BK3001

BUILDING AN ENGINE

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Building An Engine

Course Objectives

After completing Building An Engine Course Module the trainees will

- know the major component parts, the functions and

construction of piston, piston rings, cylinder block, heads
and gaskets, crankshaft , connecting rods and camshaft
etc.

- know engine mechanical systems such as flywheel,

clutch, discs, timing gears, valves rocker assembly and
also about air-cleaner, oil filter and oil cooler etc.

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BUILDING AN ENGINE
WHAT IS AN ENGINE

- An engine is a related group of

parts assembled in a specific order
and is designed to convert the
energy given off by burning fuel into
a useful form.

- We may think of an engine as a

device that allows us to pour fuel into
one end and get power from the
other.

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WHAT TO USE FOR FUEL
- If you are going to convert fuel into useful energy, you will need
something that will burn easily.

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TRAPPING EXPLOSION
- Take a sturdy metal container, spray a gasoline and air mix into it.
- Place the lid over the top and then light it,
- The resulting explosion would blow the lid light into the air.

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A SIMPLE ENGINE
- Make the same setup,
- Hook the lid to a simple crankshaft by
means of a connecting rod.
- Then place a wheel on the other end
of
the crankshaft
- Now if you explode the mixture, the
lid,
as it blows up, will give the crankshaft
a sharp upward push and
spin the wheel.
- You have built a very simple engine –
not practical- but it is pointing the
way.

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- In order to cause the wheel to
spin in proper direction, you
would have to fire the mixture
with the crank in a position
similar to A.
- If fired in position B, the lid
could not fly up.
- If fired in position C, the wheel
would spin backward.
- By studying the figure you can
see that the crank shaft
changes the RECIPROCATING
motion of the lid into ROTARY
motion.

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FASTENING THE PARTS
- To make main bearing and cylinder fix, it is better to invert the engine and
place cylinder on top.

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LENGTHEN THE PISTON
- To avoid piston from tipping side ways in the cylinder, make piston longer.
- To avoid a piston that is too heavy, make a hollow piston.

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- Connecting rod
must swing.

- Pin secures rod

to piston.

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REMOVABLE CYLINDER HEAD
- Redesign the cylinder block and make the top removable.
- The removable head is a CYLINDER HEAD.

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GETTING FUEL INTO ENGINE
- Now make a block of much thicker metal and make holes – two passages.
- A passage for fuel mixture intake and one to exhaust it.
- These passages are called VALVE PORTS.

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VALVES
- To keep an access to the valve the head is redesigned.

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- Valves are installed in the ports -

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STROKE NO. 1 – THE INTAKE STROKE

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STROKE NO. 2 –
THE COMPRESSION
STROKE

COMPRESSION RATIO.

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STROKE NO. 3 – FIRING OR POWER STROKE

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STROKE NO. 4 – THE EXUAST STROKE

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FOUR STROKES MAKE TWO REVOLUTIONS OF THE CRANKSHAFT

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COMPLETE CYCLE

COUNT, the number of one half turns in

- intake
- compression
- firing / power and
- exhaust strokes
will find two complete turns – called revolutions of the crankshaft.
- while it is turning around twice, it is receiving power only during
one-half turn, or one fourth of the time.

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CYCLE REPEATED

As soon as the piston reaches the top of the exhaust stroke,

- It starts to repeat another.
- Intake, compression, firing and exhaust cycle.
- each complete cycle consists of four strokes of piston.
- hence the name FOUR - STROKE CYCLE.

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WHAT OPENS AND CLOSES THE VALVES?
You must now design a device to open and close the valves.

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CAMSHAFT OPENS VALVES
- SHAFT will have a bump, called a cam lobe, machined as a part of the
shaft.
- This shaft with cam lobes is called a CAMSHAFT.

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HOW VALVE IS OPENED

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VALVE LIFTER
Valve lifter is a bar-like unit, with an
adjusting bolt screwed into the top, so
the distance between the valve stem
and lifter may be adjusted.

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VALVE TRAIN
- Essential parts of the valve system
built into is called VALVE TRAIN.

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- We have developed a method of opening and closing the valves.
- The next problem is how to turn the camshaft and at WHAT SPEED.
- Each valve must open for one stroke only.
- Intake is open during the intake, and remains closed during the compression,
firing and exhaust strokes.
- This would indicate that the cam lobe must turn fast enough to raise the valve
every fourth stroke.
- For every two revolutions
of the crankshaft, the camshaft
must turn once.
- Camshaft must turn
at one-half of the crankshaft speed.

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TURNING THE CAMSHAFT
- Putting small gear on the crankshaft and larger gear with twice as many teeth
on the camshaft, the crankshaft will turn the camshaft at exactly one-half
crankshaft speed.

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VALVE TIMING
- Is making the valves to open at the proper time.
- With intake stroke, the intake valve must open as the piston starts down in
the cylinder.
- Place piston at the top dead center.

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- Insert the intake camshaft, then
turn it in a counter clockwise
direction until the flank of the cam
lobe contacts the lifter.

- The timing gear should be

meshed with the crankshaft.

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MARK THE GEARS
- punch a mark on the crankshaft gear, and a mark on the camshaft gear.
- these are called TIMING MARKS.

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CAMSHAFT MAKES ONE-QUARTER TURN
- when the engine is crank, the crankshaft would pull the piston down on the
intake stroke.
- the camshaft would also rotate, causing the cam lobe to turn an raise and
lower
the valve.
- the crankshaft would make one-half turn; camshaft one-quarter turn during this

stroke.

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INTAKE REMAINING CLOSED
- As the crank continues to turn, it will push the piston up on compression, down
on firing and up on exhaust.
- During these three strokes, the intake cam lobe continues to turn.
- When the piston reaches top dead center TDC on the exhaust stroke, the
flank
of the cam lobe will again be touching the intake lifter.
- As the next stroke will be the intake, the piston is ready to start down and the
cam lobe is ready to raise the lifter to provide proper timing.

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EXHAUST TIMIED THE SAME WAY

- The only difference between intake and exhaust timing is the piston is
placed on bottom dead center BDC.

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THE FLYWHEEL
- The flywheel, which is caused to spin by the firing stroke, will continue to spin
because it is heavy.
- The inertia built up within the flywheel will cause it to keep turning.
- As it is attached to the crankshaft, it will cause the shaft to continue to turn.
- The shaft will now spin long enough to reach the next firing stroke.

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ENGINE THUS
DEVELOPED

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FOUR-STROKE CYCLE ENGINE OPERATION

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Thank You

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