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INTERNAL COMBUSTION ENGINE PARTS

 

 VIDEO LECTURE ON BASIC COMPONENTS OF IC ENGINE

INTERNAL COMBUSTION COMPONENTS

An Internal combustion engine has various parts. Some important parts are listed below.

  • Cylinder block
  • Cylinder head
  • Cylinder liner
  • Crankcase
  • Piston
  • Connecting rod
  • Crankshaft
  • Cam shaft
  • Flywheel
  • Valve and valve mechanism
  • Gaskets
  • Lubrication system
  • Cooling system
  • Spark plug and fuel injector

Cylinder block

  • It is the main body of the engine. It contains cylinder.
  • It is made by casting method.
  • Cast iron, grey cast iron and its alloys are used.
  • Crank shaft, cam shaft are available inside of the cylinder block
  • Water jackets are provided for water cooled engine blocks.
  • Air cooled cylinder block contains fins to reduce the heat produced inside of the engine.
  • The piston reciprocates inside the cylinder.
  • Cylinder head is placed at the top of cylinder block.
  • The crank case is provided at the bottom of the cylinder block.

 
CYLINDER BLOCK

Cylinder head

  • It is made by casting.
  • CI, GCI and its alloys are used.
  • It is bolted at the top of the cylinder block.
  • It contains holes to fix the valves, spark plugs and fuel injectors
  • Water jackets are given to circulate the cooling water.

 
CYLINDER HEAD

Cylinder liner

  • Cylinder liner is a cylindrical part to be filled into the cylinder block to avoid the wear out of the cylinder.
  • It gives wear resistance for surface of the cylinder bore.
  • Cylinder liners are manufactured by the centrifugal casting methods.
  • Special alloys of CI having silicon, magnesium, nickel, chromium materials are used to produce cylinder liner.
  • There are two types of cylinder liner available.

    • Dry liner
    • Wet liner

CYLINDER LINERS

Dry liner

  • When engine works there will be friction between piston and bore. It leads to wear out the cylinder and piston surface.
  • Cylinder liner provides wear resistance.
  • It is directly inserted into the cylinder block.
  • There is no contact between dry liner and cooling water but it products cylinder from wear.
  • There is contact between surface of the cylinder block and liner.
  • The thickness of the liner may be varies from 1.5 to 3 mm.
  • Replacement of the liner is difficult. It requires special tools.

DRY LINER

Wet liner

  • The cylinder liner having direct contact between cooling water is called as wet liner.
  • It is used to provide wear and also it acts as a seal for water jackets.
  • Thickness of the liner may be 3 to 6 mm.
  • It is also called as water jacket liners.
  • Due to the direct contact between coolant and liner it reduces piston temperature and it provides better cooling.
  • Replacement of the liner is easy.

WET LINER

Crank case

  • It is the housing for the crank shaft.
  • It providing support to the engine.
  • It also provides the engine from dirt.
  • It also acts as the lubricant sump.
  • It has two types.
  • If crank case integrated with the cylinder block it is called as mono block.
  • Spilt type is the one in which crank case is attached separately.
  • It is manufacture from CI and alloy steel.

CRANK CASE

Piston

  • It is hollow cylindrical part.
  • It is opened at the bottom and closed at the top.
  • It reciprocates in the cylinder. It also gives friction to the cylinder.
  • Top of the piston is called as crown. And the bottom of the piston is called as skirt.
  • It carries piston rings at its circumference.
  • The gap between the cylinder and top of the piston is called as piston clearance. it avoid seizing.
  • It manufacture by the casting and forging methods.

PISTON

Piston rings

  • Circular rings are fitted in the circumference of the piston is called as piston rings.
  • They are fitted in the grooves available in piston circumference.
  • It provides seal between piston and cylinder wall. So it prevents leakage fresh charge and burnt gases from the cylinder top to crank case.
  • It provides necessary lubrication to cylinder wall.
  • It transfer the heat from piston to cylinder wall.

PISTON RINGS

Types of piston rings

There are two types of piston rings

    • Compression rings
    • Oil rings

Compression rings:-

  • It provides effective seal to the cylinder.
  • So that it prevents leakage of high pressure gases from combustion chamber into crank case.
  • Number of compression rings may provide.
  • When the compression rings are increased, compression ratio will be increased.

Oil rings:-

  • A piston rings that scraps oil from a cylinder wall to prevent it from being burned.
  • Slots are provides in the oil rings called passages.
  • It is used to return the excess oil to the oil sump.
  • It is fitted in the lower groove of the piston.
  • It is manufactured from Cast iron and its alloys.
  • Chromium and cadmium is coated in the oil rings.

VARIOUS PISTON RINGS ASSEMBLED IN PISTON

Connecting rod

  • Connecting link between crank shaft and piston is called as connecting rod.
  • It converts reciprocating motion of the piston into rotary motion of the crank shaft.
  • It should have high strength to withstand heavy load.
  • It is made in the structure of I section. Normally carbon steels, nickel alloys are used. It is manufactured by drop forging method.
  • Upper end of the connecting rod is called as small end. It is connected to the piston by means of piston pin.
  • Lower end of the connecting rod is called as big end. It is connected to the crank shaft by means of crank pin.

CONNECTING ROD AND PISTON ASSEMBLY

Crank shaft

  • The reciprocating motion of the piston is converted into rotary motion by means of connecting rod.
  • The main parts of the crank shaft are, crank pin, journal bearings, damper, cam shaft gear.
  • Fly wheel is mounted in one end of the crank shaft.
  •  it supplies power to gear box and cam shaft.
  • It has passages to supply lubrication oil.
  • It is made by carbon steel, nickel chrome alloys and heat treated alloys materials.
  • It is produced by drop forging or casting methods.

CRANK SHAFT

Cam shaft

  • Cam is a device which converts rotary motion of the crank shaft is converted into linear motion.
  • It is a shaft on which cams are formed.
  • Inlet and outlet valves are controlled by means of cams.
  • It contains number of cams to actuate the valves in a multi cylinder engine.
  • Separate cam is available to actuate the fuel pump.
  • It is driven by cam shaft by timing gears or timing sprockets.
  • Camshaft is driven at half the speed of the crank shaft.
  • It is made by cast steel or forged steel. It manufactured by casting or forging.

CAM SHAFT

Flywheel

  • A heavy disc or wheel is connected at one end of the crank shaft is called as flywheel.
  • It stores energy produced by power stroke and delivers this energy during idle strokes.
  • Main purpose of the flywheel is to maintain the constant speed in the crank shaft.
  • Flywheel is attached for the following reasons.
  • To store energy.
  • To reduce the speed fluctuation.
  • To help the starting.

A LARGE FLYWHEEL ATTACHED IN AN AUTOMOTIVE ENGINE

Valve

  • Valves are the devices they are used to control the fresh charge and exhaust gases.
  • It admits the fresh charge in inlet side and it allows to escape burnt gases to atmosphere in outlet side.
  • Opening and closing valves are controlled by means of springs and cams (they mounted in camshaft)
  • Nickel chromium, high speed steel, cobalt steel, silicon chrome steel, tungsten steel are used to manufacture the valves.

CAM, ROCKER ARM AND VALVE ASSEMBLY

Types of valve

There are various types.

    • Poppet valve.
    • Sleeve valve.
    • Rotary valve.
  • Normally poppet valve is used in automobile engines.
  • The main parts of the poppet valve is valve head, stem and face.
  • It create the popping noise when it open and close the passage so it is called as poppet valve.
  • Top side of the poppet valve is called as valve head, lower portion of this head is called as face it has as angle of 450.
  • Opening and closing is done by reciprocating motion of stem. Stem receives power from the cam shaft.

POPPET VALVE

ROTARY VALVE

SLEEVE VALVE

Valve mechanism

There are two types of valve mechanism is available

    • Side valve mechanism
    • Overhead valve mechanism

Side valve mechanism:-

  • The valves are located in the side of cylinder block.
  • Side valve mechanism is called as straight poppet valve mechanism.
  • It consists of valve, valve guide, stem, spring, camshaft and cam.
  • When the cam rotates stem will reciprocates. So that rotation motion of the cam shaft is converted into linear motion.
  • When the cam rotates stem will be lifted and then it comes to original position by using spring force.
  • If it comes to original position, valve head seats in the valve. Now valve will be closed.
  • Cam shaft is connected to the crank shaft. So that the power is transmitted from crank shaft to cam shaft.

SIDE VALVE MECHANISM

Overhead valve mechanism:-

  • Main parts of the mechanism are cam, rocker arm, pushrod, valve and tappet.
  • This mechanism is placed over the cylinder head.
  • When the cam shaft rotates it lifts the tappet in upward direction.
  • it pushes push rod in upward direction.
  • Thus one end of rocker arm goes upward and pushes the valve in downward direction.
  • Now the valve is opened.
  • By the spring force it goes to initial position. 
OVERHEAD VALVE MECHANISM



Location: India

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