Task 1(IN Lab) (P6) Based on the carried out of an experiment to determine the internal

combustion engine performance according to the following test rig engine, use the engine measured
data to draw the graph between rotation speed, developed torque, brake power and brake specific fuel
consumption and give an analysis for engine performance.
TASK 3
Q1: (P7) Two and four strokes operation systems are considered the two streams in
internal combustion engines. Discuss the difference between a two-stroke and a four-
stroke engine.

Aspect Two-Stroke Engine Four-Stroke Engine

Figure

Completes a power cycle in two Completes a power cycle in four strokes

Cycle strokes (one up, one down) per (intake, compression, power, exhaust)
crankshaft revolution per two crankshaft revolutions
Fuel Mixes fuel and oil; combusts every Separates fuel intake, compression,
Combustion revolution power, and exhaust strokes
Uses oil mixed with fuel for Has a dedicated oil reservoir for
Lubrication
lubrication lubrication
Generally, less efficient due to Generally, more efficient due to separate
Efficiency
simpler design strokes and better combustion control
Power Typically, higher power-to-weight
Typically, lower power-to-weight ratio
Output ratio
Tends to produce more pollution due Tends to have better emission control
Emissions
to incomplete combustion due to separate cycles
Simpler design with fewer moving More complex design with additional
Complexity
parts components
Maintenance Requires more frequent maintenance Requires less frequent maintenance
Commonly used in smaller,
Commonly used in larger vehicles such
Usage lightweight applications like
as cars, trucks, and some motorcycles
motorcycles, chainsaws
Q2: (P8) The excess heat from the engine can be removed using air- or water-cooling system.
It is required to Discuss the difference between air- and water-cooling system in the internal
combustion engines.

Aspect Air-Cooling System Water-Cooling System

Figure

Cooling Relies on air circulation to Uses liquid coolant (usually water)

Medium dissipate heat circulated through engine passages
Heat dissipation occurs through
Cooling Heat is absorbed by coolant and
fins and external airflow around
Process transferred to a radiator for dissipation
the engine
Less efficient cooling, especially in More efficient cooling, particularly in
Efficiency
high-heat conditions or heavy loads extreme temperatures or heavy loads
More complex system with additional
Simpler design with fewer
Complexity components like water pump, radiator,
components
hoses, etc.
Generally lighter due to fewer Slightly heavier due to additional
Weight
parts components
Requires less maintenance due to May require more maintenance due to
Maintenance
fewer components the complexity of the system
Temperature Less precise control over operating More precise control over engine
Control temperature operating temperature
Performance
Less effective in extreme
in Extreme More effective in extreme temperatures
temperatures
Conditions
Tends to be noisier due to air Generally quieter due to the absence of
Noise
circulation and fan operation fan noise
Commonly used in smaller engines Commonly used in larger engines like
Usage
like motorcycles, lawnmowers cars, trucks, and industrial machinery
Q3: (P9) State the main components in water system and describe the function of each
component in it

1. Radiator: The radiator is a heat exchanger that cools the hot coolant by allowing air
to pass through its fins. As the hot coolant flows through the radiator, heat is
dissipated into the surrounding air.
2. Coolant: Usually, a mixture of water and antifreeze, coolant circulates through the
engine to absorb heat. It also prevents freezing in cold temperatures and protects
against corrosion.
3. Water Pump: The water pump circulates the coolant through the engine and the
radiator. It maintains the flow of coolant, ensuring that heat is carried away from the
engine components efficiently.
4. Thermostat: The thermostat regulates the flow of coolant to the radiator based on the
engine's operating temperature. It helps maintain the engine at an optimal temperature
for efficiency and performance.
5. Coolant Reservoir: Also known as the overflow tank or expansion tank, this
component allows for the expansion and contraction of the coolant due to temperature
changes. It provides a space for excess coolant to flow in and out as needed.
6. Hoses and Pipes: These connect various components of the cooling system, allowing
the coolant to flow between the engine, radiator, water pump, and reservoir.
7. Coolant Temperature Sensor: This sensor monitors the temperature of the coolant
and sends signals to the engine control unit (ECU). Based on these signals, the ECU
can adjust engine parameters for optimal performance and emissions control.
8. Fan: In some vehicles, especially at low speeds or during idle, a fan helps draw air
through the radiator to assist in cooling when there's not enough airflow passing
through naturally.
Q4: (P10) Reviewing wet sump lubricating system, there are three types: the splash system, the
pressure feed system and the splash and pressure system. Explain with aid of sketch the
principles of operation for the pressure feed system.

The pressure feed lubrication system is a method used in internal combustion engines to ensure proper
lubrication of moving parts. It operates on the principle of pumping oil under pressure to critical engine
components to reduce friction and wear. Here's an explanation with the aid of a sketch:

Components of a Pressure Feed Lubrication System:

1. Oil Pump: The oil pump is usually gear-driven by the engine and is responsible for drawing
oil from the oil pan and pumping it through the system under pressure.
2. Oil Pan (Sump): The oil pan or sump is the reservoir where the engine oil is stored. The oil
pump draws oil from here.
3. Oil Filter: The oil filter removes contaminants from the oil before it circulates through the
engine. It helps maintain the oil's cleanliness and efficiency.
4. Oil Galleries and Passages: These are internal pathways within the engine block and cylinder
head that direct the pressurized oil to specific components that need lubrication.

Operation of Pressure Feed Lubrication System:

1. Oil Pickup: The oil pump draws oil from the sump through an oil pickup tube located at the
lowest point of the oil pan.
2. Oil Pumping: The oil pump pressurizes the oil and sends it through the oil filter to remove
any impurities or contaminants.
3. Pressurized Oil Distribution: The pressurized and filtered oil is then directed through oil
galleries and passages within the engine block and cylinder head.
4. Lubrication of Components: The pressurized oil is distributed to critical engine components
such as crankshaft bearings, camshaft bearings, piston rings, and valve train. The oil forms a
protective film between moving parts, reducing friction and wear.
5. Return to Oil Pan: After lubricating the engine components, the oil returns to the oil pan to
begin the cycle again.
Q5: (P11) Explain with aid of sketch the principles of operation of the fuel system in spark
ignition • GDI (Gasoline direct injection) • PI (port injection) • SPI (single point injection).

Gasoline Direct Injection (GDI):

Gasoline Direct Injection (GDI):

Principle of Operation - GDI:
1. Fuel Pump: The high-pressure fuel pump draws fuel from the tank and pressurizes
it to extremely high levels (typically over 1,000 psi).
2. Fuel Rail: The pressurized fuel is delivered through the fuel rail, which is a pipe that
runs along the intake manifold.
3. Fuel Injector: Each cylinder has its own fuel injector mounted directly into the
combustion chamber or cylinder, capable of delivering precise amounts of fuel in a
spray pattern directly into the cylinder.
4. Engine Control Unit (ECU): The ECU controls the timing and duration of fuel
injection pulses based on various engine parameters such as throttle position, engine
speed, and load.
5. Combustion Chamber: The fuel is sprayed directly into the combustion chamber
during the intake or compression stroke, leading to better fuel atomization, improved
combustion, and increased efficiency.
Port Injection (PI):

Port Injection (PI):

Principle of Operation - PI:
1. Fuel Pump: Similar to GDI, the fuel pump draws fuel from the tank, but in this
case, it operates at lower pressures (usually below 100 psi).
2. Fuel Injector at Intake Port: Each intake port has a fuel injector mounted, which
sprays fuel upstream of the intake valve.
3. Intake Manifold: The fuel is mixed with incoming air in the intake manifold before
reaching the intake valve.
4. Engine Control Unit (ECU): The ECU manages the fuel injectors' timing and
duration based on various engine sensors.
5. Combustion Chamber: Fuel-air mixture is then pulled into the combustion
chamber during the intake stroke for ignition.
Single Point Injection (SPI):

Single Point Injection (SPI):

Principle of Operation - SPI:
1. Fuel Pump: Similarly, the fuel pump draws fuel from the tank, operating at lower
pressures.
2. Single Injector: There is a single injector mounted centrally in the intake manifold,
often above the throttle body.
3. Throttle Body: The fuel is injected directly into the throttle body, mixing with the
incoming air.
4. Intake Manifold: The fuel-air mixture travels through the intake manifold and
reaches each cylinder via the intake ports.
5. Engine Control Unit (ECU): Like the other systems, the ECU controls the
injector's timing and duration based on engine conditions.
Q6: (P12) Investigate the main components of the fuel system in diesel engine and identify the
purpose of each component
The fuel system in a diesel engine is responsible for delivering fuel to the engine cylinders at the
correct pressure and timing for combustion. Here are the main components of a typical diesel
engine fuel system and their purposes:
1. Fuel Tank: This is where diesel fuel is stored in the vehicle or machinery. It supplies fuel to the
rest of the system.
2. Fuel Lines and Fuel Filters: Fuel lines transport diesel fuel from the tank to the engine. Fuel
filters are placed along the fuel lines to remove contaminants, preventing them from reaching and
damaging other components in the system.
3. Fuel Lift Pump or Transfer Pump: The lift
pump or transfer pump draws fuel from the
tank and pushes it towards the high-pressure
injection system. In some modern diesel
engines, this function might be integrated into
the fuel injection system itself.
4. Fuel Injection Pump: The fuel injection
pump pressurizes the fuel to a high pressure
(hundreds or thousands of bars/psi). This
high-pressure fuel is then delivered to the
injectors at the correct moment for
combustion.
5. Fuel Injectors: These are responsible for spraying precise amounts of pressurized fuel into the
combustion chamber or cylinder at the right time, based on signals from the engine's control
system. The fuel is atomized into a fine mist for efficient combustion.
6. Injector Nozzles: Injector nozzles are responsible for delivering the fuel spray directly into the
combustion chamber with the correct pattern and atomization for optimal combustion.
7. Injection Timing Device or Timing Control: This component, often controlled electronically
in modern engines, determines when fuel is injected into the cylinders. It ensures that fuel is
injected at the precise moment for efficient combustion and power generation.
8. Fuel Pressure Regulator: This device regulates the pressure of the fuel entering the injectors,
ensuring a consistent and optimal pressure for efficient combustion.
9. Fuel Heater (in some systems): Particularly in cold climates, a fuel heater might be used to
warm the diesel fuel before it enters the engine, preventing fuel gelling and ensuring better
combustion in colder conditions.
10. Fuel Return System: Unused fuel from the injectors is returned to the fuel tank through the fuel
return system to maintain a constant flow and pressure in the fuel system.

Each of these components plays a crucial role in delivering clean, pressurized diesel fuel to the
engine cylinders, ensuring proper combustion and efficient operation of the diesel engine.
Q7: (M2.3) You are required to develop a report on: "Operation of closed water-cooling
system in start and normal operation in ICE" According to report quality and sources of
information you will be awarded
Report: Operation of Closed Water-Cooling System in Internal Combustion
Engines (ICE)

Introduction: Internal Combustion Engines (ICE) generate significant amounts of heat during
operation, requiring efficient cooling systems to maintain optimal operating temperatures. A closed
water-cooling system is a commonly used method to manage this heat in ICE, ensuring proper engine
function and longevity. This report explores the operation of closed water-cooling systems during
start-up and normal operation in ICE.

Closed Water-Cooling System Overview: A closed water-cooling system circulates a coolant

(usually a mixture of water and antifreeze) through the engine to absorb heat and dissipate it via a
radiator. It comprises several components working together to manage the engine's temperature.

Start-Up Operation:
1. Initial Stage: When the engine is cold and not running, the coolant remains stagnant in the
engine block and radiator. At this stage, the thermostat remains closed, restricting the flow of
coolant through the radiator.
2. Thermostat Activation: Upon starting the engine, the combustion process generates heat,
gradually warming up the engine. As the temperature rises, the thermostat, a temperature-
sensitive valve, detects the increase in heat and begins to open.
3. Coolant Circulation: As the thermostat opens, it allows the heated coolant from the engine to
flow through the coolant passages and into the radiator. The water pump, typically driven by a
belt connected to the engine, starts circulating the coolant.
4. Heat Dissipation: The hot coolant enters the radiator, a heat exchanger with multiple small
tubes and fins. As the coolant flows through these tubes, air passing through the fins helps
dissipate heat. This process cools the coolant, reducing its temperature before it returns to the
engine.

Normal Operation:
1. Continuous Circulation: During normal engine operation, the water pump continues to
circulate the coolant through the engine and radiator.
2. Heat Transfer: The coolant absorbs heat from various engine components, including the
combustion chambers, cylinder walls, and cylinder heads. It then carries this heat to the radiator.
3. Regulation by Thermostat: The thermostat continually monitors the coolant temperature. If
the engine becomes too hot, the thermostat opens wider, allowing more coolant to flow through
the radiator. Conversely, if the engine is operating within the optimal temperature range, the
thermostat maintains a partially closed position to regulate the coolant flow.
4. Coolant Reservoir: The system often includes a coolant reservoir or expansion tank. This
tank provides space for the coolant to expand and contract with temperature changes. It ensures
that the system remains properly filled and prevents air pockets from forming in the cooling
system.
Component Functions:
• Radiator: A heat exchanger that dissipates heat from the coolant into the surrounding air.
• Coolant: A mixture of water and antifreeze that absorbs heat from the engine and carries it to
the radiator.
• Water Pump: Driven by the engine, it circulates the coolant through the system, ensuring
continuous flow for proper cooling.
• Thermostat: Controls the flow of coolant to regulate the engine's operating temperature.
• Hoses and Pipes: Connect various components, allowing the flow of coolant throughout the
system.
• Coolant Reservoir: Provides space for expansion and contraction of the coolant and helps
maintain proper coolant levels.

Conclusion:
The closed water-cooling system is an essential component in Internal Combustion Engines (ICE),
serving a critical role in maintaining optimal operating temperatures. During start-up, the system
initially remains static, with the thermostat closed to facilitate engine warm-up. As the engine runs,
the thermostat gradually opens, allowing the circulation of coolant, which absorbs heat from the engine
and carries it to the radiator.
Throughout normal operation, the water pump ensures continuous circulation of the coolant. This
coolant absorbs heat generated by the combustion process, and the radiator dissipates this heat into the
surrounding air, regulating the engine's temperature.
Overall, the closed water-cooling system in ICE is vital for preventing overheating, enabling efficient
combustion, and safeguarding the engine from potential damage due to excessive heat. Proper
functioning of this system is integral to the longevity and reliability of internal combustion engines.

References:
• Heywood, John B. "Internal Combustion Engine Fundamentals."
• Stone, Richard. "Introduction to Internal Combustion Engines."
• Manufacturer technical manuals and specifications.

This report outlines the functionality of closed water-cooling systems in ICE, highlighting their
significance in maintaining engine temperatures during start-up and normal operation.
Q8 (D2.3) You are a member in technician team wants to manage the activity " removing the
thermostat valve from the ICE water cooling system" Discuss what will happen and mention the
advantages and disadvantages of this action.
As a member of the technician team considering the removal of the thermostat valve
from the Internal Combustion Engine (ICE) water cooling system
Impact of Removing the Thermostat Valve:
1. Effect on Engine Temperature Regulation:
• Without the thermostat, the engine will operate at a consistently lower
temperature. The thermostat regulates coolant flow, allowing the engine to reach
its optimal operating temperature quickly and maintain it within the ideal range.
Removing it could result in the engine running too cold, affecting fuel efficiency
and performance.
2. Fuel Efficiency and Emissions:
• An engine running at lower temperatures may experience decreased fuel
efficiency. Modern engines are designed to operate within specific temperature
ranges for optimal combustion, and lower temperatures may result in incomplete
combustion, leading to increased emissions.
3. Engine Performance and Wear:
• Operating below the ideal temperature might affect the engine's performance,
potentially causing increased wear and tear. Cold temperatures could result in poor
lubrication and increased friction between moving parts, leading to accelerated
component wear and reduced engine lifespan.
4. Condensation and Moisture Build-Up:
• Operating at consistently low temperatures may cause moisture to accumulate in
the engine, particularly in regions with fluctuating weather conditions. This could
lead to rust and corrosion within the engine components, impacting long-term
durability.

Advantages of Removing the Thermostat Valve:

1. Improved Cooling in Extreme Conditions:
• In situations where the engine tends to overheat due to a faulty thermostat,
removing it might prevent overheating issues by allowing unrestricted coolant
flow. However, this should be a temporary solution until the thermostat is
replaced.

2. Simplified System Maintenance:

• Eliminating the thermostat removes a potential point of failure in the cooling
system. However, this advantage must be weighed against the potential negative
impacts on engine performance and efficiency.
Disadvantages of Removing the Thermostat Valve:
1. Inefficient Engine Operation:
• Engine efficiency could suffer due to operating at lower temperatures, leading
to increased fuel consumption, reduced power output, and potential engine
misfires.
2. Increased Wear and Tear:
• Operating the engine at lower-than-optimal temperatures may cause increased
wear on engine components, reducing their lifespan and potentially resulting
in costly repairs or replacements.
3. Potential for Engine Damage:
• Long-term operation without a thermostat can potentially cause damage to
engine components due to inadequate lubrication, inefficient combustion, and
moisture-related issues.

Conclusion:
While removing the thermostat valve may seem like a quick fix to address overheating
issues, it's essential to consider the significant drawbacks associated with this action.
Operating an engine without a thermostat can lead to various adverse effects on fuel
efficiency, emissions, engine performance, and long-term durability. It's recommended to
address thermostat-related issues by replacing or repairing the thermostat to ensure proper
engine temperature regulation and optimal performance.
Q9 (M3.3)
The generated power from the ICE are mainly based on the filling of the cylinder
with new charge which is known by volumetric efficiency. Prepare a short
presentation in two pages of PowerPoint size at max to describe the following:
1. Reasons for a lack of cylinder charging
2. The methods to overcome the lack of cylinder charging
You should use Expressive and clear sketches
List your references used in your presentation
Attach a copy of your presentation at the end of this assignment.
 PRESENTATION

(Cylinder Charging in Internal Combustion Engines)

By
(MAHMOUD MOHAMED MAHMOUD MOHAMED)

Dr. SABRY ALLAM

(Mechanical Technology)

MISR INTERNATIONAL TECHNOLOGICAL UNIVERSITY

(MITU)

ACADEMIC YEAR: 2023-2024

Title: Analysis of Cylinder Charging Shortages and Strategies for Mitigation
Introduction: Cylinder charging shortages pose a significant challenge in various industries reliant on
compressed gas cylinders. The lack of proper charging adversely affects operations, productivity, and
ultimately, the overall efficiency of industries utilizing these cylinders. This report aims to explore the
reasons for cylinder charging shortages and proposes effective methods to overcome these limitations.
1. Reasons for a Lack of Cylinder Charging:
a. Supply Chain Disruptions:
• Supply chain disruptions, including transportation issues, raw
material shortages, or manufacturing delays, can lead to a reduced
availability of cylinders.
b. High Demand:
• An overwhelming demand for specific gases or an unexpected surge in demand can strain the
capacity of cylinder charging facilities, causing shortages.
c. Equipment Maintenance and Downtime:
• Equipment failure or scheduled maintenance of charging stations can
result in reduced output, contributing to a lack of charged cylinders.
d. Inadequate Infrastructure:
• Insufficient charging facilities or outdated infrastructure incapable of
meeting the growing demand for cylinder charging can lead to
shortages.
e. Regulatory Compliance:
• Compliance with stringent safety regulations and quality control
measures might slow down the cylinder charging process, impacting the
overall output.
 Methods to Overcome the Lack of Cylinder Charging:

a. Diversification of Suppliers:
•Collaborating with multiple suppliers and establishing
a diverse network can mitigate shortages caused by
disruptions in a single supplier's chain.
b. Inventory Management and Forecasting:
•Implementing advanced inventory management
systems and predictive analytics can help forecast
demand more accurately, allowing for better preparation
and inventory stocking.
c. Upgrading Infrastructure:
• Investing in modern charging facilities, automation, and efficient machinery can enhance charging
capacity and reduce downtime due to maintenance.
d. Collaboration and Partnerships:
• Forming partnerships or collaborations with other
industries or suppliers to share resources during
shortages can help alleviate charging deficits.
e. Regulatory Compliance Streamlining:
• Working closely with regulatory bodies to ensure
compliance without compromising efficiency can
expedite the charging process.
f. Research and Development for Alternative Solutions:
• Exploring alternative methods for charging cylinders, such as renewable energy-based charging or
advanced storage solutions, can provide more sustainable and efficient options.
 Conclusion
Cylinder charging shortages can significantly disrupt various industries and operations.
Addressing these challenges requires a multi-faceted approach, including diversifying
suppliers, upgrading infrastructure, improving forecasting methods, and fostering
collaboration. By implementing these strategies, industries can better navigate and mitigate
the impact of cylinder charging shortages, ensuring smoother operations and sustained
productivity.
In conclusion, addressing cylinder charging shortages necessitates a proactive, adaptive, and
collaborative approach. Industries must continually assess and adapt their strategies to
navigate the complexities of the supply chain and market dynamics. By implementing the
proposed strategies and embracing innovation, industries can mitigate the impact of cylinder
charging shortages, ensuring smoother operations, sustained productivity, and resilience in
the face of challenges.
References
1. Baberg, A., Freidhager, M., Mergel, H., Schmidt, K., Aspekte der Kolbenmaterialwahl bei
Dieselmotoren, MTZ, 12, 2012.
2. Blümm, M., Baberg, A., Dörnenburg, F., Leitzmann, D., Innovative Schaftbeschichtungen für Otto- und
Dieselmotorkolben, MTZ, 02, 2016.
3. Deuss, T., Ehnis, H., Freier, R., Künzel, R, Friction power measurements of a fired diesel engine –
influence of skirt geometry, MTZ 12, 2013.
4. Deuss, T., Ehnis, H., Rose, R. K., Künzel, R., Reibleistungsmessungen am Befeuerten Dieselmotor –
Einfluss von Kolbenschaftbeschichtungen, MTZ 4, 2011.
5. Golloch R., Downsizing bei Verbrennungsmotoren – Ein wirkungsvolles Konzept zur
Kraftstoffverbrauchssenkung, Springer-Verlag, Berlin, Heidelberg 2005.