CHAPTER 2== Internal Combustion (IC) Engines

2.1 Introduction and classification

2.2 Engine parts like cylinder, piston, valves, crank shaft, connecting rod and their functions,
engine terminology

2.3 Cycle of operations – Otto and Diesel cycles, their P-V diagrams and thermal efficiencies

2.4 Two-stroke and four-stroke engines, construction and working

2.5 Valve timing diagrams

2.6 Differences between two-stroke and four-stroke, and between petrol and diesel engines.

2.7 Schematic flow diagrams of cooling, lubrication and fuel systems; Introduction to MPFI.

2.8 Calculation of Brake Power, Indicated Power, various efficiencies and specific fuel
consumption.

Preparation of heat balance sheet of an IC engine.

2.1 Introduction and classification

Internal combustion engines (ICE) are the most common form of heat engines, as they are
used in vehicles, boats, ships, airplanes, and trains.

They are named as such because the fuel is ignited in order to do work inside the
engine.

The internal combustion (IC) engine is a class of heat engine wherein the chemical
energy of fuel is transformed into mechanical shaft work.

Classification
• According to the type
Petrol engine
Diesel engine
Gas engine

• According to the method of ignition

Spark ignition engine
Compression ignition engine.

• According to the cycle of operation.

Otto cycle engines
Diesel cycle engines
Dual cycle engines (Semi diesel)
• According to the speed
High speed engine
Medium speed engine
Slow speed engine

• According to the cooling system

Air cooled engine
Water cooled engine

• According to the number of cylinders

single cylinder engines
Multicylinder engine

• According to the arrangement

vertical engine
Horizontal engine
Radial engine.
Inline multicylinder engine
V-type multicylinder engines

Engine parts like cylinder, piston, valves, crank shaft, connecting rod and their
functions, engine terminology
Cylinder- Cylinder is the main body of IC engine. Cylinder is a part in which the intake of fuel,
compression of fuel and burning of fuel take place.
The main function of cylinder is to guide the piston,
To provide for engine cooling
To handle the pressure and temperature of the combustion of fuel

Cylinder head- The top end of the engine cylinder is closed by means of removable cylinder
head.
The main function of cylinder head is to seal the cylinder block.
To prevent the entry and exit of gases from the cylinder.

Piston- A piston is fitted to each cylinder as a face to receive gas pressure and transmit the
thrust to the connecting rod.
The main function of piston is to give tight seal to the cylinder through bore and slide freely
inside the cylinder.
To transmit the combustion force to connecting rod.

Valves- To control the inlet and exhaust of gases, valves are used.
Two valves are used for each cylinder,
one for inlet of air-fuel mixture inside the cylinder (Inlet Valve) and
other for exhaust of combustion gases (Exhaust Valve).

Crank shaft- The crankshaft of an internal combustion engine receives the efforts or thrust
supplied by piston to the connecting rod and converts the reciprocating motion of piston into
rotary motion of crankshaft. The crankshaft mounts in bearing so it can rotate freely.

Connecting rod- Connecting rod connects the piston to crankshaft and transmits the motion
and thrust of piston to crankshaft. It converts the reciprocating motion of the piston into
rotary motion of crankshaft.
Piston rings- To provide a good sealing fit and less friction resistance between the piston
and cylinder, pistons are equipped with piston rings

Engine bearing- The main function of bearings is to reduce friction between these moving
parts. The crankshaft is supported by bearing.
The connecting rod big end is attached to the crank pin on the crank of the crankshaft by a
bearing.
A piston pin at the small end is used to attach the connecting rod to the piston also rides in
bearings.

Crankcase
The main body of the engine at which the cylinder are attached and which contains the
crankshaft and crankshaft bearing is called crankcase. It serves as the lubricating system
too and sometime it is called oil sump. All the oil for lubrication is placed in it.

Spark plug
It is used in spark ignition engine. The main function of a spark plug is to conduct a high
potential from the ignition system into the combustion chamber to ignite the compressed air
fuel mixture.

Injector
Injector is usually used in compression ignition engine. It sprays the fuel into combustion
chamber at the end of compression stroke. It is fitted on cylinder head.

Manifold
The main function of manifold is to supply the air fuel mixture and collects the exhaust gases
equally from all cylinder. In an internal combustion engine two manifold are used, one for
intake and other for exhaust.

Camshaft
Camshaft is used in IC engine to control the opening and closing of valves at proper timing.
For proper engine output inlet valve should open at the end of exhaust stroke and closed at
the end of intake stroke. It is driven by the timing belt which drives by crankshaft.

Gudgeon pin or piston pin

These are hardened steel pin that connects the piston to connecting rod. It is made hollow
for lightness.

Flywheel
A flywheel is secured on the crankshaft. The main function of flywheel is to rotate the shaft
during non-power strokes. It also makes crankshaft rotation more uniform.

Engine terminology
Bore “D” is the diameter of the cylinder.
Stroke “L” is the linear distance, piston travels from Top Dead Center (TDC) to Bottom Dead Center
(BDC).
Compression Ratio “Cr” is the ratio of “Total Volume” in cylinder at BDC to Volume at TDC.
Piston Displacement “Vs” is the swept volume of the piston when it moves from TDC to BDC.
Engine Displacement “n x Vs” is the total of the swept volume of all the piston in the engine.
n=number of cylinder

𝑽𝒔 = 𝝅/𝟒 ∗ 𝑫𝟐 ∗ 𝑳

𝒆𝒏𝒈𝒊𝒏𝒆 𝒅𝒊𝒔𝒑𝒍𝒂𝒄𝒆𝒎𝒆𝒏𝒕 = 𝝅/𝟒 ∗ 𝑫𝟐 ∗ 𝑳 ∗ 𝒏

2.3 Cycle of operations – Otto and Diesel cycles, their P-V diagrams and
thermal efficiencies.

Otto cycle-
DIESEL CYCLE
2.4 Two-stroke and four-stroke engines, construction and working
CONSTRUCTION AND WORKING OF 2-stroke Petrol Engine

Spark plug -mounted on cylinder head.

Cylinder head- Bolted to the Cylinder
Cylinder- houses the piston. It has fins for air cooling.
Ports- holes in cylinder for Inlet, exhaust.
Piston- Movable part in cylinder connected to connecting rod by gudgeon pin.
Connecting Rod- connects piston to crankshaft.
Crankshaft- it has cranks and it bearing mounted on crankcase.
Crankcase- it houses the connecting rod, crankshaft.
Oil Sump- it is attached to crankcase at the bottom for storing lubricating oil.
WORKING OF 2-stroke Petrol Engine
Intake– Air fuel mixture from carburetor enters the crankcase from the intake port and then enters
the top of the piston through transfer port.
Compression- the upward stroke of the piston compresses the charge till the piston reaches the
TDC.
Ignition- the spark from spark plug ignites the mixture and burns it.
Power stroke- the energy released by combustion generates the force that turns the crankshaft.
Exhaust- just when the piston while moving towards BDC, exposes the outlet port, the exhaust
gases will be released to the atmosphere
All the processes occur in two strokes of the piston.
During upward stroke- inlet, exhaust, compression is achieved
During Downward stroke- power, exhaust, inlet is achieved

CONSTRUCTION AND WORKING OF 4-stroke Petrol Engine

Spark plug -mounted on cylinder head.
Cylinder head- Bolted to the Cylinder
Cylinder- houses the piston. It has fins for air cooling of cylinders or water jackets for cylinder
cooling.
Valves- they are mounted on cylinder head for inlet and exhaust operated by overhead camshaft
or lower mounted camshaft-pushrod-rocker arm assembly.
Piston- Movable part in cylinder connected to connecting rod by gudgeon pin.
Petrol injector- for injecting petrol in air in suction line to produce mixture
Or Carburetor- mounted before inlet manifold for producing air –petrol mixture.
Connecting Rod- connects piston to crankshaft.
Crankshaft- it has cranks and it bearing mounted on crankcase.
Camshaft- as mentioned above
Crankcase- it houses the connecting rod, crankshaft.
Oil Sump- it is attached to crankcase at the bottom for storing lubricating oil.

WORKING OF 4s Petrol Engine

Inlet- the piston moves from TDC to BDC, inlet valve (IV) opens to allow petrol air mixture into
cylinder.
Exhaust valve (EV) remains closed.
Compression- At BDC, the IV closes, the piston travels to TDC, it compresses the mixture raising
its temperature and pressure.
Ignition- At TDC, the Spark plug ignites the petrol air mixture thus achieving ignition.
Power-the high pressure and temperature gases pushes the piston down thus driving the
crankshaft.
Exhaust- just before the TDC, the EV opens thus releasing the low temperature and pressure
gases out, the piston also pushes the gases out on its upward stroke.
There are 4 independent strokes of piston required to complete inlet, compression, power and
exhaust processes.

CONSTRUCTION AND WORKING OF 2s DIESEL Engine

CONSTRUCTION OF 2s DIESEL Engine

Cylinder head- Bolted to the Cylinder
Cylinder- houses the piston. It has fins for air cooling of cylinders or water jackets for cylinder
cooling.
Inlet Port- holes in cylinder for Inlet.
Exhaust Valve- they are mounted on cylinder head for exhaust operated by overhead camshaft or
camshaft-pushrod-rocker arm assembly.
Piston- Movable part in cylinder connected to connecting rod by gudgeon pin.
Air Blower- is mounted before the inlet manifold.
Connecting Rod- connects piston to crankshaft.
Crankshaft- it has cranks and it bearing mounted on crankcase.
Crankcase- it houses the connecting rod, crankshaft.
Oil Sump- it is attached to crankcase at the bottom for storing lubricating oil.

WORKING OF 2s DIESEL Engine

Air enter the cylinder through the intake Port, when the piston is at BDC.
Take port also opens During upward stroke, the intake port closes and Compression process starts
When piston is at TDC, Diesel injectors sprays diesel and combustion takes place
The Piston is pushed downwards and expansion process takes place.. while moving downwards
exhaust valve opens and simultaneously intake port also opens leading to suction and discharge
process happening together.
In two strokes of Piston, all 4 processes takes place.

CONSTRUCTION AND WORKING OF 4stroke DIESEL Engine

Diesel Injector -mounted on cylinder head.
Cylinder head- Bolted to the Cylinder
Cylinder- houses the piston. It has fins for air cooling of cylinders or water jackets for cylinder
cooling.
Valves- they are mounted on cylinder head for inlet and exhaust operated by overhead camshaft
or lower mounted camshaft-pushrod-rocker arm assembly.
Piston- Movable part in cylinder connected to connecting rod by gudgeon pin.
Diesel injector- for injecting Diesel into the cylinder after air is compressed.
Connecting Rod- connects piston to crankshaft.
Crankshaft- it has cranks and it bearing mounted on crankcase.
Camshaft- as mentioned above
Crankcase- it houses the connecting rod, crankshaft.
Oil Sump- it is attached to crankcase at the bottom for storing lubricating oil.

WORKING OF 4s Diesel Engine

Suction process- the piston moves from TDC to BDC, inlet valve (IV) opens to allow air into
cylinder. During inlet, exhaust valve (EV) remains closed.
Compression Process- At BDC, the IV closes, the piston travels to TDC, it compresses the air
raising its temperature and pressure.
Ignition- At TDC, the Diesel injector injects the diesel thus achieving ignition.
Power Process-the high pressure and temperature gases pushes the piston down thus driving the
crankshaft.
Exhaust Process- just before the TDC, the EV opens thus releasing the low temperature and
pressure gases out, the piston also pushes the gases out on its upward stroke.
There are 4 independent strokes of piston required to complete inlet, compression, power and
exhaust processes.

=====================
2.5 Valve timing diagrams
2.6 Differences between two-stroke and four-stroke, and between petrol and
diesel engines.

======================================
2.7 Schematic flow diagrams of cooling, lubrication and fuel systems;
Introduction to MPFI.

Schematic flow diagrams of Water Cooling

Schematic flow diagrams of Lubrication system

Functions of lubrication system:

 To lubricate each part of the bearing, and
 To reduce friction and wear.
 Provide a film between moving parts.
 To carry away heat generated inside bearing due to friction and other causes.
 Sealing – Filling in uneven surfaces.
 To prevent corrosion and
 To prevent contamination by dirt.
 Cleaning – Holding contaminants in suspension.
 Dampening & Cushioning – Of components under high stress.
Schematic flow diagrams of fuel systems petrol or
---------------------
Introduction to MPFI

MPFI is used in Petrol engines because it gives precise control over the amount
of fuel injected in the incoming air to the cylinder.
MPFI is an intelligent way of doing what a Carburettor does.
In this system each cylinder has injectors to spray the fuel/air charge into the cylinders.
The fuel and air are mixed in what is called the intake manifold.

In MPFI, each injector in controlled by the ECU (Electronic control unit).

The injector is mounted right at the intake before the Inlet valve, hence the ability to mix the
petrol with incoming air is improved,
The ECU monitors various engine parameters and accordingly decides just how much fuel is to
be injected into the cylinder and at precisely what time.
This system also allows each injector cylinder to be controlled independently.
ADVANTAGES OF MPFI

(1) More uniform A/F mixture will be supplied to each cylinder, hence the difference in power
developed in each cylinder is minimum.
(2)Vibration from the engine equipped with this system is less, due to this the life of engine
components is improved.
(3) Immediate response, in case of sudden acceleration / deceleration.
(4) Since the engine is controlled by ECU, more accurate amount of A/F mixture will be supplied
and as a result complete combustion will take place. This leads to effective utilization of fuel
supplied and hence low emission level.
(5) The mileage of the vehicle will be improved.

ECU or the Electronic Control Unit is the brain behind the MPFI system. It is a
computer chip which receives input on various engine parameters, compares them
against preloaded engine and throttle maps and accordingly decides exactly how
much fuel is to be injected into which cylinder and at what time.

2.8 Calculation of Brake Power, Indicated Power, various efficiencies and

specific fuel consumption.
 Preparation of heat balance sheet of an IC engine.

Brake Power.

The brake power (briefly written as B.P.) of an IC Engine is the power available at
the crankshaft.

1) in case of rope brake

B.P. = 2*3.142*N*T
60

Where
W= dead load in N
S = spring balance reading in N
D= diameter of rope in m
N= speed of engine in rpm

B.P. = 2*3.142* (W-S)*N*D/2

60
Where
W= dead load in N
S = spring balance reading in N
D= diameter of rope in m
N= speed of engine in rpm
Where
N= speed of engine in rpm
T= Brake torque of shaft in N-m

Brake power unit is KN-m/sec and

Brake power= SI unit is KW (kilowatt)

Indicated power formula for 4 stroke engine

I.P. = P*L*A*N* k
2× 60
----------------------------------------------
Indicated power formula for 2 stroke engine
I.P. = P*L*A*N* k
60

Where
P= mean effective pressure given in KN/ m² = kPa
L= length of stroke given in m
A= area of bore of each cylinder given in m²
N= rotation per minute (RPM)
k = number of cylinder
Indicated power unit is KN-m/sec and
indicated power SI unit is KW (kilowatt)

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BP= Brake Power, kilowatt, kW

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Heat Balance Sheet

Heat Balance Sheet is an account of heat supplied and heat utilized in various ways in the
IC engine.
Heat balance sheet is used to get necessary information regarding the performance of IC
Engine.
 Fuel power = Indicated power + Exhaust power + Cooling Power
+Unaccounted Power

Indicated Power = Brake Power + Frictional power loss

The heat supplied to engine is only by combustion of fuel and is equal to :-

fuel power Qs = mf X CV
Where,
mf = mass of fuel used in kg/sec
CV = Calorific value of fuel in KJ/kg
Qs= fuel power = kW

List of heat which are utilized by the engines are:-

1) Heat equivalent to brake power of engine.

2) Heat carried away by cooling water.
3) Heat exhausted with the exhaust gases
4) Un-accounted heat loss.
Heat carried away by cooling water. Qw in Kilowatt

Qw = Mw * CPw * ( Two – Twi ) in KJ/s

Where ,
Mw = Mass of cooling water circulated in Kg/s
CPw = Specific heat of cooling water which is equal to 4.186 KJ/kgK
Twi = Temperature of cooling water at inlet in °C .
Two = Temperature of cooling water at outlet of the engine in °C

Heat carried away by the exhaust gases Qg in Kilowatt

Qg = mg *CPg * (Tg– TR)

Where ,
mg = mass of exhaust gases in kg/s
ma = mass of air consumed in kg/s
mf = mass of fuel consumed in kg/s
CPg = Specific heat of exhaust gases
= 1.005 KJ/kgK
Tg = Temperature of exhaust gases in °C
TR = Room temperature in °C