Module 1
IC engine components
1.2.1.2 Engine components
1. Cylinder Head
2. Cylinder block & Crank case
3. Sump or oil pan
4. Manifolds (Inlet & Outlet)
5. Cylinder liners and Gaskets
6. Cylinders
7. Piston
8. Piston Rings
9. Connecting rod
10. Piston pins (Gudgeon pin)
11. Crank Shaft
12. Main Bearings
13. Valves and Valve actuating mechanisms
14. Lubrication systems
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
1.2.1.2.1 Cylinder Head
-This is the top cover of the cylinder
- Inlet and exhaust valves, valve seats, their operating mechanisms, spark plug
or fuel injector
- It has separate cooling jacket
- Accommodate combustion chamber
- It is bolted to cylinder block
- Head gasket seals
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
1.2.1.2.1.1Different types of cylinder heads
1.Offset Cross Flow Type Cylinder Head
2. In line Cross Flow type Cylinder Head
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
1.2.1.2.2 Cylinder block and crankcase
- All engine mechanism are inside it
- cylinder block and crankcase are cast together in small engines
- by casting (Cast iron and aluminum alloys are using)
- Crank case is a cover for crankshaft
- crank shaft main bearing is located inside the crank case
- bottom potion of the crankcase is an oil sump
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
Piston
- Made from cast iron, cast aluminum, forged aluminum cast steel and forged
steel
- It should be strong but light to reduce reciprocating mass
- Reciprocating motion is converted to rotating by connecting rod and crank
Functions of piston
1. Transmit the force of combustion
to wrist pins
2. Transmit the absorbed heat of
combustion to cylinder walls
3. Hold the piston rings so that it can
perform a good seal to combustion
3/23/2
Tennison K.Jose , Asst.Professor
023
,Mechanical Engineering
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Department,Govt.Engineering College,
Piston
• A piston is a cylindrical engine
component
• Slides back and forth in the cylinder
bore by forces produced during the
combustion process.
• Pistons are commonly made of a cast
aluminum alloy for excellent and
lightweight thermal conductivity.
Piston clearance
Piston clearance is the clearance or gap
between the piston and metal cylinder, to
avoid damage due to excessive
expansion of piston on getting heated
during combustion. It is also known as a
piston to bore clearance.
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 7
Department,Govt.Engineering College,
Mains sections of a piston
1. Top of piston known as crown
or head
2. Ring belt
3. Ring land
4. Pin boss
5. Skirt
6. Piston pin
7. Piston rings
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 8
Department,Govt.Engineering College,
Piston crown
Top part is flat or combustion chamber is
cut into it
For SI engine it is raised and for CI engines
it is made like a bowl
which is subjected to tremendous forces
and heat during normal engine operation.
Ring land
It has three or more rings
Two stroke engine has no oil rings only
compression rings
Rings lands are located between ring grooves
First land is located above first
ring
It is heavily loaded with pressure
and thermal load
Second and Third ring lands are
lighter compared to first land
Ring lands are smaller in
diameter than rest of the piston
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 9
Department,Govt.Engineering College,
Pin boss
It is one of the heavily loaded
portion in piston
It supports piston pin and
also transmit the force of
combustion to pin
Piston skirt
Piston skirt wrap around the
piston
Distributes the side loads
It is connected to lower part
of piston
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
Piston materials
Piston materials should satisfies the
following requirements
• Light weight
• Good wear resistance
• Good thermal conductivity
• High strength to weight ratio
• Free from rust
• Easy to cast
• Easy to machine
• Non magnetic
• Non toxic
Commonly used materials are Cast
iron and aluminum alloys
Al-Si alloy
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 11
Department,Govt.Engineering College,
• Piston features include the piston head, piston pin bore, piston pin, skirt, ring
grooves, ring lands, and piston rings.
• The piston head is the top surface (closest to the cylinder head) of the piston A
piston pin bore is a through hole in the side of the piston perpendicular to piston
travel that receives the piston pin.
• A piston pin is a hollow shaft that connects the small end of the connecting rod
to the piston.
• The skirt of a piston is the portion of the piston closest to the crankshaft that
helps align the piston as it moves in the cylinder bore. Some skirts have profiles
cut into them to reduce piston mass and to provide clearance for the rotating
crankshaft counterweights.
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 12
Department,Govt.Engineering College,
A ring groove is a recessed area located around the perimeter of the piston that is used to
retain a piston ring. Ring lands are the two parallel surfaces of the ring groove which function
as the sealing surface for the piston ring. A piston ring is an expandable split ring used to
provide a seal between the piston an the cylinder wall.
Piston material
Generally, the piston is made up of cast aluminium alloy for good thermal conductivity. On
heating, aluminium expands more than the metal cylinder. So proper piston clearance is
necessary to maintain free piston movement in the cylinder.
Aluminum expands when heated, and proper clearance must be provided to maintain free
piston movement in the cylinder bore. Insufficient clearance can cause the piston to seize in
the cylinder. Excessive clearance can cause a loss of compression and an increase in piston
noise.
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
Piston Rings
Piston rings seal the combustion
chamber
conduct heat from the piston to the cylinder
wall, and
Return oil to the crankcase.
Piston ring size and configuration vary
depending on engine design and cylinder
material.
Piston rings are commonly made from cast
iron.
Cast iron retains the integrity of its
original shape under heat, load, and other
dynamic forces. Piston rings commonly used
on small engines include the compression
ring, wiper ring, and oil ring
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 14
-
Department,Govt.Engineering College,
Three rings
- compression rings
- Wiper ring
- One oil ring
- Split in one side
Compression ring
• Compression ring is the piston ring located in the ring groove closest
to the piston head.
• The compression ring seals the combustion chamber from any
leakage during the combustion process.
• The air-fuel mixture is ignited, pressure from combustion gases is
applied to the piston head, forcing the piston toward the crankshaft.
The pressurized gases travel through the gap between the cylinder
wall and the piston and into the piston ring groove. Combustion gas
pressure forces the piston ring against the cylinder wall to form a
seal. Pressure applied to the piston ring is approximately
proportional to the combustion gas pressure
Tennison K.Jose , Asst.Professor ,Mechanical Engineering 3/23/2
Department,Govt.Engineering College, Thrissur 023 15
A wiper ring is the piston ring with a tapered
face located in the ring groove between the
compression ring and the oil ring.
The wiper ring is used to further seal the
combustion chamber and to wipe the cylinder
wall clean of excess oil. Combustion gases that
pass by the compression ring are stopped by
the wiper ring.
An oil ring is the piston ring located in the ring
groove closest to the crankcase. The oil ring is
used to wipe excess oil from the cylinder wall
during piston movement. Excess oil is returned
through ring openings to the oil reservoir in the
engine block. Two-stroke cycle engines do not
require oil rings because lubrication is supplied
by mixing oil in the gasoline, and an oil
reservoir is not required
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 16
Department,Govt.Engineering College,
Connecting Rod
- Transforms the reciprocating motion to rotary motion
_ By casting
- Connected to crank and gudgeon pin
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
Crank Shaft
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 18
Department,Govt.Engineering College,
Crank shaft
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 19
Department,Govt.Engineering College,
Crankshaft Bearings
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 20
Department,Govt.Engineering College,
Crankshaft Bearings
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 21
Department,Govt.Engineering College,
Valve Actuating Mechanism
- Camshaft
- Push rod
- Rocker arm
- Over head cam
- Timing chain or belt
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
Valve Actuating Mechanism
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 23
Department,Govt.Engineering College,
Valve Actuating Mechanism
-Mainly two valves
- One inlet valve and one outlet valve
- Modern engines uses two inlet valves
and two outlet valves per cylinder for
better volumetric efficiency
-Mushroom type poppet valves are used
- The geometry, material of construction,
opening and closing and
pressure drop through the
valves affects the volumetric
and overall efficiency the engine
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 24
Department,Govt.Engineering College,
Valve Actuating Mechanism
Valve mechanism to operate the valves are
1.Valve mechanism in engine block
2.Valve-operating mechanism for valve
in cylinder head
3.Hydraulic valve lifter
4.Mechanism with eccentric rocker arm
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 25
Department,Govt.Engineering College,
1.Valve mechanism in engine block ( L ,T
,F head design)
The cam rotates, it lifts the tappet which
in turn lifts the valve to open position,
connecting the valve port with the
combustion chamber.
3/23/2
Tennison K.Jose , Asst.Professor023
,Mechanical Engineering
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Department,Govt.Engineering College,
2.Valve-operating mechanism for valve in
cylinder head ( I and F head design)
The cam lifts the valve lifter which actuates the
push-rod. This action rotates the rocker arm
and pushes the valve stem to open the valve.
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 27
Department,Govt.Engineering College,
3. Hydraulic Valve Lifter
- To avoid valve-tappet clearance
- minimum noise is produced,
- The tappet acts as an oil reservoir which receives lubricating oil
- A piston is connected to the push rod and moves in a cylinder which is
connected to the oil reservoir through a ball-check valve
- When the cam lifts the tappet, the ball-check valve closes the oil drain from
cylinder to reservoir and causes the entire tappet unit to lift the push rod to
open the valve
4.Eccentric Rocker Arm
-an eccentric held in the rocker arm
- it is controlled by a oil- operated plunger and a spring
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 28
Department,Govt.Engineering College,
6.Combustion chamber
Basic requirements for a combustion chamber
- High power output
- High thermal efficiency and low specific fuel consumption
- Smooth engine operation
- Reduced exhaust pollutants.
- For high compression ratio
- Maximum turbulence
-T head combustion chamber
- l head combustion chamber
- F head combustion chamber
- L head combustion chamber
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 29
Department,Govt.Engineering College,
6.1 T head combustion chamber
- Requires two cam shafts
- very prone to detonation
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
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Department,Govt.Engineering College,
6.2 L combustion chamber
- Two valves provided at same side
- Valves are operated with tappets from single cam shaft
- First introduced by Ford Motor company
Tennison K.Jose , Asst.Professor
,Mechanical Engineering
3/23/2023 31
Department,Govt.Engineering College,
