Course Title: Introduction to Mechanical Engineering

Course Code: 22ESC144/244

Course In charge: Ashoka E

Module-3
Introduction to IC Engines: Components and Working Principles, 4-Strokes Petrol and Diesel Engines,
Application of IC Engines.

I.C. Engines
Working principle of IC engine
An Internal combustion engine called i.e., IC Engine, is a heat engine which converts heat energy released
by the combustion of fuel taking place inside the engine cylinder into mechanical work. It has advantages
such as high efficiency, light weight, compactness, easy starting, adaptability, comparatively lower initial
cost has made its use as a prime mover.

Parts of I.C. Engines:

1. Cylinder: The heart of the engine is the cylinder in which the fuel is burnt and the power is
developed. The inside diameter is called bore. To prevent the wearing of cylinder block, a sleeve
will be fitted tightly in the cylinder. The piston reciprocates inside the cylinder.

2. Piston: The piston is a close fitting hollow cylindrical plunger moving to-and-fro in the
cylinder. The power developed by the combustion of the fuel is transmitted by the piston to the
crankshaft through the connecting rod.

3. Piston rings: The piston rings are the metallic rings inserted into the circumferential grooves
provided at the top end of the piston. These rings maintain a gas-tight joint between the piston and
the cylinder while the piston is reciprocating in the cylinder. They also help in conducting the heat
from the piston to the cylinder.
4. Connecting rod: It is a link that connects the piston and the crankshaft by means of pin joints. It
convertsthe rectilinear motion of the piston into rotary motion of the crankshaft.
5. Crank and crankshaft: The crank is lever that is connected to the end of the connecting rod by a pin
joint with its other end rigidly connected to a shaft called crankshaft. It rotates about the axis of the
crankshaft and causes the connecting rod to oscillate.

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6. Crank case: It is the lower part of the engine serving as an enclosure for the crankshaft and also sump
for the lubricating oil.
7. Valves: The valves are the devices which controls the flow of the intake and the exhaust gas to and
from the cylinder. They are also called poppet valves. These valves are operated by means of cams driven
by crankshaft through a timing gear and chain.
8. Fly wheel: It is a heavy wheel mounted on the crankshaft of the engine to maintain uniform
rotation of the crankshaft.

4-STROKE PETROL ENGINE: (S. I. Engine)

Petrol engines consists of cylinder, piston, connecting rod, crank, crankshaft, inlet valve, exhaust
valve and spark plug. The spark plug fitted at the top of the cylinder initiates the ignition of the petrol,
hence the name spark ignition engine.
1. SUCTION STROKE:
During this stroke the piston moves from TDC to BDC. The inlet valve is open and exhaust
valve is closed. The crankshaft rotates by half a rotation. As the piston moves downwards, suction is
created in the cylinder, asa result, fresh air-petrol mixture is drawn into the cylinder through the inlet
valve. At the end of this stroke, the piston is in BDC, the cylinder is filled with air-petrol mixture and
inlet valve closes. Horizontal line AB on the P-V diagram.

2. COMPRESSION STROKE:
During this stroke the piston moves from BDC to TDC. Both the inlet valve and exhaust valves
are closed. The crankshaft rotates by half a rotation. As the piston moves upwards, the fuel mixture in
the cylinder will be compressed. It is represented by the BC curve in the P-V diagram.

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 When the piston reaches TDC, the spark plug ignites the fuel mixture. Since the spark plug
ignites the fuel (air-petrol), this type of engine is also called as spark ignition or S.I Engine. The
combustion of fuel takes place increasing the pressure at constant volume, represented by the line CD
in the P-V diagram.
3. WORKING OR POWER STROKE:
During this stroke the piston moves from TDC to BDC. Both the inlet valve and exhaust valves are
closed. The crankshaft rotates by half a rotation. The high pressure of the burnt gases forces the piston
downwards performing power stroke. The linear motion of the piston is converted to rotary motion of
the crankshaft by connecting rod and crank. It is represented by curve on DE on PV diagram. At the
end of the stroke, the piston is in BDC, the exhaust valve opens which release the burnt gases to the
atmosphere. This will bring pressure in the cylinder to atmospheric at constant volume, represented by
the line EB in the P-V diagram.

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 4. EXHAUST STROKE:
During this stroke the piston moves from BDC to TDC. The inlet valve is closed and exhaust valve
is open. The crankshaft rotates by half a rotation. As the piston moves towards the TDC, the burnt
gases will be expelled out through the exhaust valve. Line BA on the P-V diagram. When the piston
reaches the TDC, the exhaust valve closes and this completes the cycle.
In 4 stroke engine, the 4 strokes constitute one cycle, hence the name 4 stroke cycle engine. The
crankshaft makes two revolutions to complete one cycle. The power is developed in every alternate
revolution of the crankshaft. 4 Stroke diesel engines produce higher power than 4 Stroke petrol
engines.

4- STROKE DIESEL ENGINE (CI Engine):

Diesel engines works on the principle of theoretical Diesel cycle, also known as constant pressure cycle. It
consists of cylinder, piston, connecting rod, crank, crankshaft, inlet valve, and exhaust valve and fuel
injector. The fuel injector fitted at the top of the cylinder supplies the measured quantity of diesel at high
pressure.

1. SUCTION STROKE: During this stroke the piston moves from TDC to BDC. The inlet valve is open
and exhaust valve is closed. The crankshaft rotates by half a rotation. As the piston moves downwards fresh
air is drawn into the cylinder through the inlet valve. At the end of this stroke, the piston is in BDC, the
cylinder is filled with air and inlet valve closes. Horizontal line AB on the P-V diagram.

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2. COMPRESSION STROKE: During this stroke the piston moves from BDC to TDC. Both the inlet
valve and exhaust valves are closed. The crankshaft rotates by half a rotation. As the piston moves upwards,
the air in the cylinder will be compressed. It is represented the BC curve in the P-V diagram. As the air gets
compressed its pressure and temperature increases and attains a temperature greater than the ignition
temperature of diesel. Diesel is sprayed into the cylinder through the fuel injector. The high temperature of
the air ignites the diesel as soon as it is sprayed and undergoes combustion at constant pressure. Line CD on
the P-V diagram. Since the compresses air ignites the diesel, this type of engine is also called as compression
ignition or C.I Engine

3. WORKING OR POWER STROKE: During this stroke the piston moves from TDC to BDC. Both the
inlet valve and exhaust valves are closed. The crankshaft rotates by half a rotation. The high pressure of the
burnt gases forces the piston downwards performing power stroke. The linear motion of the piston is
converted to rotary motion of the crankshaft by connecting rod and crank. It is represented by curve DE on
PV diagram. At the end of the stroke, the piston is in BDC, the exhaust valve opens which release the burnt
gases to the atmosphere. This will bring pressure in the cylinder to atmospheric at constant volume,
represented by the line EB in the P-V diagram.

4. EXHAUST STROKE: During this stroke the piston moves from BDC to TDC. The inlet valve is closed
and exhaust valve is open. The crankshaft rotates by half a rotation. As the piston moves towards the TDC,
the burnt gases will be expelled out through the exhaust valve. Line BA on the P-V diagram. When the
piston reaches the TDC, the exhaust valve closes and this completes the cycle

In 4 stroke engine, the 4 strokes constitute one cycle, hence the name 4 stroke cycle engine. The
crankshaft makes two revolutions to complete one cycle. The power is developed in every alternate
revolution of the crankshaft. 4 Stroke diesel engines produce higher power than 4 Stroke petrol engines
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COMPARISON OF PETROL AND DIESEL ENGINE
PRINCIPLE PETROL DIESEL
1. Fuel used Petrol Diesel
2. Admission of fuel During suction stroke At the end of compression
3. Charge drawn during Air and petrol mixture Only air
4. Type of ignition Spark ignition Compression
5. Uses Scooter, motor cycle, car, etc., Trucks, tractors, buses, etc.
6. Engine speed High about 7000rpm Low from 500 to 3000rpm
7. Noise & vibration Almost nil High
8. Weight of the engine Less High
9. Initial cost Less More
10 Maintenance cost Less Slightly higher
11.Starting of the engine Easily started Difficult to start in cold
12. Exhaust gas pollution More More

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Course In charge: Ashoka E
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Course Title: Introduction to Mechanical Engineering
Course Code: 22ESC144/244
Course In charge: Ashoka E
Insight into Future Mobility; Electric and Hybrid Vehicles, Components of Electric and
Hybrid Vehicles. Advantages and disadvantages of EVs and Hybrid vehicles.
Electric Vehicles
An electric vehicle (EV) is a vehicle that uses one or more electric motors for propulsion. It can be powered
by a collector system, with electricity from extra vehicular sources, or it can be powered autonomously by a
battery (sometimes charged by solar panels, or by converting fuel to electricity using fuel cells or a generator)
EVs include, but are not limited to, road and rail vehicles, surface and underwater vessels, electric aircraft
and electric spacecraft.
Below, you can see a summary of the key parts of an EV with simple definitions:

Scheme of a battery electric vehicle

Figure: Key parts of a battery electric vehicle

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 Charging port or Vehicle inlet: It is a connector present on the electric vehicle to allow it to be
connected to an external source of electricity for charging
On-board charger: It is an AC-to-DC power electronic converter (often referred to as a rectifier)
that takes the incoming AC electricity supplied via the charge port and converts it to DC power for charging
the traction battery. Using the battery management system, it regulates the battery characteristics such as
voltage, current, temperature, and state of charge
Traction battery pack: It is a high voltage battery used to store energy in the electric car and
provide power for use by the electric traction motor.
Battery power converter: It is a DC-to-DC power electronic converter that converts the voltage of
the traction battery pack to the higher-voltage of the DC-bus used for power exchange with the traction
motor.
Traction electric motor/generator: It is the main propulsion device in an electric car that converts
electrical energy from the traction battery to mechanical energy for rotating the wheels. It also generates
electricity by extracting energy from the rotating wheels while braking, and transferring that energy back to
the traction battery pack.
Transmission: For an electric car, usually a single gear transmission with differential is used to
transfer mechanical power from the traction motor to drive the wheels.

Advantages and Disadvantages of EVs and Hybrid vehicles

The electric car (EV) is a relatively new concept in the world of the automotive industry. Although some
companies have based their entire model of cars around being proactive and using electricity, An electric
car such as TATA NEXON, Nissan Leaf, Ford Focus Electric or Tesla Model S, Chevrolet Volt is a
great way for you to not only save money but also help contribute towards a healthy and stable
environment.

Advantages of an Electric Car

1. No Gas Required
2. More Convenient
3. Savings
4. No Emissions
5. Safe to Drive
6. Low Maintenance
7. Reduced Noise Pollution
8. Battery Life & Cost
9. Easy Driving
10. Regenerative Braking

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Disadvantages of an Electric Car

1. Recharge Points
2. The Initial Investment is Steep
3. Short Driving Range and Speed
4. Longer Recharge Time
5. Silence as a Disadvantage
6. Battery Replacement
7. Not Suitable for Cities, Facing Shortage of Power
8. Minimal Amount of Pollution
9. Some Governments Do Not Provide Money Saving Initiatives to Encourage You to Buy an Electric
Car

Advantages of an Electric Car

1. No Gas Required: Electric cars are entirely charged by the electricity you provide, meaning you don’t
need to buy any gas ever again. Driving fuel-based cars can burn a hole in your pocket as prices of fuel have
gone all-time high.

2. More Convenient: The electric vehicle is easy to recharge, and the best part is you will no longer need to
run to the fuel station to recharge your car before hitting the road! Even a normal household socket could be
used for charging an electric car.
3. Savings: These cars can be fuelled for very low prices, Electric cars can also be a great way to save
money in your own life.
4. No Emissions: The biggest advantage of an electric vehicle is its green credential. Electric cars are 100
percent eco-friendly as they run on electrically powered engines. It does not emit toxic gases or smoke in the
environment as it runs on a clean energy source.
5. Safe to Drive: Electric cars undergo the same fitness and testing procedures test as other fuel-powered
cars. An electric car is safer to use, given their lower center of gravity, which makes them much more stable
on the road in case of a collision. In case an accident occurs, one can expect airbags to open up and
electricity supply to cut from the battery. This can prevent you and other passengers in the car from serious
injuries.
6. Low Maintenance: Electric cars run on electrically powered engines, and hence there is no need to
lubricate the engines, anything related to the combustion engine or a ton of maintenance tasks that are
usually associated with a gas engine. Other expensive engine work is a thing of the past. Therefore, the
maintenance cost of these cars has come down. You don’t need to send it to the service station often as you
do for a standard gasoline-powered car.
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 7. Reduced Noise Pollution: Electric cars put a curb on noise pollution as they are much quieter. Electric
motors are capable of providing smooth drive with higher acceleration over longer distances.
8. Battery Life & Cost: Batteries are an integral part of an electric vehicle. Most electric vehicle batteries
are lithium ones, and their costs are improving every year.
The full capacity of a lithium-ion battery cell should be good for 300 to 500 cycles. A good battery could last
you up to ten years. With the improving technologies, the cost of these batteries is expected to come down
even more.
9. Easy Driving: Electric car1s have the simplest driving method. Electric cars come with a transmission
comprising of only one really long gear. This effectively eliminates the need to add a clutch mechanism.
Therefore, you can operate an electric car with just the accelerator pedal, brake pedal and steering wheel.
10. Regenerative Braking: In normal cars, the braking process is a total wastage of kinetic energy that gets
released as frictional heat. However, in an electric vehicle, the same energy is used to charge the batteries.

Disadvantages of an Electric Car

Although the evidence of the positives has become very clear, there are also some downsides that each
individual needs to consider before they decide to make an electric car their next big investment. These
reasons are
1. Recharge Points: Electric fuelling stations are still in the development stages. Not a lot of places you go to
on a daily basis will have electric fuelling stations for your vehicle, meaning that if you’re on a long trip or
decide to visit family in a rural or suburban area and run out of charge, it may be harder to find a charging
station. You may be stuck where you are.
2. The Initial Investment is Steep: As EVs are very new, you may be surprised when you take a look at the
price for EVs. Even the more affordable brands can be around Rs.20Lakhs to 30Lakhs.
3. Short Driving Range and Speed: Electric cars are limited by range and speed. Most of these cars have a
range of about 50-100 miles (80-160km/hr) and need to be recharged again. You just can’t use them for long
journeys as of now, although it is expected to improve in the future.
4. Longer Recharge Time: While it takes a couple of minutes to fuel your gasoline-powered car, an electric car
takes about 4-6 hours and sometimes even a day to get fully charged. Therefore, you need dedicated power
stations as the time taken to recharge them is quite long.

5. Silence as a Disadvantage: Silence can be a bit disadvantage as people like to hear the noise if they are
coming from behind them. An electric car is, however, silent and can lead to accidents in some cases.
6. Battery Replacement: Depending on the type and usage of battery, batteries of almost all electric cars are
required to be changed every 3-10 years.
7. Not Suitable for Cities, Facing Shortage of Power: As electric cars need the power to charge up, the cities
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that already facing acute power shortages are not suitable for electric cars. The consumption of more power
would hamper their daily power needs.
8. Minimal Amount of Pollution: Electric vehicles are also not 100% emission-free; they cause a little amount
of pollution indirectly. The batteries and electricity needed for charging are not necessarily generated from
renewable energy sources
9. Some Governments Do Not Provide Money Saving Initiatives to Encourage You to Buy an Electric Car

Electric Vehicles in India: (Optional)

EV parameters: Capacity, state of charge, range, energy consumption,

power, torque (Optional)
1) Nominal battery capacity (Enom, in Wh or kWh): It is total electric energy that can be
stored in the battery. Alternately, it is the maximum amount of electric energy that can be
extracted from a fully charged battery state to the empty state. Generally speaking, EV
batteries have a battery capacity between 5 kWh to 100 kWh depending on the type of EV. The
higher the battery capacity, the more energy it can store and the longer the time it takes to fully
charge it.
(Note: What does 60 kWh battery mean: Energy in Car Batteries To sum it up, a 60 kWh
battery can generate 60 kW sustained over one hour . If you only use 15 kW per hour, you get four
hours of energy. If you use more power, say 120 kW, your battery will only last for half an hour).
2. State of charge: (SOC , in %): The battery state of charge (SOC) is defined as the ratio
between the amount of energy currently stored in the battery, (Ebatt ) to the total battery
capacity, (Enom ) :BSOC=(Ebatt/Enom) 100.
3. Range (Rmax, in km): It is the maximum distance that can be driven by an electric car when
the battery is full. Usually an electric car is tested using a standardized driving cycle to estimate
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the range. The range can be expressed in miles, kilometre or other units based on the region. In
this set of definitions, we stick to the European convention of using kilometre.
4. Motor power (Pm, in W): It is the power delivered by the motor to the wheels for propulsion.
The motor power is positive or negative based on whether the car is driving or under regenerative
braking. The motor power can be expressed as a product of the motor torque, Tm and the motor
rotational speed, wm and the units normally used are watts (W), kilowatts (kW) or horsepower
(hp). Note: The equation is as simple as hp = kW x 1.369 , so a 100-kW motor produces 136
horsepower

Hybrid Electric vehicles

Hybrid electric vehicles are powered by an internal combustion engine and an electric motor, which uses
energy stored in batteries. A hybrid electric vehicle cannot be plugged in to charge the battery. Instead,
the battery is charged through regenerative braking and by the internal combustion engine. The extra
power provided by the electric motor can potentially allow for a smaller engine. The battery can also
power auxiliary loads and reduce engine idling when stopped. Together, these features result in better fuel
economy without sacrificing performance

Block Diagram of Hybrid electric Car

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 Key Components of a Hybrid Electric Car
The internal combustion of the petrol engine continues to remain the primary source of power to the
hybrid car. The electric motor derives power from regenerative braking; however, the hybrid’s battery
pack cannot recharge without the primary petrol engine.
Internal combustion engine (spark-ignited): In this configuration, fuel is injected into either the intake
manifold or the combustion chamber, where it is combined with air, and the air/fuel mixture is ignited by
the spark from a spark plug.
Traction Battery Pack: The pack stores electricity to power the electric motors and it also recharges
through the electric generator.
Electric traction motor: This motor draws power from the battery pack and sends power to the wheels.
Electric generator: Generates electricity from the rotating wheels while braking, transferring that energy
back to the traction battery pack
DC/DC converter: This device converts higher-voltage DC power from the traction battery pack to the
lower-voltage DC power needed to run vehicle accessories and recharge the auxiliary battery.
Exhaust system: The exhaust system channels the exhaust gases from the engine out throughthe tailpipe.
Power electronics controller: This unit manages the flow of electrical energy delivered by the traction
battery, controlling the speed of the electric traction motor and the torque it produces.
Thermal system (cooling): This system maintains a proper operating temperature range of the engine,
electric motor, power electronics, and other components.

Transmission: The transmission transfers mechanical power from the engine and/or electric traction
motor to drive the wheels.

Advantages and Disadvantages of Hybrid Cars:

Hybrid cars may be a stepping stone before the automobile industry moves into pure electric vehicles. So,
understanding the pros and cons of hybrid cars will help you understand the technology.
Advantages/ Pros of Hybrid Cars:

Cleaner Emission: Compared to the internal combustion engine, hybrid cars employ both electric and
internal combustion engines. The result is reduction in emissions and is environmentally friendly.
Less Fuel Dependency: With an electric motor to support the primary petrol engine, there is additional
power available. Hence, there is less dependency on fossil fuel. Smaller and Efficient Engine: Since smaller
engines don’t have to power the hybrid car alone since there is an electric motor. Also, petrol engines used in
hybrid cars are smaller in size and comparatively fuel efficient.

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Regenerative Braking: Every time the brake is applied in a hybrid vehicle, the electric generator generates
electricity and recharges the battery. This eliminates the need to stop the vehicle to charge the battery pack.

Disadvantages/Cons of Hybrid Cars:

Lower Performance: Since the main motive is to increase the fuel efficiency or range of the hybrid car, the
power or acceleration can lag behind a conventional internal combustion engine car.
Expensive to Buy: Although car companies are trying to bridge the gap in pricing between a conventional
vehicle and hybrid, hybrids continue to demand higher costs.
High Maintenance Cost With several mechanical parts in the cars and with two sets of engines powering
the hybrids, the maintenance continues to be on the higher side. Also, not all mechanics are trained to repair
a hybrid car.

Difference between Hybrid and Electric Cars:

Specifications Hybrid Cars Electric Cars

Power/Fuel Electricity and Fossil Fuel (Petrol and Electricity Through Battery Pack (DC)
Source Diesel)
Engine Internal Combustion Engine (ICE) and Electric Motor(s)
Electric Motor(s)
Fuel Efficiency Combination of ICE and Battery Range Depends on Battery Range
Emission Levels Higher Compared to Electric Cars Lower Compared to ICE and Hybrid
Cars
Price Range Similar to Conventional ICE Cars High
Charging Not Needed Needed
Specifications Hybrid Cars Electric Cars

Hybrid Cars in India (Optional)

1. Maruti Suzuki 4. Toyota Glanz 8. Kia Niro

2. ErtigaMaruti Suzuki Ciaz 5. Toyota Corolla 9. Hyundai Ioniq
3. Maruti Suzuki Baleno 6. Hyundai Ioniq 10. Toyota C-HR
7. Toyota Prius

Course In charge: Ashoka

E
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