ENGINEERING

FUNDAMENTAL
Presenting By,
S OF IC ENGINE
Karthick S,
Senior Service Engineer,
Maheshwari Mining Private Limited.
 Engine is a Mechanical Component,
designed to convert one or more forms
of energy into Mechanical Energy.

What Is Engine also called as,

Machine
Motor
Engine? Convertor
Prime mover
Transformer
Etc.,
 Stem Engine:
In 1698 Thomas Savery patented a pump with
hand-operated valves to raise water from mines by

Inventio suction produced by condensing steam. In about

1712 another Englishman, Thomas Newcomen,
developed a more efficient steam engine with a

n of
piston separating the condensing steam from the
water. In 1765 James Watt greatly improved the
Newcomen engine by adding a separate condenser
to avoid heating and cooling the cylinder with each

Engine stroke. Watt then developed a new engine that

rotated a shaft instead of providing the simple up-
and-down motion of the pump, and he added many
other improvements to produce a practical power
plant
 Diesel Engine
• In the 1870s, steam was the main supplier of power for
factories and trains.
• Rudolf Diesel was a student learning about
thermodynamics at the time, and he got the idea for
creating an engine that would be highly efficient and

Invention
convert the heat it generated into power. He got to work
developing what would become the diesel engine.
• He set up his first shop in 1885 to start the development
of this new engine and to put his theories into practice.

of Engine One of his hypotheses was that higher amounts of

compression would lead to higher efficiency and power.
• Diesel received patents for his designs during the 1890s.
The first diesel engine prototype was built in 1893,
though the first engine test was unsuccessful, so it was
back to the drawing board.
• In 1897, Diesel produced successful results after many
improvements and tests. In February of that year, he was
able to show an efficiency of 26.2% with the engine.
Compared with the steam engine popular at the time, the
engine Diesel had developed was more efficient by
16.2%.
 Any engine that converts thermal energy to
mechanical work output. Ex: steam engine,
steam power plant, jet engine, gas turbine
power plant, diesel engine, and gasoline
HEAT (petrol) engine etc.
ENGINE Based on how thermal energy is being
delivered to working fluid of the heat engine,
Heat engine can be classified as
• Internal Combustion (IC) Engine
• External Combustion Engine
 • In an Internal combustion engine, combustion takes place within
working fluid of the engine, thus fluid gets contaminated with
combustion products.

Classificatio – Petrol engine is an example of internal combustion engine,

where the working fluid is a mixture of air and fuel .

n • In an External combustion engine, working fluid gets energy using

boilers by burning fossil fuels or any other fuel, thus the working fluid
does not meet combustion products.
– Steam engine is an example of external combustion engine,
where the working fluid is steam.
 Internal combustion engines may be classified as :
– Spark Ignition engines.
– Compression Ignition engines.

Internal • Spark ignition engine (SI engine): An engine in which the combustion
process in each cycle is started by use of an external spark.

combustion • Compression ignition engine (CI engine): An engine in which the

combustion process starts when the air-fuel mixture self ignites due to

engine
high temperature in the combustion chamber caused by high
compression.
– Spark ignition and Compression Ignition engine operate on
either a four-stroke cycle or a two-stroke cycle.
 • Four stroke cycle : It has four piston strokes
Internal over two revolutions for each cycle.
combustion • Two stroke cycle : It has two piston strokes
over one revolution for each cycle.
engine
Internal Combustion Engines
– Two Stroke -
 Internal Combustion Engines
– Four Stroke -

2. compression
1. intake
starting position
a. piston moves up
a. piston starts moving b. both valves
down closed
b. intake valve opens c. air-fuel mixture
c. air-fuel mixture gets in gets compressed
 Internal Combustion Engines
– Four Stroke -

4. exhaust
ignition 3. power
a. piston moves up
a. air-fuel mixture b. exhaust valve
explodes driving the opens c. exhaust
piston down leaves the cylinder
Engine
• Top Dead Center (TDC): Position of the • Bottom Dead Center (BDC):
piston when it stops at the furthest point Position of the piston when it stops
away from the crankshaft. at the point closest to the
crankshaft.
Terminolog – Top because this position
is at the top of the engines
(not always), and dead
– Some sources call this
Crank End Dead

y because the piston stops as

this point. Because in
some engines TDC is not
Center (CEDC)
because it is not
always at the bottom
at the top of the of the engine. Some
source call this point
engines(e.g: horizontally opposed
Bottom Center (BC).
engines, radial engines,etc,.) Some sources
call this position Head End Dead Center • Stroke : Distance traveled by the
(HEDC). piston from one extreme position
– Some source call this to the other : TDC to BDC or BDC
point TOP Center (TC). to TDC.

– When the piston is at • Bore :It is defined as cylinder

TDC, the volume in the diameter or piston face diameter;
cylinder is a minimum piston face diameter is same as
called the clearance cylinder diameter( minus small
volume. clearance).
 • •
Engine Swept
volume/Displacement
volume : Volume displaced
Clearance volume : It is
the minimum volume of
the cylinder available for
Terminolog by the piston as it travels
through one stroke.
the charge (air or air fuel
mixture) when the piston
y – Swept volume is
defined as stroke
reaches at its outermost
point (top dead center or
times bore. outer dead center) during
compression stroke of the
– Displacement can cycle.
be given for one
– Minimum
cylinder or entire
volume of
engine (one
combustion
cylinder times
chamber with
number of
piston at
cylinders).
TDC.
Engine
Terminology
• Compression ratio : The
ratio of total volume to
clearance volume of the
cylinder is the compression
ratio of the engine.
– Typically,
compression ratio
for SI engines
varies from 8 to
12 and for CI
engines it varies
from 12 to 24
CLASSIFICATION 1. According to thermodynamic
cycle
5. According to type of fuel used
i. Petrol

OF INTERNAL i. Otto cycle

ii. Diesel cycle
ii. Diesel
iii. Gas
COMBUSTION iii. Dual combustion iv. Bio fuel

ENGINES
cycle
6. According to position of
2. According to number of cylinder
strokes v. Horizontal engine
i. Two stroke vi. Vertical engine (car,
ii. Four stroke bus, truck engines)
vii.Vee engine
3. According to number of viii.Opposed cylinder
cylinders engine
i. Single cylinder
engine 7. According to method of cooling
ix. Air cooling
ii. Multi cylinder
engine x. Water cooling
xi. Liquid cooling
4. According to method of
ignition 8. According to speed of engine
i. Spark ignition xii.Slow speed engine
(petrol) xiii.Medium speed
ii. Compression engine
ignition (diesel) xiv.High speed engine
Systems of
IC engine
• Air Intake System
Systems of
IC engine
• Fuel Supply System
Systems of IC • Exhaust Air System

engine
Systems of • Engine Cooling System

IC engine
Systems of
IC engine
• Engine Lubrication System
Parts of I.C Engine
  Cylinder  Fuel Pump and Fuel Transfer Pump

 Cylinder Head  Spark Plug or Fuel Injector

 Piston  Cooling Jackets or Fins

Parts of I.C  Piston Ring  Flywheel

Engine
 Gudgeon pin or Piston Pin  ECM and Wiring Harness

 Piston Cooling Nozzle  Sensors

 Connecting Rod  Turbocharger

 Small End and Big End Bearing  After Cooler/Inter Cooler

 Crank Shaft  Engine Oil Cooler

 Cam Shaft  Water Pump

 Crank Case  Self-starter

 Valves or Ports  Alternator

 Manifold  Fan Drive

 Push Rod  Radiator

 Rocker Arm  Lubricating Oil Pump

 1. Cylinder Block: - 2.Cylinder Head/Cylinder Cover: -

 It is a container fitted with a piston,  One end of the cylinder is closed

where the fuel is burnt, and power is utilizing a cylinder head. This consists
produced. of an inlet valve for admitting air-fuel

Parts of I.C
mixture and exhaust valve for
 Cylinder is the main body of the IC removing the products of combustion.
engine. Cylinder is a part in which the 

Engine
The inlet valve, exhaust valve, spark
intake of fuel, compression of fuel and plug, injector, etc. are bolted on the
burning of fuel take place. The main cylinder head. The main function of
function of the cylinder is to guide the the cylinder head is to seal the
piston. cylinder block and not to permit entry
and exit of gases on the cover head
 For cooling of the cylinder, a water valve engine.
jacket (for liquid cooling used in most
cars) or fin (for air cooling used in  Function: It provides the housing for
most of the bikes) is situated at the exhaust and intake valves, threaded
outer side of the cylinder. holes for the spark plugs or fuel
injector and necessary linkages,
passage for cooling jackets and
 At the upper end of the cylinder, the
passages for the fuel and air mixture.
cylinder head and at the bottom end
crankcase is bolted.  Material: Aluminium alloys

 Material: Ductile (Nodular) Cast  Manufacturing Method: Casting, Pres

Iron,30C8 (Low Carbon Steel) sure Die Casting, forming.

 Manufacturing method: Casting,

Forging and after that heat transfer,
Machining
 3. Piston:- 4. Piston Rings: -

 These are used to maintain a

 Piston is used to reciprocate pressure-tight seal between the piston

Parts of I.C
inside the cylinder. and cylinder walls, and it transfers the
heat from the piston head to cylinder
 It transmits the energy to the walls.

Engine crankshaft through the

connecting rod.  These rings are fitted in grooves that
have been cut in the piston. They are
split at one end so they can expand or
 Material: Aluminium Alloy slipped over the end of the piston.
4652 because of its Low
Specific Gravity.  Function of Piston rings:
1. To provide a pressure seal to
prevent blow-by of burnt gases.
 Manufacturing 2. To form the main path for
Method: Casting conduction of heat from the piston
crown to the cylinder walls.

 Function of Compression Ring:

To control the flow of oil to the skirt
and rings themselves in adequate
quantity while preventing an excessive
amount reaching the combustion
chamber with consequent waste and
carbonization.

 Material: cast iron of fine grain and

high elastic material

 Manufacturing Method: Pot

casting method
Parts of I.C 5. Gudgeon pin or piston pin: - 6. Piston Cooling Nozzle

 These are hardened steel  help with the thermal

Engine parallel spindles fitted management of the piston
and provide lubrication to
through the piston
the cylinder liner and the
bosses and the small end piston’s wrist pin.
bushes or eyes to allow
the connecting rods to  Material: Piston cooling
swivel. It connects the nozzle used in automobiles
piston to the connecting is made up of metals like
rod. It is made hollow for steel, aluminium. It is
lightness. manufactured by die
casting process. This is
 Material: Plain Carbon replaced by plastics
steel 10C4 material Nylon66+30GF
which are manufactured by
injection moulding process
 7. Connecting Rod: - 8. Small End and Big End Bearing:

Parts of I.C
 One end of the connecting rod is  Small end bearing attached in inside the
connected to the piston through a piston joining of the piston and connecting rod, and
pin while the other is connected to crank big end bearing is attached inside the joining
of connecting rod and crank.

Engine
through a crank pin.

 The Functions of Small End and Big End

 It transmits the reciprocator motion of Bearing:
the piston to the rotary crank.
 To provide smoother functioning between the
 There are two ends of connecting rod one piston, connecting rod and crank.
is known as the big end and other as
small end. The big end is connected to the
 To minimize power loss due to friction.
crankshaft and the small end is connected
to the piston by use of piston pin.
 Material: structure of steel back +
antifriction alloy. Antifriction alloys are
 Function: commonly used in three categories: Babbitt
1) It converts the reciprocating motion of alloy, copper-based alloy, and aluminium-
the piston into rotary motion of based alloy.
crankshaft.
2) It connects piston to the crankshaft.  Babbitt alloys are classified into tin-based
and lead-based ones. Babbitt alloys have low
 Material: Low Carbon steel 30C8 fatigue strength, low allowable specific
pressure, and low operating temperature,
and are generally used for gasoline engines
 Manufacturing Methods: Forging and with a lower degree of strengthening.
after that heat treatment.
 Copper-based alloys are classified into lead
bronze and copper-lead alloys.

 Aluminium-based alloys are divided into

high-tin alloys and low-tin alloys. Aluminium-
based alloys are currently the most widely
used in crankshaft bearings of internal
combustion engines.
 9. Crank Shaft:- 10. Cam Shaft:-

 The function of the crankshaft is to  Camshaft is used in the IC engine to

transform reciprocating motion into a control the opening and closing of valves

Parts of I.C
rotary motion. at proper timing.

 The crankshaft of an internal combustion  For proper engine output inlet valve

Engine
engine receives the efforts or thrust should open at the end of the exhaust
supplied by the piston to the connecting stroke and closed at the end of the intake
rod and converts the reciprocating stroke.
motion of the piston into rotary motion of
the crankshaft.  So, to regulate its timing, a cam is used
which is oval and it exerts pressure on the
 The crankshaft mounts in bearing so it valve to open and release to close.
can rotate freely.
 It is drive by the timing belt which drives
 The shape and size of crankshaft depends by the crankshaft. It is placed at the top
on the number and arrangement of or the bottom of the cylinder.
cylinders.
 Function:1. Camshaft is responsible for
 Functions: 1. It converts the reciprocating opening of the valves. Cam shaft has
motion to the rotating motion. number of cams along the length, two
2. It transmits Power to the Flywheel. cams for each cylinder, one operates inlet
3. It receives Power from flywheel. valve, and another operates exhaust
valve.
2. The camshaft has an eccentric lobe
 Material:37C15 Alloy Steel.
which operates fuel feed pump.
3. A gear is present on the camshaft
 Manufacturing Method: Forging which drives ignition
distributor and oil pump.

 Material: Plain Carbon steel 10C4

• Manufacturing Method: Grinding, Case

Hardening
 11. Crank Case: - 12. Valves or Ports:-

 It supports and covers the  Valves or Port is a basic and important

part of an IC Engine. So let me first tell
cylinder and the crankshaft. It is you whare valve and where a port is
used to store the lubricating oil. used! So in a four-stroke engine, we
use a valve and in case of the two-

Parts of I.C  The main body of the engine to

which the cylinder is attached, 
stroke engine, we use ports.
In a four-stroke IC Engine, there are

Engine
and which contains the two valves. one is Inlet Valve, and the
crankshaft and crankshaft other one is Exhaust Valve.
bearing is called crankcase. It
 Valves are fitted in the valve spring,
serves as the lubricating system which driven by a camshaft with the
too and sometimes it is called oil help of rocker arm and pushes rod.
sump. All the oil for lubrication is
placed in it.  These valves are located on the
cylinder head.

 The Functions of Valves:

• During suction stroke inlet v/v allow

the charge [Air Fuel or only Air] to go
inside the engine cylinder.

• And after the exhaust stroke, through

exhaust v/v the burnt gas is going out
of the cylinder.

• They also seal the piston-cylinder

when compression stroke happens.

• Martials: Valves are available in a wide

range of material like Stainless Steels,
Martensitic Valve Steel, Austenitic
Valve Steel, Nickel Alloy, Stellite Alloy,
 13. Manifold: - 14. Push Rod:-

• The main function of the manifold is to • It is a rod which is operated by the

supply the air-fuel mixture and collects the camshaft to open or close the valves.

Parts of I.C exhaust gases equally form all cylinder. In

an internal combustion engine two
manifold are used, one for intake and
• Functions of Push Rod:

Engine
other for exhaust. • It is used for opening and closing of
Poppet Valves
• Function of inlet manifold: • Material: steel column with a couple of
1) Inlet manifold carries air fuel mixture balls affixed to each end and a hollow
from carburetor to engine cylinders. center to allow oil to find its way to the
2) It provides large enough space to allow rockers and valve springs.
sufficient flow of charge for maximum
power and on other hand it must be small
enough to maintain adequate velocity for
keeping the fuel droplets suspended in air.
3) It should provide least resistance to
flow.
4) In MPFI it facilitates the injection of fuel
in inlet manifold before supplied to
cylinder.

• Function of exhaust manifold:

1) The function of an exhaust manifold is to
expel the exhaust gases from the
combustion chamber of each cylinder out
to the atmosphere through the exhaust
pipe after combustion stroke is completed.
2) To keep back pressure minimum.

• Material: Aluminum alloy -Alloy 4600,

Cast Iron.
 15. Rocker Arm: - 16. Fuel Injection Pump: -

 Rocker Arms are typically in • Fuel injection pump (FIP) is

between the pushrod and the the device used in the diesel
Parts of I.C intake and exhaust valves. They
allow the pushrods to push up
engine for pumping the fuel to
the injectors and it also helps to

Engine
on the rocker arms and therefore distribute and meter the supply
push down on the valves. of fuel to all injectors
• Following are the different types
 Material: Medium Carbon steel
of fuel injection pumps used in
diesel engines
 Manufacturing
methods: Forging
• Inline fuel injection pump

• Distributor fuel injection pump

• Continuous fuel injection pump

 17. Spark Plug or Fuel Injector: - 18. Cooling Jackets or Fins: -

• Spark Plug and Fuel Injector, these two • As we already know, inside the engine

Parts of I.C
things are different and use in different cylinder the temperature can be raised to
engines. 3000-degree centigrade, so to avoid wear
and tear we need to use the cooling
• The spark plug is used in Spark Ignition system.

Engine Engine [SI Engine] where Fuel Injector is

used in Compression Ignition Engine [CI
Engine].
• In four strokes engines, there are two
types of a cooling system can be
noticeable.
• The Function of Spark Plug:
• One is liquid colling and other is Air
 Spark Plug is used to generate the spark cooling. Air cooling is used for small
in SI Engine [Petrol]. engines like a motorcycle, and for a larger
engine like 4-to-6-cylinder engines, we
• Functions of Fuel Injector: need to use liquid cooling, as heat
transfer rate is more.
 The fuel injector is used for injecting the
fuel inside the engine cylinder, in • Functions of Cooling Jackets or Fins:
atomised form.
• To reduce the temperature of the engine.
 Common types of Fuel Injectors,
• To protect the engine from wear and tear.
1. Mechanically Controlled Fuel
Injectors
2. Electronically Controlled Fuel
Injectors
 19. Flywheel:- 20. ECM and Wiring Harness: -

 The flywheel is a rotating mass • Engine control unit (ECU) is an

Parts of I.C
used as an energy storing device. electronic control unit that
ensures the optimal work of
 A flywheel is secured on the an internal combustion
Engine crankshaft. The main function of
the flywheel is to rotate the shaft
engine. It controls fuel supply
and injection, fuel-to-air ratio,
during the preparatory stroke. It ignition, idle speed, and the
also makes crankshaft rotation
timing of valve opening and
more uniform.
closing.
 Function: 1. Flywheel absorbs • Wiring harness refers to wiring
energy during power stroke and that supplies power necessary
supplies it during remaining to operate all electronic
strokes. components in a vehicle and
2. Flywheel keeps the crankshaft transmits electrical signals to
rotating at the uniform speed
each electronic control
throughout despite uneven
power impulses of engine module, and is located
cylinders. separately according to its use
4. Flywheel carries the drive
from the starting motors to
crankshaft while the starting the
Engine.

 Material: cast Iron

 Manufacturing Method: Casting

 21. Sensors: -
22. Turbocharger: -
• Engine Oil Level Sensor – Measures the

Parts of I.C •
engine oil level
Engine Oil Pressure Sensor – Measures
• A turbocharger is a
turbine-driven, force
Engine
the engine oil pressure in system
induction device that
• Coolant Temperature Sensor –
Measures the temperature of the increases the efficiency
coolant and power output of
• Fuel Temperature Sensor – Measures
the temperature of the fuel in system
internal combustion
engines by forcing extra
• Fuel Pressure Sensor – Measures the
pressure of the fuel in system compressed air into the
• Boost Pressure Sensor – Measures the combustion chamber.
boost pressure in the air intake manifold This hot air induction
• Exhaust Temperature Sensor – Measures
the exhaust gas temperature
seems to work because
the compressor can
• Cam/Crank Position Sensor - Engine
timing relies on a perfect symphony force more air and
between the crankshaft and camshaft –
and their respective position sensors let
proportionately more
the ECM know precisely where each one fuel into the
is at.
combustion chamber
• Intake Air Temperature Sensor –
Measures the temperature of the intake than normal
air. atmospheric pressure.
• Common Rail Pressure Sensor –
Measures the pressure in the common
rail.
Parts of I.C
23. After Cooler/Inter Cooler: 24. Engine Oil Cooler:-

• What Is an Intercooler? • An oil cooler is designed to

Engine • An intercooler is a heat
exchanger that functions to
remove excessive heat from the
oil used to lubricate vehicles,
machinery, and mechanical
remove heat from the air equipment. For example, a hot
generated by an air compressor. engine transfers heat to the oil
An efficient intercooler will which then circulates through a
restore the temperature of heat-exchanger (also known as
compressed air to near an oil cooler), using either air or
environmental levels. water to cool the oil.
• What Is an Aftercooler?
• An aftercooler is a mechanical
cooling unit that operates on the
principles of heat exchange
between two mediums usually
water and air. Aftercooler units
can be used to attain
temperatures between 5-20°F
immediately after compressed
air is released from the
compression unit.
Parts of I.C 25. Water Pump:- 26. Lubricating Oil Pump: -

Engine
• The water pump, also known • The oil pump is a mechanical
as the coolant pump, is the device that is used in an
heart of the engine's cooling engine to circulate oil to the
system. It is the water moving parts like bearing,
pump's job to regulate the camshaft, and pistons to
coolant flow rate, and to avoid wear and tear of the
constantly circulate coolant parts. It is one of the
throughout the engine and essential parts of an engine
cooling system. lubrication system that must
not go wrong, or faulty else
breakdown will occur.
• Below are the three types of
oil pump used in engines,
1. Rotor Oil Pump
2. Twin Gear Pump
3. Front Cover Oil Pump
Parts of I.C
27. Self Starter:- 28. Alternator:-

• A starter (also self- • An alternator can be defined as

Engine starter, cranking motor, or starter
motor) is a device used to rotate
an electrical generator that
converts mechanical energy into
(crank) an internal-combustion electrical energy. The work is
engine to initiate the engine's done in the form of an
operation under its own power. alternating current.
• Below are the functions of
alternators

 The primary function of an

alternator is to charge a car
battery so that other electrical
components in the car can be
powered.

 The charged battery provides the

electricity needed for the starter
motor to start the car. And

 When the car is running,

alternators generate energy to
feed the electrical system and
the battery.
Parts of I.C
29. Radiator Fan:- 30. Radiator:-

• A cooling fan is a vital • Generally, a radiator is a heat

Engine component in a car cooling
system, that helps takes away all
exchanger that is used to
transfer thermal energy from
heat absorbed from the engine one medium to another for the
using coolant. All its work is essence of cooling and heating.
done through the radiator by Radiators are consisting of a
pushing or pulling air through large area of the cooling surface
the radiator. A radiator cooling and use the stream of air to take
fan is located in front of a car, away the surrounding heat. with
and it’s electrically powered, easy access to the coolant heat,
well, depending on the vehicle efficient cooling is achieved.
design.
• Modern cars use aluminium
radiators, but they usually made
of copper and brass. This is
because of their high heat
conductivity. their various
sections are joined by soldering.
• Below are the major parts of
radiators
1. Core
2. Cap
3. Inlet and Outlet Port
Some Videos
• Petrol Vs Diesel Engine - https://youtu.be/bZUoLo5t7kg

• Diesel Engine - https://youtu.be/fTAUq6G9apg

• Cooling System - https://youtu.be/V7inC4lOpGs

• Lubrication System - https://youtu.be/1EZVgBOKxRQ

• Air Intake and Exhaust System - https://youtu.be/lWQQZCZf5H8

• Common Rail Fuel System - https://youtu.be/5AQ07-LF5JA

• Inline Fuel System - https://youtu.be/emBAbb9f3bc

• Turbocharger - https://youtu.be/DqWKNuTppmU

• Locomotive Engine - https://youtu.be/wgHh-JYRlts