Topic No.

01
Internal Combustion Engine
16*1.5=24 Marks
Heat Engine - The device used chemical energy of fuel convert into thermal energy to perform some useful
mechanical work is known as Heat Engine.
Heat Engine having two types
1. Internal Combustion Engine. 2. External Combustion Engine
Internal Combustion Engine - The engine in which combustion of fuel takes place inside the cylinder is
known as Internal Combustion Engine.
External Combustion Engine - The engine in which combustion of fuel takes place Outside the cylinder
is known as External Combustion Engine.
Classification of I.C. ENGINES according to
Type of fuel used as (1) Petrol engine (2) Diesel engine (3) Gas engines (4) Bi-fuel engine (two fuel engine)
Nature of thermodynamic cycle as: (1) Otto cycle engine (2) Diesel engine cycle (3) Duel or mixed cycle
engine
Number of strokes per cycle as: (1) Four stroke engine (2) Two stroke engine
Method of ignition as: (1) Spark Ignition engines (Mixture of air and fuel is ignited by electric spark) (2)
Compression Ignition engines (The fuel is ignited as it comes in contact with hot Compressed air)
Method of Cooling as: (1) Air cooled engines (2) Water cooled engines
According to use 1) Stationary engine 2) Automotive engine 3) Marine engine 4) Aircraft engine 5)
Locomotive engine.
According to arrangement of cylinder: 1)Horizontal 2)Vertical 3)V-type engine 4)Radial engine
I.C. Engine Parts

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Engine Terminology

1. Cylinder- Cylinder is a closed container in which piston travel in reciprocating motion.

2. Cylinder bore (D): The nominal inner diameter of the working cylinder.
3. Stroke - It is maximum distance travelled by the piston in the cylinder.
4. Bottom Dead Centre (BDC) - Extreme position of piston at the Bottom of the cylinder.
5. Top Dead Centre (TDC) - Extreme position of piston at the top of the cylinder.
6. Cylinder volume(V) - Volume contained above BDC to below cylinder head
V = Vs + Vc
7. Swept volume(Vs) - Volume contained above BDC to TDC Vs = A × L
8. Clearance volume (Vc) – The volume above TDC.
9. Compression ratio (rk): It is ratio of Cylinder volume to Clearance volume.
rk = V / Vc rk = (Vs + Vc ) / Vc
10. Power – It is work done in a given period of time.
11. Horse Power (HP) – It is defined as the rate at which work is done.
One HP = 4500 kg-m/min
12. Indicated Horse Power (IHP) – The Power that is actually generated inside the engine cylinder
IHP = P*L*A*N/ 4500 P- effective pressure, L-stroke length, A-Area of cylinder, N-No. of
revolution per minute, 4 stroke N=rpm/2, for 2 stroke N=rpm
13. Expansion ratio – The ratio of volume after expansion to the volume before expansion.
14. Cut Off ratio – The ratio of volume at the end of heat supplied to the volume before heat supplied.
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 15. Brake Power (BP) - Brake power of an engine is the useful power available in the crank shaft. BP
= 2πNT/60
16. Engine Torque – It is the force of rotating action about the crank axis at any given instant of time.

Explain with neat sketch working of four stroke petrol engine.

4 Stroke Spark Ignition engines (SI Engine)

Suction/intake – Intake valve opens. Piston moves down TDC (Top Dead Centre) to BDC (Bottom Dead
Centre) It is a process of filling the cylinder with the proper air-fuel mixture through the intake valve.
Compression- Both valves close. Piston moves from BDC to TDC. It is a process of compressing the air-
fuel mixture in the cylinder to make it more combustible.
Combustion - It is a process of igniting the compressed air-fuel mixture to create motion and the overall
power of the engine.
Exhaust- It is a process of releasing the exhaust out of the cylinder through the exhaust valve.

4 Stroke Compression Ignition engines (CI Engine)

Suction/intake - Intake valve opens. Piston moves down TDC (Top Dead Centre) to BDC (Bottom Dead
Centre) A vacuum is created in the cylinder. Atmospheric pressure pushes the air into the cylinder.
Compression - Both valves close. Piston moves from BDC to TDC. Air is compressed. At the end, fuel is
dropped by fuel injector.
Power Stroke - Both valves remain closed. Due to high Temperature Fuel combustion takes place. Piston
moves down from TDC to BDC Heat is converted to mechanical energy.
Exhaust Stroke - Exhaust valve opens. Piston moves from BDC to TDC. Exhaust gases are pushed out
polluting the atmosphere.

Compare between SI and CI engine on the basis of following factors

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 Parameter Petrol engine (S.I) Diesel engine (C.I)
Working cycle Otto cycle Diesel cycle
Air fuel Air fuel mixture is inducted into cylinder Only air is inducted into cylinder
Pressure at the end of compression is Pressure at end of compression is about
Pressure
about 10 bar 35 bar
The charge is ignited with the help of The fuel is injected in the form of fine
Ignition
spark plug spray. Which gets auto-ignited.
Compression
6 to 10 15 to 25
ratio
As compression ratio is low weight of As the compression ratio is high the
Weight
engine is less. diesel engines are heavier.
The running cost of petrol engine is high The running cost of diesel engine is low
Running cost
because of higher cost of petrol because of lower cost of diesel
Thermal
The thermal efficiency is about 26% The thermal efficiency is about 40%
efficiency
Noise and
Less noise and vibration More noise and vibration
vibration
It is used in heavy duty vehicles and
It is used in motorcycles and light motor
Applications earth moving equipment’s and for power
vehicles, sporting vehicles
plants.

Working of 2 stroke S.I. Engine

Two-Stroke Engine Parts

Piston: The piston moves by the forces generated by the combustion of the gasses. The piston converts this
chemical energy into mechanical energy for the crankshaft.
Crankshaft: It is connected to the pistons and converts the reciprocal motion of the pistons into the
rotational motion which drives the driving gears.
Connecting Rod: It connects the piston head to the crankshaft.
Inlet Port: It is the opening for fuel and air mixture to come inside the piston chamber.
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Exhaust Port: It is the opening for the exhaust fumes which opens during the downstroke.
Spark Plug: Spark plug is the device inside the piston chamber that causes the combustion of the fuel-air
mixture.

Compare between 2 stroke engine and 4 stroke engine on the basis of following factors
Parameter Two-Stroke Engine Four-Stroke Engine

Number of strokes per cycle 2 strokes 4 strokes

Intake stroke During upward stroke Separate intake stroke

Compression stroke During downward stroke Separate compression stroke

Power stroke During upward stroke Separate power stroke

Exhaust stroke During downward stroke Separate exhaust stroke

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 Weight Lighter weight Heavier weight

Emissions Produces more emissions Produces less emissions

Fuel/air mixture Pre-mixed fuel/air mixture Separate fuel and air intake

Lubrication Oil is mixed with fuel Oil is separated from fuel

Efficiency Lower efficiency Higher efficiency

Applications Small engines, motorcycles, Cars, trucks, motorboats

chainsaws

Notifications & basic terms

1.R = Characteristics of gas constant 2.Cv = Specific heat at constant Volume
3.Cp = Specific heat at constant Pressure 4.COP = Coefficient of performance
5.ɣ (gamma) =Isentropic index = Cp/Cv 6.Qa= Heat supplied
7.Qr= Heat Rejected 8. Cp - Cv =R
Power Cycles
1) Otto Cycle / Constant volume cycle 2) Diesel Cycle / Constant Pressure & Volume cycle
3) Carnot Cycle / Imaginary Cycle 4) Dual diesel Cycle 5) Brayton Cycle
Draw labelled sketch of otto cycle on PV and TS Diagram
Otto /Constant Volume Cycle

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Formulae for Otto /Constant Volume Cycle

Draw PV & TS diagram for Diesel cycle. Name the process involved in it.
Diesel/Constant Pressure & Volume Cycle

Formulae for Diesel/Constant Pressure & Volume Cycle

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State effect of compression ratio (Rc) on Air standard efficiency of i) Otto cycle ii) Diesel Cycle
According to thermodynamics, otto cycle & Diesel has its own P-V diagram and based on that diagram we
can derive the efficiency equation. Now compression ratio is common term in all these cycles. Compression
ratio is defined as the ratio of the total volume of the cylinder to the clearance volume of the engine. It is a
fundamental specification for many common combustion engines.
The equation of efficiency
For Otto cycle is given by, For Diesel cycle is given by,

Where r is compression ratio

So, you can see that in in above cases the efficiency equation contains, compression ratio term, so
compression ratio is an important term in all three cases. Higher the compression ratio, higher the efficiency.

Draw PV & TS diagram for carnot cycle. Name the process involved in it.
Carnot/Imaginary Cycle

Formulae for Carnot/Imaginary Cycle

Draw PV & TS diagram for Dual cycle. Name the process involved in it.
Dual diesel Cycle

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Compare Otto cycle with Diesel cycle
Parameters Otto cycle Diesel cycle
Heat addition Constant volume Contant pressure
Compression ratio Less (6.1 to 10.1) High (15.1 to 22.1)
Thermal efficiency Less More
Application Petrol engines Diesel engines

Draw the actual and theoretical indicator diagram for 4 stroke engines. State the reasons of change
in diagram.

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Draw the actual and theoretical indicator diagram for 4 stroke engine. State the reasons of
change in diagram.

Differentiate between theoretical Otto cycle and actual Otto cycle on PV Diagram.
Above fig. shows both theoretical and actual PV chart for Otto Cycle
➢ In Theoretical Otto cycle it is observed that both suction and exhaust stroke take place at same
pressure and opening and closing of valves is either at TDC or BDC
➢ In actual PV chart of Otto cycle suction take place at below atmospheric pressure. inlet valve open
before TDC.
➢ In actual PV chart of Otto cycle inlet valve closes after BDC (at point 1)
➢ Ignition will start before end of compression stroke.
➢ Exhaust valve will open before BDC (i.e. before point 4) Exhaust will take place above atmospheric
pressure and exhaust will close after TDC.
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IC Engines Auxiliaries
Draw and explain theoretical and actual valve timing diagram for 4 stroke single cylinder petrol and
diesel engine. Valve timing Diagram for 4 stroke Petrol and Diesel engine

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Valve timing Diagram for 2 stroke Petrol and Diesel engine

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VVR-i Engine
Variable Valve Timing or VVT is the timing for which the valves open. The VVT system controls the
duration for which the intake and the exhaust valves open and the incline of the lift. All this activity happens
within the engine while it's operating. The valve timings of a VVT engine vary according to the engine speed
and load. The valves only open as much as the engine needs, based on the speed and the load. These minor
changes in the intake and exhaust valves make a significant difference to engine performance, efficiency,
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and power. VVT-i, where the I stands for intelligence, is an implementation of VVT technology along with
microprocessors to control VVT functionality using actuators.

The Variable Valve Timing (VVT) system includes

➢ ECM (Engine control module)
➢ OCV (Oil control valve)
➢ VVT controller
Working
➢ The ECM controls the OCV, based on the signals transmitted by several sensors. The VVT controller
regulates the intake camshaft angle using oil pressure through the OCV. As a result, the relative
positions of the camshaft and crankshaft are optimized, the engine torque and fuel economy improve,
and the exhaust emissions decrease under overall driving conditions. The ECM detects the actual
intake valve timing using signals from the camshaft and crankshaft position sensors, and performs
feedback control.
➢ The ECM sends a target duty-cycle control signal to the OCV. This control signal regulates the oil
pressure supplied to the VVT controller. The VVT controller can advance or retard the intake
camshaft.
ADVANTAGES of VVT-i
➢ Improved torque & output
➢ Battery & fuel economy
➢ Reduced nitrogen oxide & hydrocarbon emissions
➢ Increase the overall engine efficiency and performance
➢ Increase engine life.
Supercharging

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Supercharging is the forcing of air to the cylinder during suction stroke under pressure with the help of
compressor called supercharger, in order to increase mass mixture admitted to the cylinder. This gives each
intake cycle of the engine more oxygen, letting it burn more fuel and do more work, thus increasing power.
The supercharger in the S.I. engine mounted before the carburettor. It should be seated sufficiently which
reduce the carburettor size.
Object & Applications of supercharging
➢ To increase power output of an engine when greater power required (Racing Car)
➢ To maintain power of aircraft engine in high altitudes where less oxygen is available for
combustion.
➢ To reduce weight and space occupied by engine (as required in marine engine)
➢ To increase mechanical & thermal efficiency
Effect of supercharging on S.I. engine with respect to following parameters

Advantages
➢ Higher power output.
➢ Reduced smoke from exhaust gases. The extra air pushed into cylinder, helps the air to complete
combust leading to lesser smoke generation.
➢ Quicker acceleration of vehicle. Supercharger starts working as soon as the engine starts running.
This way the engine gets a boost even at the beginning leading to quicker acceleration.
➢ Cheaper than turbocharger.
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Turbocharging
About 30% of heat input goes with the exhaust gas. This exhaust gas is use to run a gas turbine. This gas
turbine directly coupled to a centrifugal compressor which supply extra air to the engine. These results
increase power of engine & better thermal efficiency. The compressor & exhaust turbine is known as
turbocharger The engine is known as turbocharged engine

Advantages
➢ Reduce pollution from exhaust gases.
➢ Better torque characteristics.
➢ Power output of engine increase.
➢ Reduce fuel consumption.
➢ Reduce in power loss.

VARIABLE GEOMETRY TURBOCHARGER

With sketch, justify use of Variable Geometry Turbocharger as compared to fixed geometry
turbocharger.

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Variable Turbine Geometry technology is the next generation in turbocharger technology where the turbo
uses variable vanes to control exhaust flow against the turbine blades. The problem with the fixed geometry
turbocharger that big turbochargers do not work well at slow engine speeds, while small turbochargers are
fast to spool but run out of steam quick. A turbocharger equipped with Variable Turbine Geometry has little
movable vanes which can direct exhaust flow onto the turbine blades. The vane angles are adjusted via an
actuator. The angles of the vanes vary throughout the engine RPM range to optimize turbine behaviour.

Difference between Turbocharger and Supercharger

MPFI (Multipoint Fuel Injection) System

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Differentiate between D-MPFI and L-MPFI system

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 Sr. D-MPFI System L-MPFI System
No.

1 It is Manifold injection system It is Port injection system

2 Vacuum in the intake manifold and volume of air Fuel metering is regulated by the engine
by its density are sensed in this type of MPFI speed and amount of air that actually enters
system in the engine.
3 As air enters into intake manifold the manifold As air enters into the intake manifold, the air
pressure is sensor detects the intake manifold flow sensor measures the amount of air and
vacuum and sends the information to the ECU sends information to ECU.

Following are the diagnostic tools used in fault finding of MPFI engines
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1. Engine Code Readers 5. Scan Tool
2. Compression Testers 6. Battery Tester
3. Spark Plug Testers 7. Power Probe III
4. Mechanic’s Stethoscope
Sensors - The various types of sensors applied to the MPFI System send a signal in the form of voltage or
current to ECU (Electronic control Unit)
Types of Sensors
Oxygen sensor- The amount of oxygen in the engine exhaust is senses & determine air fuel ratio. Sensor
output voltage changes in proportion to air fuel ratio
Air flow sensor- The determine of mass or volume of air entering in the manifold is adjusted & also the
quantity of fuel intake.
Engine sensor- The temp of the engine coolant is senses that sensor is called Engine sensor.
Air inlet temp sensor- The ambient air temp is senses during suction of engine for fine tuning mixture
strength.
Manifold pressure sensor- The vacuum in the engine intake manifold is senses so that the air fuel mixture
can be adjusted.
Throttle position sensor- The flow of charge admitted to the engine is adjusted for engine speed and
acceleration by sensing the movement of throttle valve
Camshaft position sensor- The engine control unit uses the camshaft position sensor to record the
exact position of the camshaft.
Detonation (Knock) Sensor- Microphone type sensor that detects detonation noise so that the ignition
timing can be retarded.
Exhaust Gas Recirculation (EGR)
Exhaust Gas Recirculation (EGR) is a technique used in internal combustion engines to reduce nitrogen
oxide (NOx) emissions. The basic principle behind EGR is to recirculate a portion of the engine's exhaust
gas back into the intake air, which then enters the combustion chambers for the next cycle. This process
helps to lower the peak combustion temperatures, thereby reducing the formation of NOx emissions.

EGR Valve: The EGR system includes an EGR valve that controls the flow of exhaust gases into the intake
manifold. The valve is controlled by the engine control unit (ECU) based on various parameters such as
engine speed, load, temperature, and emissions requirements. So, the valve can be either open or closed
depending on the operating conditions of the engine.
Combustion Process: When the EGR valve opens, a portion of the exhaust gas is allowed to flow into the
intake manifold. The exhaust gas mixes with the fresh air entering the engine, reducing the oxygen
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concentration in the combustion chamber. This helps to lower the peak combustion temperatures, thereby
reducing the formation of NOx emissions., which are harmful pollutants.
CRDI (Common Rail Direct Injection)

The common rail which is connected to all the fuel injectors. Whereas ordinary diesel direct fuel-injection
systems have to build up pressure repeatedly for each and every injection cycle, the new common rail
(line) engines maintain constant pressure regardless of the injection sequence. This pressure then remains
permanently available throughout the fuel line. The engine's electronic timing regulates injection pressure
according to engine speed and load. The electronic control unit (ECU)modifies injection pressure precisely
and as needed, based on data obtained from sensors on the cam and crankshafts. In other words,
compression and injection occur independently of each other. This technique allows fuel to be injected as
needed, saving fuel and lowering emissions. Solenoid or piezoelectric valves make possible fine electronic
control over the fuel injection time and quantity
State advantages of CRDI system used in CI engine.
➢ Uniform circulation of fuel to each cylinder
➢ More power is developed
➢ Precise injection timing is obtained which increases the combustion quality
➢ The arrangement of system is simple and requires less maintenance
➢ The CRDI engines also produce a lesser noise.
➢ The modern CRDI engines less polluting too.

Differentiate between MPFI and CRDI

Sr. MPFI CRDI
No.
1 Stands for multipoint fuel injection Stands for common rail direct injection system

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 2 Used in petrol and gasoline engine Used in diesel engines
3 Fuel is infected into the runner of the Fuel is directly injected into the combustion
intake manifold before the intake valve chamber
4 Operates at a lower pressure than the Operates at a higher pressure than the MPFI
CRDI system system
5 Cost is lower Cost is more
7 Less maintenance cost Comparatively more maintenance cost

List changes made by automobile manufactures in achieving BS VI norms in diesel engines.

1. Reduction in HC emission by 45% 2. Reduction in NOX emission by 70%
3. Reduction in PM emission by 80% 4. Use of Lean NOX traps
5. Use selective catalytic reduction (SCR) 6. Use of Diesel particulate filter
7. Five times reduction in Sulphur % 8. OBD for all diesel vehicles
9. Real Driving Emission introduced in vehicles 10. Fumigation
11. Catalytic converter monitoring 12. Misfire detection

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