Automotive Engineering

AUTOMOTIVE ENGINEERING
Automotive engineering, along with Aerospac engineering and Naval architecture

is a branch of vehicle engineering, incorporating elements
of mechanical, electrical, electronic, software, and safet engineering as applied to
the design, manufacture and operation of motorcycles, automobiles, and truck and
their respective engineering subsystems. It also includes modification of vehicles.
Manufacturing domain deals with the creation and assembling the whole parts of
automobiles is also included in it. The automotive engineering field is research
-intensive and involves direct application of mathematical models and formulas.
The study of automotive engineering is to design, develop, fabricate, and test
vehicles or vehicle components from the concept stage to production stage.
Production, development, and manufacturing are the three major functions in this
field.
AUTOMOBILE ENGINEERING
Automobile engineering is a branch study of engineering which teaches
manufacturing, designing, mechanical mechanisms as well as operations of
automobiles. It is an introduction to vehicle engineering which deals with
motorcycles, cars, buses, trucks, etc. It includes branch study of mechanical,
electronic, software and safety elements. Some of the engineering attributes and
disciplines that are of importance to the automotive engineer and many of the other
aspects are included in it.
AUTOMOBILE
Automobile, by name auto, also called motor-car or car, is usually a four-wheel
vehicle designed primarily for passengers transportation and commonly propelled
by internal combustion engine using volatile fuel.
SYSTEMS/COMPONENTS OF AN AUTOMOBILE
 Chasis and frame
 Electrical system
 Steering system
 Braking system
 Suspension system
 Cooling system
 Internal combustion engine
CHASIS AND FRAME
It supports the engine, wheels, body, braking system, steering, etc.The chasis is
formed by the frame with the frame side members and cross members. The frame
is usually made of box, tubular and channel members that are welded or riveted
together. In addition to this, it comprises of the springs with the axles and wheels,
the steering system and the brakes, the fuel tank, the exhaust system, the radiator,
the battery and other accessories. Along with this the frame supports the body.
Fig 3.2 Chasis
ELECTRICAL SYSTEM
The electrical systems are electrically controlled devices in an automobile, they
receive energy from the battery and return it back to the battery through hearth.
The charging system comprises of alternator and battery. This battery is used to
power the stater motor which enables the engine to start running while the
alternator is used to charge the battery and other electrical components in the
vehicle.
Fig 3.3 Electrical system
STEERING SYSTEM
In front wheels can be turned to left and right by steering system so that the vehicle
can be steered. The steering wheel is placed in front of driver. It is mechanically
linked to the wheels to provide the steering control. The primary function of the
steering system is to provide angular motion to front wheels so that vehicle can
negotiate a turn. It also provides directional stability to vehicle when the vehicle
moves ahead in straight line. Now-a-days, many vehicles are equipped with power
steering which uses pressure of a fluid to reduce steering effort. When driver turns
the steering wheel, a hydraulic mechanism comes into play to provide most of the
effort needed to turn the wheel.
Fig 3.4 Steering system
BRAKING SYSTEM
Brakes are used to slow down or stop the vehicle. Hydraulic brakes are generally
used in automobiles, where brakes are applied by pressure on a fluid. Mechanical
brakes are also used in some vehicles. These brakes are operated by means of
leavers, linkages, pedals, cams, etc. Hand brake or parking brake is known usually
mechanical brake. These are used for parking the vehicles on sloppy surfaces and
also in case of emergency.
Fig 3.5 Braking system

SUSPENSION SYSTEM
Suspension system of an automobile separates the wheel and axle assembly ofthe
automobile from its body. Main function of the suspension system is to isolate the
body of the vehicle from shocks and vibrations generated due to irregularities on
the surface of roads. Shock absorbers are provided in the vehicles for this purpose.
It is in the form of spring and damper. The suspension system is provided both on
front end and rear end of the vehicle.A suspension system also maintains the
stability of the vehicle in pitching or rolling when vehicle is in motion.
Fig 3.6 suspension system
COOLING SYSTEM
Almost all automobiles employ liquid cooling systems for their engines. A typical
automotive cooling system comprises of the following
1. A series of channels cast into the engine block and cylinder head,

surrounding the combustion chambers with circulating water or other
coolant to carry away excessive heat,
2. A radiator, consisting of many small tubes equipped with a honeycomb of

fins to radiate heat rapidly, which receives and cools hot liquid from the
engine,
3. A centrifugal-type water pump with which to circulate coolant

4. A thermostat, which maintains constant temperature by automatically
varying the amount of coolant passing into the radiator,
5. A fan, which draws fresh air through the radiator.
Fig 3.7 cooling system
INTERNAL COMBUSTION ENGINE
 Small Two Stroke Petrol Engine : Used when operation is simple and
requirement of low cost of prime mover (scooters, pumping sets etc.)
 Small Four Stroke Petrol Engine : Used in automobiles, generators, pumping
set.
 Two Stroke Diesel Engine : High power, generally used in ship propulsion.
 Four Stroke Diesel Engine : Mostly used engine, have diameter 50 to 600
mm, speed ranges from 100 to 4400 rpm, power developed is 1 to 1000 kW.
Used in pumping sets, construction machinery, drilling rigs, tractors, diesel
electric locomotive, mobile & stationary electric generation plants.
PARTS OF I. C. ENGINE :
1. Cylinder
2. Cylinder Head
3. Piston
4. Piston Rings
5. Gudgen Pin
6. Connecting Rod
7. Crank Shaft
8. Crank
9. Engine Bearing
10.Fly wheel
TERMS CONNECTED WITH I. C. ENGINES :

 Bore : The inside diameter of the cylinder is called bore.
 Stroke : when the piston reciprocate in the cylinder it has the limiting upper
and lower positions beyond which it can not move. The linear distance between
the two limiting positions of the cylinder is called Stroke.
 Top Dead Centre (TDC) : The top most position of the piston towards top end
side is called top dead center. But, in case of Horizontal Engines it is known as
inner dead center.
 Bottom Dead Center (BDC) : The lowest position of the piston towards crank
end side is called Bottom dead center. But, in case of Horizontal Engines it is
known as outerdead center.
 Clearance Volume : The volume contained in the cylinder above the top of the
piston when piston is at the top is called Clearance Volume.
 When L = D - Called Square Engines
 When L D - Under Square Engine
 Swept Volume : The volume swept by piston between between top and bottom
dead center is called swept volume / piston displacement.
 Compression Ratio : It is ratio of total cylinder volume to clearance
Volume.Compression ratio (r) = Vs + Vc / Vc
 Piston Speed : The average speed of the piston is called Piston Speed & =
2LN, where L = Stroke of Piston & N = RPM of engine. Average engine speed
of engines is 5 to 15 m/sec. ( This speed is kept in this range Because of
strength of material & noise consideration.
 Direct Injection : Fuel injected to the main combustion chamber of an engine.
 Indirect Injection : Fuel injected to the secondary combustion chamber of an
engine.
 Smart Engine : The Engines made with computer controls that regulate
operating characteristics such as air-fuel ratio, ignition timings, valve timings,
intake tuning and exhaust control.
 Air fuel Ratio : It is ratio of the mass of Air to mass of Fuel.
WORKING CYCLES :
I.C.Engines (Four & Two stroke) works on any one of the following cycles –
 Constant Volume (Otto Cycle)
 Constant Pressure (Diesel Cycle)
 Dual Combustion Cycle.
Constant Volume (Otto Cycle):
Heat is supplied at constt. Volume Petrol & air is mixed in carburator outside the
Cylinder.Fuel in required proportion is drawn in cylinder during Suction Stroke.
Constant Pressure(Diesel Cycle):
The air sucked during suction stroke is compressed during compression stroke and
pressure and temp. rises by considerable amount then the measured amount of fuel
is finely sprayed in cylinder by fuel injector. Due to very heavy pressure &
temperature the fuel ignites and produce hot gases. These gases throw the piston
downwards and work is obtained.
FUEL SUPPLY SYSTEM IN SPARK IGNITION ENGINE
The fuel supply system of spark ignition engine consists of
1. Fuel tank
2. Sediment bowl
3. Fuel lift pump
4. Carburetor
5. Fuel pipes
In some spark ignition engines the fuel tank is placed above the level of the
carburetor. The fuel flows from fuel tank to the carburetor under the action of
gravity. There are one or two filters between fuel tank and carburetor. A
transparent sediment bowl is also provided to hold the dust and dirt of the fuel. If
the tank is below the level of carburetor, a lift pump is provided in between the
tank and the carburetor for forcing fuel from tank to the carburetor of the
engine.The fuel comes from fuel tank to sediment bowl and then to the lift pump.
From there the fuel goes to the carburetor through suitable pipes. From carburetor
the fuel goes to the engine cylinder through inlet manifold of the engine
FUEL SUPPLY SYSTEM IN DIESEL ENGINE
Fuel supply system of diesel engine consists of the following components
1. Fuel tank
2. Fuel lift pump or fuel feed pump
3. Fuel filter
4. Fuel injection pump
5. High pressure pipe
6. Over flow valve. F
7. Fuel injector
Fuel is drawn from fuel tank by fuel feed pump and forced to injection pump
through fuel filter. The injection pump supplies high pressure fuel to injection
nozzles through delivery valves and high pressure pipes. Fuel is injected into the
combustion chamber through injection nozzles. The fuel that leaks out from the
injection nozzles passes out through leakage pipe and returns to the fuel tank
through the over flow pipe. Over flow valve installed at the top of the filter keeps
the feed pressure under specified limit. If the feed pressure exceeds the specified
limit , the over flow valve opens and then the excess fuel returns to fuel tank
through over flow pipe.
Fig 3.8 IC Engine
ON-BOARD DIAGNOSTICS (OBD)
On-board diagnostics (OBD) is an automotive term referring to a vehicle's self-

diagnostic and reporting capability. OBD systems give the vehicle owner or repair
technician access to the status of the various vehicle sub-systems. The amount of
diagnostic information available via OBD has varied widely since its introduction
in the early 1980s versions of on-board vehicle computers. Early versions of OBD
would simply illuminate a malfunction indicator light or "idiot light" if a problem
was detected but would not provide any information as to the nature of the
problem. Modern OBD implementations use a standardized digital
communications port to provide real time in addition to a standardized series
of diagnostic trouble codes, or DTCs, which allow a person to rapidly identify and
remedy malfunctions within the vehicle.
Fig 3.9 OBD Device
TYPES MAINTENANCE IN AUTOMOBILE
R1OUTINE MAINTENANCE
Routine maintenance refers to any maintenance task that is done on a planned and
ongoing basis to identify and prevent problems before they result in equipment
failure. Some common routine maintenance includes regular inspections or service
work.
PREVENTIVE MAINTENANCE
Prevention without breakdown or without giving trouble on road some attention or
maintenance taken to the vehicle is called as preventive maintenance. It intends to
reduce or totally eliminate breakdown and accidents due to mechanical failure and
reduces repair cost. A good preventive maintenance program lead to following
advantages:
 Reduce the breakdown of vehicle.

 Increase safety due to reduced breakdown.
 Less expenses on repairs.
 Good control on inventory of spare parts.
 Lesser number of equipment are require.
PERIODIC MAINTENANCE
Periodic maintenance or operatives maintenance is attentions provided attention

provide to motor vehicles after in operation for a specified time or covered
distance.
CORRECTIVE MAINTENANCE
Maintenance is carried out following detection of an anomaly and aimed at

restoring normal operating conditions. This approach is based on the firm belief
that the costs sustained for downtime and repair in case of fault are lower than the
investment required for a maintenance program. This strategy may be cost-
effective until catastrophic faults occur.
BREAKDOWN MAINTENANCE
Break down maintenance is a attention which is to be provided when the motor

vehicle becomes immobilized due to fault created during running. These fault are
started difficulties, puncture, electrical fault, carburetor and fuel supply fault,
overheating, fan belting, breakage and accident etc.
OPERATIONAL MAINTENANCE
Operational maintenance may entail keeping machinery well lubricated to reduce

the risk of friction or failure. Many basic machine adjustments needed during the
course of operation also fall within this category of preventative maintenance.
Operational maintenance on a car may include checking brakes and brake lines.

Automotive Engineering

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AUTOMOTIVE ENGINEERING

Automotive engineering, along with Aerospac engineering and Naval architecture

Fig 3.2 Chasis

Fig 3.5 Braking system

Fig 3.6 suspension system

1. A series of channels cast into the engine block and cylinder head,

2. A radiator, consisting of many small tubes equipped with a honeycomb of

3. A centrifugal-type water pump with which to circulate coolant

5. A fan, which draws fresh air through the radiator.

Fig 3.7 cooling system

INTERNAL COMBUSTION ENGINE

TERMS CONNECTED WITH I. C. ENGINES :

Fig 3.8 IC Engine

ON-BOARD DIAGNOSTICS (OBD)

On-board diagnostics (OBD) is an automotive term referring to a vehicle's self-

TYPES MAINTENANCE IN AUTOMOBILE

 Reduce the breakdown of vehicle.

Periodic maintenance or operatives maintenance is attentions provided attention

Maintenance is carried out following detection of an anomaly and aimed at

Break down maintenance is a attention which is to be provided when the motor

Operational maintenance may entail keeping machinery well lubricated to reduce

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