinders generally provide greater power output and
torque, enhancing acceleration and responsiveness. They contribute to smoother operation
by generating more frequent power strokes, reducing vibrations. Additionally, a higher
cylinder count can improve combustion efficiency, leading to better fuel economy and
lower emissions. However, more cylinders often result in increased engine size, weight, and
complexity, which can impact costs and maintenance. Ultimately, the number of cylinders is
a crucial factor in balancing performance, efficiency, and vehicle design.
Single Cylinder:
A single-cylinder internal combustion engine (ICE) consists of one
cylinder where all combustion processes occur. This design is
prevalent in small machinery, motorcycles, and portable
equipment due to its simplicity and compactness.
One of the key advantages of single-cylinder engines is their
lightweight structure, making them easy to transport and install.
Their fewer components contribute to lower manufacturing and
maintenance costs, making them cost-effective choices for various
applications.
However, single-cylinder engines can exhibit noticeable vibrations
and less smooth power delivery compared to multi-cylinder
engines, as they generate power in fewer strokes. While they are
typically fuel-efficient for low-speed operations, efficiency may
decline under heavier loads or higher RPMs.
Multi-cylinder Engine:
A multi-cylinder internal combustion engine features two or more
cylinders, allowing for smoother operation and greater power
output. Each cylinder completes its combustion cycle at different
times, providing a continuous flow of power and reducing
vibrations. This design enhances performance, responsiveness, and
torque, making it suitable for automobiles and heavy machinery.
Multi-cylinder engines can be configured in various arrangements,
such as inline, V, or flat. They also typically offer better fuel
efficiency and emissions control compared to single-cylinder
engines. While more complex and costly, multi-cylinder engines
are favored for their balance of power and refinement in driving
experiences.
In-Line:
An inline multi-cylinder engine features cylinders arranged in a straight line. This
configuration is commonly used in four-cylinder and six-cylinder engines, providing a
compact design that promotes efficient engine cooling and balance. Inline engines offer
smooth power delivery and are relatively simple to manufacture and maintain. They are
popular in a wide range of vehicles, from compact cars to larger sedans, due to their good
performance and fuel efficiency.
V Engine:
A V engine features cylinders arranged in two banks forming a "V" shape, allowing for a
more compact design. This configuration enhances power output and performance while
maintaining a shorter engine length. V engines are often found in high-performance and
luxury vehicles, typically ranging from V6 to V12 configurations. They provide smooth
operation and higher torque, making them suitable for demanding applications while
offering a distinctive sound and driving experience.
Opposed Cylinder Engine:
An opposed cylinder engine, also known as a flat or horizontally opposed engine, features
cylinders arranged in two banks facing away from each other. This configuration helps to
lower the engine's center of gravity, improving vehicle stability and handling. Commonly
used in aircraft and some automobiles, opposed engines are known for their smooth
operation and reduced vibrations. Their compact design also allows for efficient cooling and
contributes to better aerodynamics in certain applications.
W engine:
A W engine, also known as a Wankel or rotary engine, features a unique design where a
triangular rotor rotates within an oval chamber. This configuration allows for continuous
combustion and power delivery, resulting in fewer moving parts compared to traditional
piston engines. W engines are compact, lightweight, and produce high power relative to
their size. Commonly used in sports cars and aircraft, they offer smooth operation but may
have higher fuel consumption and emissions.
Opposed piston engine:
An opposed piston engine features two pistons within a single cylinder, moving in opposite
directions. This design eliminates the need for a cylinder head, allowing for more efficient
combustion and reduced weight. Commonly used in high-performance applications, such as
military and some commercial engines, opposed piston engines offer improved power
output and thermal efficiency. They also have fewer moving parts, which can enhance
reliability and reduce maintenance requirements compared to traditional piston engines.

Description of main Parts:

Cylinder Block:
The cylinder block is a key component of an internal
combustion engine (ICE), housing the cylinders where
combustion occurs. It serves as the foundation for the
engine, providing structural support for various parts,
including pistons, crankshaft, and camshaft. Typically
made from cast iron or aluminum, the cylinder block
contains coolant passages for effective cooling and oil
channels for lubrication. It also incorporates mounting
points for accessories like the intake and exhaust
manifolds. The design and construction of the cylinder
block significantly influence the engine's performance,
durability, and overall efficiency, making it a critical
element in engine design.
Cylinder Head:
The cylinder head is a crucial component of an internal
combustion engine (ICE), located on top of the cylinder
block. It seals the combustion chamber, housing vital
parts such as the intake and exhaust valves, spark plugs
(in petrol engines), and fuel injectors (in diesel engines).
The cylinder head facilitates the flow of air and fuel into
the combustion chamber while allowing exhaust gases to
exit. Its design influences engine performance,
efficiency, and thermal management. Typically made
from cast iron or aluminum, the cylinder head must
withstand high temperatures and pressures, making its
construction and design critical for overall engine
durability and performance.
Piston:
The piston is a critical component in an internal combustion engine (ICE)
that converts the energy from combustion into mechanical work. It is a
cylindrical metal piece that moves up and down within the cylinder,
creating pressure during the compression stroke and transferring force
during the power stroke. As fuel ignites, the expanding gases push the
piston down, turning the crankshaft and generating power. Pistons are
typically made from lightweight alloys to withstand high temperatures
and pressures. They also have rings that create a seal against the cylinder
walls, preventing gas leakage and maintaining efficiency while reducing
oil consumption.
Connecting Rod:
The connecting rod is a vital component in
an internal combustion engine (ICE) that
links the piston to the crankshaft. It
converts the linear motion of the piston into
the rotational motion of the crankshaft.
Typically made from forged steel or
aluminum alloys for strength and
lightweight, the connecting rod features a
large end that connects to the piston and a
small end that attaches to the crankshaft.
This component is designed to withstand
high stress and vibrations during operation.
Proper design and material choice for connecting rods are essential for the engine's
performance, reliability, and longevity.
Crankshaft:
The crankshaft is a crucial component
in an internal combustion engine (ICE)
that converts the linear motion of the
pistons into rotational motion.
Positioned at the bottom of the engine,
it consists of a series of journals and
crankpins, which allow it to rotate
while supporting the pistons via
connecting rods. The crankshaft plays a
key role in powering the vehicle by
transmitting torque to the transmission
and ultimately to the wheels. Typically made from forged steel or cast iron for strength and
durability, its design and balance are essential for smooth operation, minimizing vibrations,
and ensuring engine efficiency.
Oil Sump:
The oil sump, also known as the oil pan, is a
vital component of an internal combustion
engine (ICE) that stores engine oil. Located
at the bottom of the engine block, it acts as a
reservoir for lubrication, cooling, and
cleaning the engine's moving parts. The
sump collects oil that drains down from the
engine, ensuring a constant supply for the
oil pump to circulate. It also helps to
dissipate heat generated during operation.
Typically made from stamped steel or aluminum, the oil sump is designed to withstand
pressure and temperature variations, contributing to the engine’s overall performance and
longevity.
Camshaft:
The camshaft is a critical component
in an internal combustion engine
(ICE) that controls the timing of the
opening and closing of the intake and
exhaust valves. It consists of a
rotating shaft with lobes that push
against valve lifters, translating
rotational motion into linear
movement for the valves. Proper
camshaft design affects engine
performance, efficiency, and power
output by determining valve timing and duration. Typically made from forged steel or cast
iron, the camshaft can be located in the engine block (overhead valve design) or in the
cylinder head (overhead cam design). Its precision and durability are essential for optimal
engine operation.
Valves:
Valves in an internal combustion engine (ICE) regulate the flow of air-fuel mixtures into the
combustion chamber and exhaust gases out of it. There are two main types: intake valves
and exhaust valves. Intake valves open to allow the air-fuel mixture into the cylinder during
the intake stroke, while exhaust valves open to release spent gases after combustion.
Typically made from heat-resistant materials like steel, valves are operated by the camshaft,
which controls their timing and duration. Proper valve operation is crucial for engine
performance, efficiency, and emissions control, significantly impacting overall engine
power and responsiveness.
Piston Rings:
Piston rings are essential components in
an internal combustion engine (ICE) that
fit into grooves on the piston. They serve
multiple critical functions, including
sealing the combustion chamber to
prevent gas leakage, controlling oil
consumption by scraping excess oil off
the cylinder walls, and aiding in heat
transfer from the piston to the cylinder
wall. Typically made from cast iron or steel, piston rings come in various designs, including
compression rings and oil control rings. Proper functioning of piston rings is crucial for
maintaining engine efficiency, performance, and longevity, as they help ensure optimal
compression and reduce emissions.
Gaskets:
Gaskets are critical components in an internal
combustion engine (ICE) that create a seal
between two surfaces, preventing fluid and gas
leaks. They are typically made from materials
like rubber, cork, or metal, designed to
withstand high temperatures and pressures.
Gaskets are used in various locations,
including between the cylinder head and the
engine block, oil pans, and intake manifolds.
Proper sealing is essential for maintaining engine performance, efficiency, and reliability, as
leaks can lead to oil loss, coolant contamination, or exhaust emissions. Overall, gaskets play
a vital role in ensuring the integrity and functionality of the engine.
Gudgeon Pin:
The gudgeon pin, also known as the wrist pin, is a vital component in an internal
combustion engine (ICE) that connects the piston to the connecting rod. It allows the piston
to pivot as it moves up and down in the cylinder, converting the linear motion of the piston
into the rotational motion of the crankshaft. Typically made from high-strength steel or
aluminum, the gudgeon pin must withstand significant stress and high temperatures. Proper
design and lubrication are essential to reduce friction and wear, ensuring the smooth
operation of the engine and contributing to its overall efficiency and longevity.
Engine Bearing:
Engine bearings are crucial components in an
internal combustion engine (ICE) that provide
support and reduce friction between moving
parts, such as the crankshaft, connecting rods,
and camshaft. They are typically made from
materials like aluminum, designed to withstand
high loads and temperatures. Bearings facilitate
smooth rotation and help maintain proper
alignment of engine components, which is
essential for efficient operation. They also aid
in heat dissipation and oil retention. Proper
lubrication and maintenance of engine bearings
are vital to prevent wear, ensure longevity, and enhance overall engine performance and
reliability.
Fuel Pump:
The fuel pump is a critical component in an internal combustion engine (ICE) that delivers
fuel from the tank to the engine at the required pressure. There are two main types:
mechanical pumps, which are typically driven by the engine, and electric pumps, which use
an electric motor to operate. The fuel pump ensures a consistent flow of fuel to the
carburetor or fuel injectors, enabling optimal combustion. Proper functioning of the fuel
pump is essential for engine performance, responsiveness, and efficiency. If the fuel pump
fails, it can lead to engine stalling, poor acceleration, or starting difficulties.
Fly Wheel:
The flywheel is an important component in an internal combustion engine (ICE) that stores
rotational energy and helps maintain consistent engine speed. Located at the rear of the
crankshaft, it acts as a stabilizer by smoothing out the power delivery from the engine,
reducing fluctuations caused by the combustion process. The flywheel's mass allows it to
absorb excess energy during the power stroke and release it during the exhaust and intake
strokes. Additionally, it provides inertia for starting the engine and helps in the operation of
the clutch in manual transmissions. Overall, the flywheel enhances engine efficiency and
performance.
Carburetor:
The carburetor is a key component in an internal combustion engine (ICE) that mixes air
and fuel in the correct ratio for combustion. It operates by creating a vacuum that draws fuel
from the float chamber into the airstream, atomizing it for efficient mixing with air. The
carburetor includes adjustable jets to control fuel flow and throttle valves to regulate
airflow, enabling precise control of engine power and speed. While modern vehicles often
use fuel injection systems for better efficiency and emissions control, carburetors remain
common in small engines, older vehicles, and certain performance applications due to their
simplicity and ease of tuning.
Spark Plug:
The spark plug is a crucial component in internal combustion engines (ICE) that utilize
spark ignition. Its primary function is to ignite the air-fuel mixture in the combustion
chamber at the precise moment for optimal power generation. The spark plug consists of a
ceramic insulator, a metal shell, and electrodes that create a spark when voltage is applied.
This spark initiates combustion, generating the pressure needed to drive the piston down.
Spark plugs must withstand high temperatures and pressures, requiring materials that resist
wear and fouling. Proper functioning of spark plugs is vital for engine efficiency,
performance, and emissions control.

Working Principle of Petrol Engine:

The working principle of a petrol engine, specifically a 4-stroke spark ignition engine,
involves four distinct strokes: intake, compression, power, and exhaust, which collectively
convert fuel into mechanical energy.

1. Intake Stroke: The cycle begins with the intake stroke. The intake valve opens as
the piston moves down the cylinder, creating a vacuum that draws a mixture of air
and petrol into the combustion chamber. This mixture is essential for combustion.
2. Compression Stroke: Once the piston reaches the bottom of its travel, the intake
valve closes. The piston then moves upward, compressing the air-fuel mixture. This
compression raises the mixture’s temperature and pressure, making it more volatile
and ready for ignition. The spark plug is positioned at the top of the cylinder for
optimal ignition timing.
3. Power Stroke: At the peak of the compression stroke, the spark plug generates a
spark, igniting the compressed air-fuel mixture. The rapid expansion of gases from
this combustion pushes the piston down during the power stroke, converting
chemical energy into mechanical energy. This downward movement of the piston
turns the crankshaft, generating power for the vehicle.
4. Exhaust Stroke: After the power stroke, the exhaust valve opens, and the piston
moves back up the cylinder, expelling the spent gases from the combustion process.
This clears the cylinder for the next cycle.

Conclusion:
In conclusion, diesel engines are a fundamental technology in various sectors, known for
their efficiency, durability, and high torque output. Operating on the diesel cycle, these
engines utilize compression ignition, which allows them to achieve higher thermal
efficiency compared to petrol engines. This efficiency translates into lower fuel
consumption and longer range, making diesel engines particularly suitable for heavy-duty
vehicles, such as trucks, buses, and construction equipment.
Diesel engines also excel in industrial applications and power generation, where reliability
and performance are paramount. Their robust construction can withstand high pressures and
temperatures, contributing to a longer lifespan. While they are often praised for their
advantages, diesel engines face scrutiny due to emissions concerns, particularly nitrogen
oxides (NOx) and particulate matter.
Recent advancements in technology, including turbocharging, intercooling, and after-
treatment systems, aim to reduce emissions and enhance performance. Additionally, the rise
of alternative fuels, such as biodiesel, presents opportunities for more sustainable diesel
engine operation. As regulations continue to evolve, diesel engines are adapting to meet
environmental standards while maintaining their critical role in transportation and industry.
Ultimately, diesel engines remain a vital component of the global economy, balancing
power and efficiency in an increasingly demanding world.