INTRODUCTION – PISTON ENGINE
Piston engines are internal combustion engines that burn a mixture of fuel and air inside
a combustion chamber. The chamber is provided with a piston that moves within the
compression chamber. The energy for the movement of the piston is provided by the air-
fuel mixture. Piston engines operate similar to the car and other automobile engines. In
its basic operation, a valve in the engine permits air into the chamber (called the
cylinder) which is compressed by the moving piston. When an appropriate compression
is reached, fuel is allowed into the compressed air through another inlet as a fine spray.
Finally, the compressed fuel-air mixture is ignited with a spark provided by a spark plug,
which causes the mixture to explode violently. The explosive power is used to move the
piston back, and remove the exhaust gases from the compression chamber. The return
movement of the piston is conveyed to the wheel and fans of the aircraft which causes it
to rotate at high speed. In a propeller powered aircraft, much of the thrust is created by
the propellers, which creates the upward lift for the aircraft.
The general aircraft piston engine used for thrust generation, consist of the following
basic components.
CRANK CASE:
The crank case of an engine is the housing that houses the various components
surrounding the crankshaft. Therefore it is the basic foundation of the engine. The crank
case performs the following functions:
It contains bearings in which crankshaft revolves.
It provides a tight enclosure for lubricating oil.
It supports various internal and external mechanism of power plant
It provides a support for attachment of cylinder.
It prevents the misalignment of the shaft and its bearings.
BEARINGS:
Bearing is any surface that supports or is supported by another surface. The
bearings in any aircraft engine are designed to minimize the friction and wear resistance.
They must reduce the friction of moving parts and also take the thrust loads, radial loads
or combination of both.
CRANK SHAFT:
The crankshaft transforms the reciprocating motion of the piston to rotating motion for
turning the propeller. It is a shaft composed of one or more cranks located at definite places
between the end. Since the crank shaft is the backbone of the engine it is subjected to all forces
developed within the engine and hence should be strongly constructed.
CONNECTING ROD ASSEMBLIES:
Connecting rod is the link which transmits forces between the piston and crankshaft of an
engine. It transmits the reciprocating motion of the piston to the rotating movement of the crank
shaft. The principle type of connecting assemblies are the
Plain type
Fork and handle type
Articulated type
PISTON:
The piston is a plunger that moves back and forth or up and down within the engine
cylinder barrel. It transmits the force of the burning and expanding gases in the cylinder through
the connecting rod to the engine crank shaft. As the piston moves down the cylinder, during
intake stroke, it draws in the air fuel mixture. As it moves up, it compreses the charge. Ignition
takes place and the expanding gases cause the piston to move towards the crank shaft.The piston
forces the burnt gases out of the combustion chamber during the next stroke.
CYLINDERS:
The cylinder of an IC engine converts chemical heat energy of the fulel to mechanical
energy and transmits it through the connecting rods to the rotating crank shaft. The cylinder
assembly used for present day engines usually includes cylinder barrel, cylinder head, valve grid,
valve seats, rocker arms, cooking fins
VALVES:
In general a valve is a device for regulating or determining the check on the flow of a
liquid or a gas by a movable part which opens or closes into a passage.The main purpose of a
valve in IC engine is to open and close parts which are into the combustion chamber of the
engine namely intake and exhaust ports.The valves are associated with valve guides,valve seats
and valve springs.
PROPELLERS:
They are essential aircraft parts that provide the necessary thrust for moving the aircraft.
The propeller is connected to the engine by means of a shaft.The propeller consists of two or
more blades and a central hub to which the blades are attached service. For an aircraft to remain
in an airworthy condition the following conditions have to be fulfilled.
Periodic inspection Repairs Overhauls and replacements
EX.NO 1 DISMANTLING OF PISTON ENGINE
AIM:
To dismantle a piston engine and study its particular components.
TOOLS REQUIRED:
Special tools for notching crank shaft.
Universal socket for spark plug
Selected spanner no: 6-19
Ring spanner no: 6-22
Adjustable spanner
Plier, cutter and screwdriver
Value depression tool
Crow foot spanner
PROCEDURE:
1.Remove spark plug and rocker curves
2.Remove starter and accessories
3.Turn the engine over such that cylinders are upper most
4.Remove controls completely with universal joints.
5.Remove air scoop, plug leads, distribution covers.
6.Remove induction system with carburetor.
7.Unscrew push rod ball socket from rockers.
8.Take out push rod and push rod covers.
9.Remove cylinder baffle plate.
10.Remove cylinder.
11.Remove piston rings.
12.Extract gudgeon pin, air clip.
13.Withdraw gudgeon pin and piston. Remove magnetos.
14.Remove gearbox with timing gear cover.
15.Turn the engine cover on its stand. Remove starter.
16.Remove adaptor, thrust bearing cover and top cover.
17.Detach big and bearing caps. Withdraw connecting rod.
18.Remove main, intermediate bearing caps.
19.Lift crankshaft. Unscrew idle gear hub bolt.
20.Draw off gear wheel. Remove magneto drivers.
21.Unscrew camshaft gagging the gear.
22.Remove camshaft rear bearing bush.
23.Withdraw camshaft. Remove tappet and guides.
24.The parts are kept for visual inspection.
RESULT:
Thus the stripping of piston engine is carried according to instructions in the
manufacturer’s maintenance manual.
EX NO 2 PISTON ENGINE –CLEANING,VISUAL INSPECTION ,NDT CHECKS
AIM:
To perform the NDT checks on aircraft components
APPARATUS REQUIRED:
Aircraft component
Kerosene
Lubricating oil
French chalk
Methylated spirit
Heating source
PROCEDURE:
I. For parts that can be removed from aircraft
a) For these components, hot fluid chalk method is used cleaning must be done
b) A mixture of three parts of kerosene and one part of lubricating oil is heated at 90 –
o
95 C.
c) The removal components such as piston’s connection rods, cylinders,
combustion chamber are dipped in the hot fluid
d) Take the component out and dried out apply French chalk on it.
e) Extra French chalk is to be removed by tapping.
f) Then cool the component, the contraction of the piston on cooling will force the
oil out of any crank and stain the French chalk with a yellowish color.
B For components that cannot be removed from aircraft.
a) For a components that cannot be removed from aircraft such as landing gear
mounting, cold fluid chalk method is used cleaning is done.
b) French chalk is mixed with Methylated spirit and applied on the components that are
to be checked
c) Excess chalk is removed by tapping.
d) Methylated spirit will evaporate off leaving the cracks stain with French chalk
RESULT:
Thus the NDT checks have been performed on aircraft component
