Chapter-2

IC engines
Heat engine:
It is a device which generates power by converting heat energy
into mechanical energy. This mechanical energy can be used to
produce electricity, to pump water, to drive automobiles etc.,

Types of Heat engines:

 External combustion engines
 Internal combustion engines
If combustion takes place outside of the engine the engines are
called external combustion engines, if the combustion takes place
inside the engine the engines are called I.C engines.
Advantages of I.C engines over E.C engines: (3 Marks)
 More compact in size
 Occupies less space
 Starting of the engine is easy
 High thermal efficiency
 Simple in design

Constructional features of IC engines: (8 Marks)

 1. Cylinder Head: It is the one of the main part of an IC engine
which is located on the top of the engine and it contains camshaft,
valves, spark plug, fuel injector. It is made up of grey cast iron.
2. Cylinder: It is cylindrical hallow barrel in which the piston
reciprocates. One end of the cylinder is connected to cylinder head
and other end is open to the crankcase. It is made up of grey cast
iron.
3. Piston: It is component of IC engine which reciprocates inside the
cylinder to complete all the events of an IC engine. It transmits
the force generated in the cylinder to the crankshaft through
connecting rod.

4. Piston rings: The piston rings provides a tight seal between

piston and cylinder wall to prevent the leakage of combustion
gases. These rings are made up of cast iron with chrome plating
to reduce the wear of the rings.

5. Connecting rod: It is connected between piston and the crank. It

converts the reciprocatory motion of the piston into rotory motion
of the crank shaft. It is made up of steel.

6. Camshaft: it is a shaft located on the top of the engine and it is

rotated by the crankshaft. The speed of the camshaft is half of the
speed of the crankshaft. The camshaft opens and closes the inlet
and outlet valves.

7. Valves: two valves are provided for each cylinder of the engine.
One is inlet valve and other one is exhaust valve. Inlet valve is
used for intake of air fuel mixture and exhaust valve is used for
sending out the combustion gases out of the cylinder.

Important terms in IC engines: (3 Marks)

a) Bore(d): the inside diameter of the cylinder is called bore

diameter.
b) TDC and BDC: The upper most position of the cylinder is called
TDC and bottom most position of the cylinder is called BDC.
c) Piston stroke(L): The distance travelled by the piston from one
dead center to another dead center is called stroke length.
 d) Stoke Volume (Vs): The volume displaced by the piston from one
dead center to another is called stroke volume or swept volume.
It is measured in Cubic centimeters (c.c)
e) Clearance volume (Vc): The space between cylinder head and face
of the piston at TDC is called clearance volume
f) Compression ratio(r): The ratio of total volume of the cylinder
when the piston is at BDC and the clearance volume is called
compression ratio.
Events of an IC engine:
 Suction
 Compression
 Expansion
 Exhaust
Tpes of IC engines: (3 Marks)
 Petrol engine
 Diesel engine
 Single cylinder engine
 Multi cylinder engine
 Air cooled engines
 Water cooled engines
Working of four stroke petrol engines (S.I engine): (8 Marks)
 In this engine, all the events of IC engine like suction,
compression, expansion and exhaust are completed in four movements
of the piston. This is why these engines are called four stroke engines.
Suction stroke: During this stroke, the inlet valve is opened and
exhaust valve is closed. The piston moves from TDC to BDC, as the
piston moves downwards, partial vacuum is created inside the engine
cylinder due to which the fresh charge i.e., air fuel mixture enters into
the cylinder.
Compression stroke: During compression stroke, the piston moves
from BDC to TDC and both the valves are closed and the piston
compresses the charge. At the end of the compression stroke the spark
plug supplies spark to ignite the fuel.
Expansion stroke: During expansion stroke, due to combustion high
pressure is generated inside the cylinder which forces the piston to
move from TDC to BDC. Here the power is transmitted to the
crankshaft.
Exhust stroke: During this stroke, exhaust valve is opened and inlet
valve is closed. The piston moves from TDC to BDC and the exhaust
gases are sent out of the cylinder.

Working of four stroke Diesel engines (C.I engine): (8 Marks)

 In this engine, all the events of IC engine like suction,
compression, expansion and exhaust are completed in four movements
of the piston. This is why these engines are called four stroke engines.
Suction stroke: During this stroke, the inlet valve is opened and
exhaust valve is closed. The piston moves from TDC to BDC, as the
piston moves downwards, partial vacuum is created inside the engine
cylinder due to which the fresh charge i.e., only air enters into the
cylinder.
Compression stroke: During compression stroke, the piston moves
from BDC to TDC and both the valves are closed and the piston
compresses the air to a high temperature. At the end of the
compression stroke the fuel is injected into the engine cylinder by the
fuel injector. As the temperature of the air is high, each and every air
particle acts as spark to burn the fuel.
Expansion stroke: During expansion stroke, due to combustion high
pressure is generated inside the cylinder which forces the piston to
move from TDC to BDC. Here the power is transmitted to the
crankshaft.
Exhust stroke: During this stroke, exhaust valve is opened and inlet
valve is closed. The piston moves from TDC to BDC and the exhaust
gases are sent out of the cylinder.

Working of Two stroke petrol engines (S.I engine): (8 Marks)

 In this engine, all the events like suction, compression, expansion
and exhaust are completed in two movements of the piston. This is why
these engines are called two stroke engines.
During the upward movement of the piston from BDC to TDC, the
inlet port is opened and the fresh charge enters into the crank case. At
the same time the charge which is above the piston is compressed and
the at the end of the compression the spark is supplied by the spark
plug to burn the air fuel mixture.
After combustion, high pressure is developed inside the cylinder
due to which the piston is forced to move from TDC to BDC. During the
downward movement of the piston, exhaust port is opened first and the
combustion gases are send out of the cylinder and then the transfer
port is opened to allow the fresh charge into the top of the cylinder and
the process is repeated.
Advantages of S.I engines over C.I engines: (3 Marks)
 Initial cost is less
 Light in weight than CI engine
 Easy to start
 Required lighter fly wheel
Disadvantages of S.I engines over C.I engines:
 Chances of pre-ignition
 Suitable for light duty vehicle
Differences between 2 stroke and 4-stroke engines: (3Marks/8Marks)

2-Stroke Engine 4-Stroke Engine

 Contains ports  Containes valves
 The charge enters into the  The charge enters into the
crank case engine cylinder
 All events are completed in 2  All the events are completed
strokes of the piston in 4 strokes of the piston
 Thermal efficiency is low  Thermal efficiency is high
 More noisy  Less noisy
 Used in light duty vehicles  Used in heavy duty vehicles
 Requires light weight fly  Requires heavy fly wheel
wheel
Differences between S.I and C.I engines: (3 Marks/8 Marks)

S.I.Engine(Petrol Engine) C.I Engine(Diesel Engine)

 works on otto cycle  Works on diesel cycle
 Petrol is the fuel  Diesel is used as fuel
 air fuel mixture is  Only air is supplied
supplied during suction. during suction stroke
 Compression ratio is
 Compression ratio is low
high
 Spark plug is used for  Spark plug is not used
ignition for ignition
 Low thermal efficiency  High thermal efficiency
 Light in weight  More in weight
Indicator diagram: (3 Marks/8 Marks)

The indicator diagram is pressure volume graph which indicates

the variation of pressure and volume inside the engine cylinder. This
diagram is generated by using an instrument called engine indicator.
It contains a small cylinder with piston. The piston movement is
proportional to pressure with in the cylinder. A link mechanism is
placed between piston and pencil. When the piston moves inside the
cylinder, the link mechanism moves the pencil on the surface of the
drum. A chord or paper is wrapped around the drum and the pencil
movement on this paper generates P-V diagram which is called
indicator diagram. The area in the p-v diagram indicates the work done.
Indicator diagram for 4-Stroke S.I engine: (3 Marks)

Indicator diagram for 4-Stroke C.I engine: (3 Marks)

Components of fuel injection system in S.I engine:

 Fuel feed pump
 Fuel filter
 Simple carburator
 Zenith carburator.
Fuel feed Pump: (8 Marks)

Fuel feed pump is used to supply fuel to the engine.

It contains fuel chamber, plunger, barrel, inlet valve, outlet valve,

springs, cam, etc.,

In a fuel feed pump the plunger moves in upward and downward

direction by the rotation of cam. When the plunger moves in downward
direction the inlet valve opens and outlet valve is closed, due to this the
fuel enters into the fuel chamber. Now, when the plunger moves in
upward direction, the fuel pressure in the fuel chamber is increased,
due to this the outlet valve is opened and inlet valve is closed. This
pressurized fuel goes to the next component of the fuel injection
system.

Fuel filter: (8 Marks)

 Fuel filter is used to remove impurities which are present in the
fuel.

It contains a bowl, filter element, perforated tube, inlet and outlet

etc.,

In a fuel filter the fuel enters into the bowl through inlet and
passes through the filter element during which the impurities are
removed from the fuel. The clean fuel now enters into the perforated
tube from where it goes into the next component of the fuel injection
system through the outlet. The dust particles which are collected at the
bottom of the bowl are removed periodically.

Fuel injection pump: (8 Marks)

The fuel injection pump is used to supply pressurized fuel to the

engine cylinder.

It contains a barrel, plunger, inlet port, spill port, delivery valve,

outlet passage, rack and pinion etc.,

In a fuel injection pump, the plunger reciprocates inside the

barrel. During the downward movement of the plunger the fuel enters
into the barrel through inlet port. When the plunger moves in upward
direction both the ports are closed and the fuel pressure is increased.
If this fuel pressure is greater than the spring force of the delivery valve,
the delivery valve is opened and the fuel goes into the fuel injector
through outlet passage.

Up on further movement of the plunger in upward direction, the

helical groove on the plunger opens the spill port which reduces the
pressure of the fuel. If the pressure of the fuel is less than the spring
force of the delivery valve then the delivery valve is closed and the fuel
supply is stopped.

Fuel injector: (8 Marks)

The purpose of fuel injector is to supply high pressure fuel into

the engine cylinder.

It contains a valve, fuel passage, pressure chamber, orifice etc.,

In a fuel injector, the high pressure fuel enters into the pressure
chamber through fuel passage. If the fuel pressure is greater than the
spring force of the valve, the valve is lifted up and the fuel is injected
into the engine cylinder through orifice. When the fuel pressure is less
than the spring force of the valve, the valve moves downwards and
closes the orifice to stop the fuel supply.
Simple carburetor: (8 Marks)

The purpose of a carburetor is to supply air fuel mixture to the

engine cylinder.

It consists of float chamber, float, venturi tube, mainjet, choke

valve, throttle valve, throat section, etc.,

In a simple carburetor the fuel enters into the float chamber and
when sufficient fuel is reached the needle valve closes the opening of
the float chamber. A vent hole is provided on the top of the float
chamber so that atmospheric pressure acts on the fuel.

During suction stroke, a partial vacuum is created inside the

carburetor due to which the atmospheric air enters into the venturi
tube and when it passes through the throat area, the velocity increases
and pressure decreases. Due to this pressure difference between throat
area and float chamber, the fuel starts flowing from the main jet in the
form of fine spray which mixes with air to form air fuel mixture. This
air fuel mixture is supplied to the engine cylinder according to the
engine requirements.
Zenith carburetor: (8 Marks)

The purpose of zenith carburetor is to supply air fuel mixture to

the engine cylinder.

It consists of float chamber, float, vent hole, compensating well,

venturi tube, main jet, compensating jet, starting jet, choke valve,
throttle valve etc.,

In a zenith carburetor during idle or starting condition of the

vehicle, the throttle valve opening is less and it creates a vacuum near
the starting jet. Due to this pressure difference between the starting jet
and the compensating well, the fuel starts flowing from starting jet.

As the throttle valve is opening is increased, high vacuum is

created at the throat section and fuel starts flowing from main jet due
to the pressure difference between the float chamber and throat
section. When more amount of fuel is to be supplied to increase the
speed of the vehicle, the compensating jet starts supplying fuel along
with main jet until the required speed of the vehicle is reached.
Battery ignition system: (8 Marks)

The purpose of the battery ignition system is to supply spart for

ignition.

It consists of core, battery, ignition switch, primary windings,

breaker point, condenser, secondary windings, distributor, rotor, spark
plugs, etc.,

In a batter ignition system when the ignition switch is closed, a

low voltage current starts flowing from the battery to the primary
windings and magnetize the core. If the breaker points are opened, this
low voltage current passes into the condenser and charges the
condenser to a voltage higher than the battery. When the breaker
points are closed, the condenser starts discharging of the current in
opposite direction.

Due to the rapid reversal of the current and magnetic field in the
core, a very high voltage is induced in the secondary windings and this
high voltage current is supplied to the spark plugs by means of
distributor and rotating rotor.
Magneto ignition system: (8 Marks)

The purpose of the magneto ignition system is to supply spark for

ignition.

It consists of permanent magnet, ignition switch, primary

windings, breaker point, condenser, secondary windings, distributor,
rotor, spark plugs, etc.,

In a Magneto ignition system, the primary and secondary

windings are located on the top of the coil and rotating magnet is
located at the bottom of the coil.

when the ignition switch is closed, due to the rotation of the

magnet a low voltage current starts flowing from the coil to the primary
windings. If the breaker points are opened, this low voltage current
passes into the condenser and charges the condenser to a voltage
higher than the coil. When the breaker points are closed, the condenser
starts discharging of the current in opposite direction.

Due to the rapid reversal of the current and magnetic field in the
coil, a very high voltage is induced in the secondary windings and this
high voltage current is supplied to the spark plugs by means of
distributor and rotating rotor.
Air cooling system: (8 Marks)

The purpose of air cooling system is to remove unwanted heat

from the engine cylinder. It consists of cylinder, metaling fins, etc.,

In an air-cooling system, the heat from the engine cylinder is

removed by circulating air around the cylinder. To increase the heat
transfer, metallic fins are provided around the cylinder, so that the
surface area increases and more amount of air can be circulated for
effective heat removal.

Gravity type water cooling system: (8 Marks)

The purpose of gravity type water cooling system is to remove

unwanted heat from the engine cylinder. It consists of engine
cylinder, water jacket, radiator, fan, etc.,

In a gravity type cooling system, circulation of water between

radiator and engine cylinder takes place due to the density difference
between hot water and cold water. Initially, the cold water flows into
the water jacket from the bottom and it absorbs heat from the engine
and the water becomes hot and this hot water comes to the top. This
hot water is then moved into the radiator due to the density difference
and flows through the radiator tubes. The water is cooled in the
radiator tubes by means of atmospheric air passing through the tubes.
The cooled water reaches the bottom of the radiator and then moves
into the engine cylinder and the process is repeated.

Forced circulation water cooling system: (8 Marks)

The purpose of a forced circulation water cooling system is to

remove excess heat from the engine cylinder.

It contains engine cylinder, water jacket, radiator, radiator

tubes, thermostat, water pump etc.,

In a forced circulation cooling system, a thermostat is used to

control the flow of water between the radiator and water jacket. In this
system, the water is supplied to the water jacket from the bottom by
using a pump. The water then absorbs the heat from the cylinder and
when desired temperature of water is reached, the thermostat valve is
opened and the hot water passes to the top of the radiator. This hot
water passes through the radiator tubes where heat transfer takes
place between the air and radiator tubes and the water temperature is
reduced. This cold water moves to the bottom of the radiator and the
process is repeated.
Splash lubrication system: (8 Marks)

The purpose of lubricating system is to provide lubrication to the

moving parts of an engine.

It consists of cylinder, piston, connecting rod, crank, dipper, oil

sump, crankcase etc.,

In this system, the movement of the piston inside the engine

cylinder rotates the crank. The dipper is connected to one end of the
crank. When the crank rotates, the dipper dips into the oil and splashes
the oil into the cylinder and lubricates the parts. In this system small
pockets are provided to retain the splashed oil for effective lubrication.

Pressure lubrication system: (8 Marks)

 The purpose of lubricating system is to provide lubricantion to the
moving parts of an engine.

It contains oil sump, filter, pump, oil lines, oil gallery, engine parts
etc.,

In this system, the oil from the sump is filtered and sent to the oil
galleries by using oil pump. The galleries are the horizontal tubes which
are located in between the engine parts. The oil from the oil gallery
passes through the oil lines and reaches drilled holes of the connecting
rod and lubricates the bearing of the crank and crank shaft. Now the
oil passes through the drilled holes into the piston and lubricates the
piston and cylinder walls. Similarly, the oil lines are provided to
lubricate the cams, valves which are located on the camshaft.

Important properties of the lubricating oil: (3 Marks)

 High viscosity
 Low freezing point
 Good corrosion resistance
 High oiliness

Governing: (3 Marks)
The process of controlling the speed of the engine by adjusting the
supply of fuel is called governing. The device used for this process is
called governor.

Methods of governing: (8 Marks)

 Hit and miss governing method
 Quality governing method
 Quantity governing method
 Combined governing method.

Hit and miss governing method:

In this governing method, the fuel supply is stopped for one or

more number of cycles to control the speed of the engine.
Quality governing method:

In this method, the quality of fuel which is supplied to the engine

is changed by changing the air fuel ratio. Here, the amount of air is
constant but the amount of fuel in air fuel mixture is changed to control
the speed of the engine.

Quantity governing method:

In this method, the quantity of air fuel mixture supplied to engine

is changed to control the speed of the engine. Here, the amount of fuel
is not changed but the amount of air in air fuel mixture is changed.

Combined governing method:

In this method, both quantity and quality of air fuel mixture is

changed to control the speed of the engine. Here, the amount of fuel
and amount of air in air fuel mixture is changed.

Super charging in IC engines: (3 Marks)

The process of increasing the pressure of air which enters into the
cylinder is called supercharging. It is done by using compressor or
blower. Supercharging increases power output, volumetric efficiency of
the engine.