Table of Contents

Introduction....................................................................................................................................1

Construction of Engine..................................................................................................................1

Main Components of a Four-Stroke Engine...............................................................................1

1. Piston.................................................................................................................................1

2. Crankshaft.........................................................................................................................2

3. Connecting Rod.................................................................................................................2

4. Flywheel............................................................................................................................2

5. Inlet and Outlet Valves.....................................................................................................2

6. Spark Plug.........................................................................................................................2

Principle of Operation...................................................................................................................3

1. Suction/Intake Stroke.....................................................................................................3

2. Compression Stroke..........................................................................................................3

3. Power/Combustion Stroke................................................................................................3

4. Exhaust Stroke..................................................................................................................4

Comparison Between a 2-stroke engine and a 4-stroke engine.............................................4

Honda GX160.................................................................................................................................4

Details of Components of Set 5[4]................................................................................................6

Engine Block...................................................................................................................................7

Recoil Starter with Metal Pawls and cup...................................................................................7

Throttle Lever................................................................................................................................7

Bearings..........................................................................................................................................8

Material Analysis of Aluminum Alloy.........................................................................................8

Manufacturing Analysis of Engine Block..................................................................................13

REFERENCES............................................................................................................................16

1
 Four-Stroke Petrol Engine

Introduction
An internal combustion engine with a four-stroke cycle uses the intake, compression, power, and
exhaust piston strokes to accomplish a single operational cycle. One operational cycle is
completed by the piston making two full passes through the cylinder. Crankshaft rotation is two
revolutions (720°) for an operating cycle. The most prevalent kind of small engine is the four-
stroke cycle engine. Five strokes are completed by a four-stroke engine in a single running cycle:
the intake, compression, ignition, power, and exhaust strokes[1].

Construction of Engine
A four-stroke cycle engine is an internal combustion engine that completes a single operational
cycle using four distinct piston strokes. The intake, compression, power, and exhaust strokes are
among them. The piston travels through the cylinder twice in its entirety to complete a working
cycle. One working cycle requires the crankshaft to rotate twice, or 720°. The most popular cycle
type for small engines is the four-stroke version. A four-stroke engine completes the intake,
compression, ignition, power, and exhaust strokes in a single operating cycle.

Main Components of a Four-Stroke Engine

1. Piston

Through a connecting rod, a piston in an engine converts the expanding pressures of gas into the
mechanical rotation of the crankshaft.

2. Crankshaft

The component that changes reciprocating motion into rotating motion is called a crankshaft.

3. Connecting Rod

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It functions as a lever arm, transferring motion from a piston to a crankshaft.

4. Flywheel

An energy-storing revolving mechanical device is called a flywheel.

5. Inlet and Outlet Valves

It enables us to remove the wasted air-fuel mixture from the cylinder and introduce fresh air with
fuel.

6. Spark Plug

It is an apparatus that feeds the combustion chamber with electric current, which ignites the fuel-
air mixture and causes sudden gas expansion.

Figure 1 Main Components of Four-Stroke Engine

Principle of Operation
The operation of a stroke engine involves the following processes[1].

1. Suction/Intake Stroke

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When the air-fuel mixture is supplied to the combustion chamber, the intake stroke happens. The
piston travels from the Top Dead Center (TDC), which is the piston's furthest position from the
crankshaft, to the Bottom Dead Center (BDC), which is the piston's closest position from the
crankshaft. A region of low pressure is created in the cylinder by the piston moving in the
direction of the BDC. After BDC, the inlet valve needs to open by a few crankshaft rotations.
Following the closure of the intake valve, the cylinder's air-fuel mixture is sealed.

2. Compression Stroke

The trapped air-fuel mixture inside the cylinder is compressed during the compression stroke.
The air-fuel combination is compressed when the piston travels from BDC to TDC during the
stroke. The piston advances with the assistance of the flywheel's momentum. When the charge
ignites, more energy is produced due to the compression of the air-fuel mixture. The amount of
fuel and compressed air that is waiting to ignite inside the combustion chamber is known as the
charge. For the cylinder to be sealed and cause compression, the inlet and exit valves must be
closed.

3. Power/Combustion Stroke

After the crankshaft completes one full rotation during the compression stroke, the second
rotation starts. When a spark plug is used to ignite the compressed air-fuel mixture, the power
stroke happens. Ignition or Combustion is the rapid, oxidizing chemical reaction in which a fuel
chemically combines with oxygen in the atmosphere and releases energy in the form of heat. The
piston head is forced apart from the cylinder head by the hot, expanding gasses.

4. Exhaust Stroke

Exhaust gases fill the cylinder when combustion is complete, which occurs when the piston
reaches BDC during the power stroke. During this stroke, the exhaust valves open, driving the
exhaust gases through the open exhaust valve as the flywheel and other moving components'
inertia force the piston back to TDC. The piston is at TDC at the end of the exhaust stroke,
marking the completion of one running cycle.

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Comparison Between a 2-stroke engine and a 4-stroke engine

The weight of a 4-stroke engine is 50% more than that of a 2-stroke engine. Because gasoline is
used only once per four strokes, a 4-stroke engine is more efficient than a 2-stroke engine. The
torque produced by a 4-stroke engine is higher at a lower RPM than that of a 2-stroke engine at a
higher RPM. Because 2-stroke engines are made to run at a faster RPM, they can wear out
quickly. Due to their simple structure, 2-stroke engines are simpler to repair. Four-stroke engines
are more expensive and require more repairs due to their intricate architecture and larger number
of parts.

Will petrol engines be utilized in a sustainable future?

The source of gasoline and diesel is oil which is a finite resource.
As a result, as it runs out, it will become increasingly rare and expensive, and astute people will
start seeking alternatives that don't use oil. The same applies to cars.
Even though electric propulsion is extremely efficient, it won't likely be the only kind of
propulsion used in cars; other forms will also likely be developed. Vehicles powered by fossil
fuels will ultimately run out of fuel and need to be replaced. T
Oil reserves are commercially viable for between 40 and 50 years, so finding alternatives now is
crucial—not just because oil causes pollution, but also because it's a one-time solution[3].

Honda GX160
The GX160 engine is suitable for a wide range of heavy-duty applications such as construction
equipment, tillers, generators, welders, pumps, and other industrial applications[4].

Engine features:
 OHV design enhances combustion efficiency
 High power-to-displacement ratio
 Easy starting with an automatic decompression system and an easy-to-grip soft recoil starter
handle
 High-quality materials and purpose-built components which ensure reliable, long-term use
 Meets the world's most stringent environmental legislation

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 Low fuel and oil consumption
 Reduced vibration and noise levels

Figure 2 Honda GX160 Model

Table 1 Technical Specification

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 Details of Components of Set 5[4].

The set-5 consists of components as shown in Figure 3.

Engine Block

Recoil Starter

Bearings

Recoil Starter cup

Throttle lever

Figure 3 Set 5 Components name

Engine Block
An essential part of the design and construction of internal combustion engines is an engine
block, sometimes known as a cylinder block. The engine's main parts, such as the cylinders,
pistons, and crankshaft, are supported by this robust piece of equipment.
Recoil Starter with Metal Pawls and cup
The components of this starter mechanism include a spring, molded rope reels, and a rope with a
grasp at the end. Within a reel that is supported by spring tension within another reel, the rope is
wound.
Within a reel that is supported by spring tension within another reel, the rope is wound. One end
of the crankshaft is in touch with this reel assembly via a ratcheting mechanism.
A pulley is usually encircled by a pull rope in recoil starters, and the pulley is turned by pushing
on the pull cord. A ratchet and/or clutch mechanism transfers the rotational energy produced by
the pulley and pull cord to the engine's drive shaft

7
Throttle Lever
The throttle is most often used in gasoline engines to control the amount of fuel and air that can
enter the engine. On the other hand, the throttle in a gasoline direct injection engine just controls
the volume of air that can enter the engine. When a diesel engine has one, the throttle controls
the amount of air that enters the engine.
Bearings
The bearings are used to assist the rotation of the shaft in the engine block through piston
rotation while supporting. "Components that aid in the rotation of objects" is what bearings are.
They support the rotating shaft inside the apparatus. Several equipment, including power
generators, cars, and airplanes, require bearings.

Material Analysis of Aluminum Alloy

The material used for the engine block is aluminum alloy has been analyzed.
Aluminum is a metal that can have its mechanical and physical properties changed by combining
it with other elements like silicon, copper, magnesium, zinc, and manganese. The precise ratios
of these metals are mixed to obtain the required qualities for a particular application. Aluminum
and magnesium, for example, can be combined to create a strong, lightweight alloy that is perfect
for usage in the automotive and aerospace sectors. Because of its low density, resistance to
corrosion, and thermal conductivity, aluminum alloys are widely used in a wide range of sectors.

Composition of Aluminum Alloy:

Aluminum becomes stronger and harder when copper is added. The strength and resistance to
corrosion of aluminum-zinc alloys are well-known. (Mg) 7075 is a typical example of an
aluminum-magnesium alloy that is lightweight and has exceptional corrosion resistance. 5083 is
one such example of an alloy. Aluminum's casting qualities are enhanced and solidification
shrinkage is decreased when silicon is added. 4043 aluminum alloy is one of the alloys that
provide these remarkable properties.
Physical Properties
The physical properties of aluminum alloys are as follows:

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  Lightweight: Because aluminum alloys have low densities, they are perfect for
applications where weight is a crucial consideration.
 Corrosion Resistance: In certain conditions, the naturally occurring oxide layer that
forms on the surfaces of aluminum alloys protects against corrosion.
 High Strength-to-Weight Ratio: Aluminum alloys are excellent in a variety of
applications where strength and weight must be carefully balanced because they are
robust and durable despite their low mass.
 Formability: Aluminum alloys are versatile in manufacturing processes because they are
easily shaped and formed.
 Ductility: The majority of aluminum alloys have a high degree of ductility, making
shaping them simple and free from cracking or breaking.
Thermal Conductivity: Aluminum alloys are excellent thermal conductors in any area
where effective heat transfer is required.
The properties of Aluminum alloy obtained from Granta Edupak software are given below.

Figure 4 Properties of Aluminum Alloy

9
 Figure 5 Properties of Aluminum Alloy

10
 Table 2 Physical Properties of Aluminum Alloy

The mechanical properties of aluminum are shown below.

Table 3 Mechanical Properties of Aluminum Alloy

The majority of aluminum alloys are colored a metallic silver-gray. This is due to the surface
oxidation of the material, which results in the formation of a thin coating of aluminum oxide by
nature. But other finishing methods, like as painting, powder coating, or anodizing, might alter
their appearance.
Environmental Effect

11
Aluminum is one of the most abundant resources in the world and is robust and extremely
malleable. Because of this, it is highly profitable. It is also virtually infinitely recyclable, highly
sustainable, and kind to the environment.

Cost of Aluminum Alloy

The cost of aluminum alloy per pound can differ significantly based on several variables, such as
the state of the market, the alloy's composition, and the quantity being bought. The average cost
of an aluminum alloy pound as of August 2023 is between $1.15 and $1.25.

Figure 6 Cost Analysis

Phase Diagram of Aluminum Alloy

The maximum solubility of aluminum is likewise attained when it forms a eutectic with copper
at 547 °C and 33 mass percent copper. It is just 0.1% at ambient temperature; at lower
temperatures, it declines dramatically.

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 Figure 7 Phase diagram

Manufacturing Analysis of Engine Block

Sand casting is the most popular and extensively utilized technique for producing engine blocks.
Major Honda components, including the cylinder block, cylinder head, and transmission cases,
are casts made of aluminum alloy.

Sand Casting
Melted metal is poured into a sand mold with a hollow chamber in the required shape during the
sand-casting process. The casting cools and solidifies after a while. After that, the sand is broken
up and shaken out. Concrete, metal, epoxy, plaster, and clay are among the casting materials
used in sand casting.

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Sand casting produces parts with complex geometries made of a variety of metals in a wide
range of sizes and weights. The cost of the casting process is greatly decreased by using sand as
the casting material. A significant amount of the expenses in the metal mold process are related
to the machining of the molds.
Whether or not sand will be disposed of or reused determines the kind of sand that is used in the
sand-casting process. In dry sand casting, the sand is discarded, but in green sand casting, the
molds can be used again.

Manufacturing Process
Sand molds, which are used in sand casting, are created by mixing binders with sand to preserve
the mold cavities. Sand molds are more affordable to make, but they are only useful for a single
casting. To enable the insertion of patterns to create cavities, the mold is segmented. Typically,
plastic, metal, or wood are used to create the pattern. Because the metal will compress after
solidification, extra care must be given while designing patterns to ensure that dimension
tolerance is maintained. Melted metal is poured into the mold cavity and allowed to cool once
the pattern is removed. The sand mold is disassembled to make the engine block or cast product

14
ready for machining when the metal has solidified. Excess sand is removed by vibrating the
casted engine block. After that, the cast block is machined to provide the necessary dimensions
and smooth the surfaces.
Applications of Sand Casting

Sand Casting is used to manufacture the following components.

 Pump bodies
 Bearings
 Bushings
 Air compressor pistons
 Impellers
 Electronic equipment
 Engine crankcases
 Fittings
 Engine oil pans
 Gears
 Flywheel castings
 Gas and oil tanks
 Machine parts

REFERENCES

[1] VGaneshan, “Internal Combustion Engine,” Tata McGraw Hill Publishing Company

Limited, Second Edition, pp 35, 606-670.

[2] Sprouse III, Charles; Depcik, Christopher (1 March 2013). "Review of organic Rankine

cycles for internal combustion engine exhaust waste heat recovery". Applied Thermal

Engineering. 51 (1–2): 711–722. doi:10.1016/j.applthermaleng.2012.10.017.

15
[3] Ferreira, Omar Campos (March 1998). "Efficiencies of Internal Combustion

Engines". Economia & Energia (in Portuguese). Brasil. Retrieved 11 April 2016.

[4] GX160 - Honda engines (honda-engines-eu.com)

[5] Davis, J.R. (2001). "Aluminum and Aluminum Alloys" (PDF). Alloying: Understanding the

Basics. pp. 351–416. doi:10.1361/autb2001p351 (inactive 31 January 2024). ISBN 0-87170-744-

6.

[6] Kaufman, John Gilbert (2000). "Applications for Aluminum Alloys and

Tempers". Introduction to aluminum alloys and tempers. ASM International. pp. 93–

94. ISBN 978-0-87170-689-8.

[7] Asthana, R. (2006). Materials processing and manufacturing science. A. Kumar, Narendra B.

Dahotre. Amsterdam: Boston. ISBN 978-0-08-046488-6. OCLC 85814321.

[8] Metal Casting Techniques - Vacuum ("V") Process Molding, retrieved 2009-11-09.

[9] M. Chabkra, R. Singh,. Rapid Casting solution: a review. Rapid Prototyping Journal, 17

(2011) 328-350.

[10] E. Bassoli, A. Gatto, L. Iuliano, M. G. Violante, 3D printing technique applied to rapid

casting. Rapid Prototyping Journal, 13 (2007).148-155.

[11] D. Snelling, H. Blount, C. Forman, K. Ramsburg, The Effects of 3D Printed Molds on Metal

Castings. Proceedings of the Solid Freeform Fabrication Symposium (2013) 827-845.

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[12] M. Chhabra, R. Singh, Obtaining desired surface roughness of castings produced using

ZCast direct metal casting process through Taguchi’s experimental approach. Rapid Prototyping

Journal 18 (2012) 458-471.

[13] J. Campbell, Complete casting handbook: metal casting processes, metallurgy, techniques,

and design. Butterworth-Heinemann (2011), Oxford

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