IME Module 4 (1) - 1
IME Module 4 (1) - 1
MODULE IV
AUTOMOBILE & AERONAUTICAL ENGINEERING
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
Panhard and Daimler in France had the engine placed in the front of a chassis, hooked up to a
sliding gear transmission, and incorporated the brake pedal, clutch and accelerator.
The Locomotives Act 1865, framed in Britain for steam-driven traction engines, set an
overall speed limit of 4 mph in open country and 2 mph in towns and villages. Cars had to be
preceded by a man carrying a red flag to warn the drivers of horse-drawn vehicles. Although
the flag was abolished in 1876, the man was still required by law until 1896.
In 1908, Ford started his model with an initial run of 20,000 vehicles, an output unheard of at
that time. This was the period when the designers chief objective was to make the vehicle run
in mass production, at the lowest possible price. In 1920 there was a gradual change and
refinement in automobile design. By that time the spark-ignition gasoline engine was to be the
power plant of the modern motor vehicle. Water-cooled engines were almost universal. The
sliding gear transmission had established itself predominantly. The poppet valve was used in
almost every engine design. Engines were all located in the front of the chassis.
Substantial progress has been made after the second world war in every car feature. The
designers during this time tried to produce a vehicle which not only functioned at all times
...............................................
..............................................
under all conditions, but which was also comfortable to ride and easy to operate. The increased
.............................................
life of tyres,..............................................
brakes, independent front wheel suspension, beating and ventilation, improved
...............................................
engine design. Safety and exhaust emission were the additional features. However, this is not
.............................................
an end. Further research and development efforts continue and are focussed to produce a better,
.................................................
cheaper,.....................................................
safer and in the future, computer controlled vehicles.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
The production of all these cars was far below the nation's demand. In 1980, Hindustan Motors
produced only 21,572 cars, Premier Automobiles 8,729, while Standard motors produced only
6 cars.
The complacency of these manufacturers and the silence of the consumers was finally
broken in 1973, the period of the oil crisis. It was finally in this period that the small car concept
came into being and Maruti took shape. In 1982, Maruti was established in collaboration with
Suzuki.
Maruti however, was not the country's first small car. In the last decade, the Banglore-
based Sipani Automobiles Ltd. brought out the Badal/Dolphin based on technology from the
Reliant Motor Works, England. Though only a limited number of cars are produced each year
despite the licensed capacity of 3000, these cars are the only fibre-glass body automobiles in
the country.
New models introduced by various companies in recent years have been: The Hindustan
Motors Contessa, a very highly priced car, which has a 69 Vauxhall body over an Ambassador
engine; The...............................................
Standard 2000 which has a 2000 cc and a body designed by Austin/Rover, again
a very highly..............................................
priced car. The Premier 118 NE, with a Nissan 1200 cc petrol engi11e and a Fiat
.............................................
124 body, Peugeot 309 with 1360 cc petrol engine are manufactured by Premier Automobile.
..............................................
Maruti 800,...............................................
Maruti Yan with 800 cc petrol engine, Maruti Gypsy with 970 cc petrol engine,
.............................................
Maruti 1000, Maruti Zen with 993 cc engine, and Maruti Esteem with 1300 cc petrol engine
.................................................
are the .....................................................
models of Maruti Udyog Ltd., Tata Sierra, Tata Estate with 1948 cc diesel engine are
multi-purpose cars and again highly priced cars introduced by Telco. Recently, new small car
models introduced by various companies in the Indian market have been Daewoo's Matiz with
796 cc petrol engine, Hyundai's Santro with 999 cc petrol engine, Fiat's Uno with 999 cc petrol
and Telco's indica with 1405 cc petrol and diesel engine.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
2. Load Capacity
• Light duty vehicle Car, Jeep, Scooter, Motor cycle, etc.
• Heavy duty vehicle Bus, Truck, Tractor, Coach
4. Fuel Used
• Petrol vehicle Car, Jeep, Motor-Cycle, Scooter
• Diesel vehicle Car, Truck, Tractor, Bus, Bulldozer.
• Steam vehicle Steam road roller
...............................................
..............................................
• Electric vehicle Fork Lift, Battery truck
.............................................
..............................................
...............................................
5. Suspension System Used
.............................................
• Conventional Leaf spring
.................................................
• .....................................................
Independent oil spring, Torsion bar, Pneumatic
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
の
>
の
コ
...............................................
..............................................
.............................................
..............................................
...............................................
.............................................
.................................................
.....................................................
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
1. Engine
The engine is a power generator/power plant or a motor, which provides power to drive the
automobile.
In most automobile engines, the explosive power of the mixture of air and gasoline drives the
pistons. The pistons turn a crankshaft to which they are attached. The rotating force of the
crankshaft makes the automobile's wheels turn.
A number of systems are necessary to make an engine work. A lubrication system is needed to
reduce friction and prevent engine wear. A cooling system is required to keep the engine's
temperature within certain limits. The engine must be provided with the correct amount of air·
and fuel by a fuel system.
The mixture of air and fuel must be ignited inside the cylinder at just the right time by an
ignition system. Finally, an electrical system is required to operate the cranking motor that
...............................................
..............................................
starts the engine and to provide electrical energy to power engine accessories.
.............................................
2. Lubrication..............................................
System
...............................................
An engine has.............................................
many moving parts which eventually develop wear, as they move against each
.................................................
other. The engine circulates oil between these moving parts to prevent the metal-to-metal
.....................................................
contact that results in wear. Parts that are oiled can move more easily with less friction and
hence power loss due to friction is minimized. The secondary function of a lubricai1t is to act
as a coolant and also as a sealing medium to prevent leakages. Finally, a film of lubricant on
the cylinder walls helps the rings in sealing and thus improves the engine's compressions.
3. Cooling System
Due to the combustion of fuel with air inside the cylinder, the temperature of the engine parts
increases. This increase of temperature directly affects the engine performance and the life of
the engine parts. The cooling system keeps the engine operating at an efficient temperature.
4. Fuel System
The main function of the fuel supply system is to provide fuel to the carburettor or injection
system at a rate and pressure sufficient to meet engine demands under any conditions of load,
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
speed and gradients encountered by the vehicle. The fuel system must also have enough
reserve fuel for several miles of vehicle operation.
5. lgnition System
The purpose of the ignition system is to provide assistance for the combustion of fuel either
by a high voltage spark or self-ignition in each of the engine's cylinders at the right time so
that the air-fuel mixture can burn completely.
The fuel supplied to the combustion chamber must be ignited to deliver power. In a spark-
ignition engine an electric spark is used for this purpose. The compression-ignition engine
does not require a separate ignition system because the ignition is affected by compression of
the mixture to a high pressure.
6. Electrical System
The engine's electrical system provides energy to operate a starting motor and to power all
the accessories. The main components of the electrical system are a battery, an alternator, a
...............................................
..............................................
starting motor, ignition coil and heater.
.............................................
..............................................
7. Frame/Chasis
...............................................
.............................................
The frame provides a foundation for the engine and the body of the vehicle. The frame is
.................................................
constructed from square or box-shaped steel members strong enough to support the weight of
.....................................................
the body and other components.
The automobile frame is usually made up of a number of members welded or riveted together
to give the final shape. The engine is mounted on the frame with rubber pads which absorb
vibrations and also provide damping of these vibrations. Absorption and damping of
vibrations protects passengers from discomfort caused by shocks.
The frame is supported on wheel axles by means of springs. This whole assembly is called
the chassis.
8. Suspension System
The function of the suspension system is to absorb vibrations due to the up and down motion
of wheels, caused by the irregularities in the road surface. The springs, connecting linkages,
and shock absorber comprise the suspension system of a vehicle. The suspension system is of
two types:
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
In the rigid system, the road springs are attached to a rigid beam axle. It is mostly used in the
front axle of commercial vehicles and in the rear axle of all types of vehicles.
The independent system does not have a rigid axle. Each wheel is free to move vertically
without any reaction on its mating wheel. The independent system is mostly used in small
cars.
9. Power Train
The power train carries the power that the engine produces to the car wheels. It consists of the
clutch (on cars with a manual transmission), transmission (a system of gears that increases
the turning effort of the engine to move the automobile), drive shaft, differential and rear
axle.
...............................................
..............................................
.............................................
..............................................
...............................................
.............................................
.................................................
.....................................................
10. Clutch
A clutch is required with the manual transmission system to temporarily disconnect the
engine from wheels. Such disengagement of the power train from the engine is essential
while changing the gear ratio or while stopping the vehicle.
11 . Transmission
The main function of the trans1russ10n is to provide the necessary vanatJon to the torque
applied by the engine to the wheels. This is achieved by changing the gearing ratio between
the engine output shaft and the drive shaft.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
The drive shaft or propeUer shaft connects the gearbox and the differential unit. The drive
shaft has universal joints at its ends.
13. Differential
The function of the differential is to split the power received from the propeller shaft to the
rear axle shaft. It allows the rear wheels to be d1·iven at different speeds when the vehicle
takes a bend or falls into a ditch.
14. Axles
Axles are the shafts on which road wheels are mounted. The road wheels are provided with
the required drive through these axles.
15. Wheels
The automobile wheels take the load of the vehicle and also produce tractive force to move
...............................................
the vehicle. The wheels are also used for retardation and for stopping the vehicle.
..............................................
.............................................
16. Steering..............................................
System
...............................................
The steering system is used for changing the direction of the vehicle. The major requirements
.............................................
.................................................
in any steering mechanism are that it should be precise and easy to handle, and that the front
.....................................................
wheels should have a tendency to return to the straight-ahead position after a turn. A gear
mechanism, which is known as steering gear, is used in this system to increase the steering
effort provided by the driver. This system makes the vehicle steering very easy as the driver
does not have to put in much effort. Vehicle steering is not only required on a curved road but
also while manoeuvring on the busy traffic roads. The steering system allows the vehicle to
be guided, i.e. to be turned left or right. Figure shows a simplified diagram of the steering
system.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
17. Braking...............................................
System
..............................................
.............................................
Brake is a machine element which is used either to stop an automobile or retard the motion.
..............................................
Most brakes...............................................
commonly use friction between two surfaces pressed together to convert the
kinetic energy.............................................
of the moving object in to heat. The difference between clutch and brake is
.................................................
that in clutch, both the members to be engaged are in motion, whereas in brake, there is
.....................................................
engagement of moving member to a stationery member.
The main purpose of the bodywork is to provide accommodation for the driver and
passengers, with suitable protection against wind and weather. The degree of comfort
provided depends upon the type of car and its cost.
The body on the first automobiles was little bit more than a platform with seats attached. It
gradually developed into a closed compartment complete with roof and windows. The
modern automobile body is constructed of sheet steel formed to the required shape in giant
punch presses. Most of the body components are welded together to form a light rattle-free
unit.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
...............................................
..............................................
.............................................
..............................................
...............................................
19. Accessories
.............................................
.................................................
The modern automobile uses a wide variety of accessories to make driving safer and more
.....................................................
comfortable. Typical examples are self-starter driving and signalling lights such as
headlights, tail lights, brake lights, parking lights, windshield wipers, horn, indicators, radio,
heating and air conditioning system, power steering, etc.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
...............................................
..............................................
.............................................
..............................................
...............................................
.............................................
The four forces of acting on a body in flight are lift, weight, thrust and drag. These forces make
.................................................
an object move up and down, and faster or slower. How much of each force there is changes
.....................................................
how the object moves through the air. Figure shows the forces that act on an airplane in flight.
Flight of an aeroplane is made possible by a careful balance of four forces.
Weight is a force that is always directed toward the center of the earth.
The magnitude of the weight depends on the mass of all the airplane parts, plus the amount of
fuel, plus any payload on board (people, baggage, freight, etc.). The weight is distributed
throughout the airplane. But we can often think of it as collected and acting through a single
point called the center of gravity.
Lift is the push that lets something move up. It is the force that is the opposite of weight.
Everything that flies must have lift. For an aircraft to move upward, it must have more lift than
weight. A hot air balloon has lift because the hot air inside is lighter than the air around it. Hot
air rises and carries the balloon with it. A helicopter's lift comes from the rotor blades at the
top of the helicopter. Their motion through the air moves the helicopter upward. Lift for an
airplane comes from its wings.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
The shape of an airplane's wings is what makes it able to fly. Airplanes' wings are
curved on top and flatter on the bottom. This particular shape of wing is called “aerofoil”. That
shape makes air flow over the top of the wings faster than under the bottom. So, less air pressure
is on top of the wing. This condition makes the wing, and the airplane it's attached to, move
up. Using curves to change air pressure is a trick used on many aircraft. Helicopter rotor blades
use this trick. Lift for kites also comes from a curved shape. Aircraft lift acts through a single
point called the center of pressure.
...............................................
..............................................
.............................................
..............................................
...............................................
.............................................
.................................................
.....................................................
As the airplane moves through the air, there is another aerodynamic force present. The
air resists the motion of the aircraft and the resistance force is called drag. Drag acts opposite
to the flight direction or simply drag opposes thrust. Like lift, there are many factors that affect
the magnitude of the drag force including the shape of the aircraft, the "stickiness" of the air,
and the velocity of the aircraft. And like lift, drag acts through the aircraft center of pressure.
Thrust is the push that moves something forward. For an aircraft to keep moving
forward, it must have more thrust than drag. A small airplane might get its thrust from a
propeller. A larger airplane might get its thrust from jet engines.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
For jet engines, it is often confusing to remember that aircraft thrust is a reaction to the
hot gas rushing out of the nozzle. The hot gas goes out the back, but the thrust pushes towards
the front. Action and reaction is explained by Newton's Third Law of Motion.
Besides gliders, balloons and airships were the first airborne vehicles and therefore first
to be propelled: in the beginning they flew with the winds. Later on attempts were made to
propel them by means of propeller. A propeller driven by a 3 h.p steam engine was employed
in 1852 for the first time to propel a balloon in France. Later a battery operated electric motor
was used for driving the propeller.
Later aircrafts employed successfully the reciprocating internal combustion engines for
driving the propellers. Engine cylinders were arranged in various configurations such as “in
line”, radial and V-arrangements. Petrol engines which were lighter in construction due to its
low compression ratio was ideally suited for aircraft propulsion. Super charged engines were
also used. ...............................................
..............................................
The reciprocating piston engines, on account of limitation of size and speed could not
.............................................
..............................................
be employed for generating much higher power.
...............................................
.............................................
With the development of gas turbines in nineteen thirties and forties in Britain, France,
.................................................
Germany and United States of America they were successfully employed in the turbo prop and
.....................................................
turbo jet aircraft engines.
As stated earlier the piston engines such as radial engines were widely used to drive the
propellers of early aircrafts. However the speeds, size and weight became major limitations.
Therefore, now its use is restricted in the propulsion of only comparatively small and low speed
aircrafts flying at lower altitudes.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
In turbojet engines, air is drawn in by a compressor which raises internal pressures many
times over atmospheric pressure. The compresed air then passes into a combustion chamber
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
where it is mixed with fuel to be ignited and burned. Burning the fuel-air mixture expands the
gas, which is accelerated out the rear as a high velocity jet-stream. In the turbine section of the
engine, the hot expanded gas rotates a turbine wheel which provides power to run the
compressor. The gas turbine engine operates on the principle of intake, compression, power,
and exhaust. Unlike the reciprocating engine, these events are continuous. Approximately two
thirds of the total energy developed within the combustion chamber is absorbed by the turbine
wheel to sustain operation of the compressor. The remaining energy is discharged from the rear
end (nozzle) of the engine as a high velocity jet, the reaction to which is to provide thrust or
propulsion power .
Applications
Military Aircrafts, Guided missiles, Piloted aircrafts etc…
Advantages
Used for long distance flights at higher speeds and higher altitudes
Lower frontal area hence less drag.
...............................................
Disadvantages
..............................................
Low thrust at low speeds, Hence a longer runway is needed.
.............................................
..............................................
...............................................
.............................................
.................................................
b) TURBOPROP ENGINE
.....................................................
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
Turboprop engines have a propeller at the front and are popular in smaller, more
economical aircraft and helicopters. There are two main parts to a turboprop propulsion system,
the core engine and the propeller. The core is very similar to a basic turbojet except that instead
of expanding all the hot exhaust through the nozzle to produce thrust, most of the energy of the
exhaust is used to turn the turbine. There are many additional turbine stage present, which is
connected to a drive shaft. The drive shaft is connected to a gear box. The gear box is then
connected to a propeller that produces most of the thrust. The exhaust velocity of a turboprop
is low and contributes little thrust because most of the energy of the core exhaust has gone into
turning the drive shaft. Because propellar become less efficient as the speed of the aircraft
increases, turboprops are used only for low speed aircraft like cargo planes.
Applications
Used in smaller aircrafts at comparatively lower speeds ( less than 800kmph)
Used in small capacity aicrafts
Advantages
...............................................
High thrust at low speeds, Hence only a shorter runway is needed.
..............................................
Disadvantages
.............................................
..............................................
Cannot be used at high speeds and altitudes
...............................................
Large frontal area hence drag is more
.............................................
.................................................
.....................................................
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
c) TURBOFAN ENGINE
...............................................
..............................................
Turbofan .............................................
engine is very similar to the turboprop in principle, except that a fan is used
..............................................
instead of a propeller, and this fan is contained within a duct as shown in the figure. Most
...............................................
airliners use modem turbofan engines because of their high thrust and good fuel efficiency. In
.............................................
a turbofan .................................................
engine, the air is sucked by the engine inlet. Some of the incoming air passes through
.....................................................
the fan and continues on into the core compressor and then the combustion chamber, where it
is mixed with fuel and combustion occurs. The hot exhaust passes through the core and fan
turbines and then out the nozzle, as in a basic turbojet. The rest of the incoming air passes
through the fan and bypasses, or goes around the engine, just like the air through a propeller.
The air that goes through the fan has a velocity that is slightly increased from free stream. So
a turbofan gets some of its thrust from the core and some of its thrust from the fan. Because the
fuel flow rate for the core is changed only a small amount by the addition of the fan, a turbofan
generates more thrust for nearly the same amount of fuel used by the core. This means that a
turbofan is very fuel efficient.
Applications
Used for long distance flights at higher speeds and higher altitudes
Used in Passenger Aircrafts
Advantages
High thrust at low speeds, Hence only a shorter runway is needed.
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
d) RAMJET ENGINE
The ...............................................
ramjet operates on the same cycle as a turbojet. It consists of a diffuser, combustion
chamber and..............................................
a nozzle. Ramjets do not need compressors and consequently no turbines as well.
.............................................
All the compression in the cycle is made to occur in the intake diffuser producing a significant
..............................................
rise in pressure. Fuel is burnt in this high pressure air and the mixture is then expanded through
...............................................
.............................................
a nozzle system. The ramjet engine produces power by increasing the momentum of the
.................................................
working.....................................................
fluid by induction of energy by combustion of fuel, so that the momentum of the
exhaust jet exceeds that of the incoming air, on a continuous basis. In contrast to the other air
breathing engines, the working cycle is accomplished without additional components of
compression and expansion, and also without any need for enclosed combustion. Ramjet
engine is mechanically the least complicated air breathing.engine for thrust production for
flying vehicles. The biggest drawback of the ramjet is its high rate of fuel consumption. A
ramjet engine working under supersonic speeds is called Supersonic ramjet or Scram jet
engine.
Applications
Military applications such as missiles.
Weather Rockets
Advantages
As moving components are less construction is simple and economical
Disadvantages
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
e) PULSEJET ENGINE
Pulse jet engine consist of an inlet diffuser, valve grid, combustion chamber, spark plug and a
...............................................
discharge nozzle. The function of the diffuser is to change the kinetic energy of the entering
..............................................
.............................................
air in to pressure energy by slowing down air velocity. When a certain pressure is reached the
..............................................
valves will ...............................................
open and allow the fresh air to enter in to the combustion chamber where fuel is
.............................................
injected and mixed with air. Hence combustion takes place with spark ignition. There is a rapid
.................................................
increase.....................................................
in pressure, which causes the valve to close rapidly and as a result the products of
combustion move towards the nozzle where they expand and escape with higher velocity than
the entrance velocity. Thus thrust is produced at the nozzle exit.
Since firing in the combustion chamber is intermittent , intermittent thrust is produced, Hence
the name.
Advantages
Due to less moving parts Construction is economical and cheap.
High mechanical efficiency
Disadvantage
Noise and vibrations are high
Dept. of ME VISAT
................
KTUweb.com
Introduction to Mechanical Engineering Module 4
3 Mark Questions
1. What is meant by chassis of an automobile?
2. Give any 3 different classifications of automobiles.
3. Explain the function of clutch in an automobile?
...............................................
6 Mark Questions
..............................................
1. Write a short note of current scenario of Indian automobile sector.
.............................................
2. What..............................................
are the major components of an automobile? Give special emphasis to their
function.
...............................................
3. Give the different types of air craft engines and their applications.
.............................................
4. List.................................................
the major components required to transmit power from the engine to an automobile
.....................................................
wheels. Mention the function of each component.
5.
a) Differentiate between Front wheel drive, Back wheel drive and all wheel drive in
automobiles.
b) List the various applications of automobiles
6. Name 6 major automobile manufacturers in India and list 3 of their popular models.
7.
a) What is aerodynamics?
b) Compare turbo prop and turbo jet engines.
Dept. of ME VISAT
................
KTUweb.com