TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY

Wardha Road, Nagpur - 441108

Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
NOTES UNIT - 1

Introduction of Automobile Engineering

1. What is an automobile?
 An automobile is a self−propelled vehicle that may be used for transportation of
passengers or goods.
 By self−propelled it means the power required for propulsion is produced from within the
vehicle (may be from an IC Engine).
 Majority of the automobiles are assemblies of two broad component groups:
the Chassis and the Body.
 The word automobile comes, via the French automobile from the Ancient Greek word
αὐτός (autós, "self") and the Latin mobilis ("movable"); meaning a vehicle that moves
itself. The alternative name car is believed to originate from the Latin word carrus or
carrum ("wheeled vehicle")

2. History of the automobile

 The early history of the automobile can be divided into a number of eras, based on the
prevalent means of propulsion. Later periods were defined by trends in exterior styling,
size, and utility preferences.
 In 1769 the first steam powered auto-mobile capable of human transportation was built
by Nicolas-Joseph Cugnot.
 In 1807, François Isaac de Rivaz designed the first car powered by an internal
combustion engine fuelled by hydrogen.
 In 1886 the first petrol or gasoline powered auto-mobile the Benz Patent-Motorwagen
was invented by Karl Benz.
 At the turn of the 20th century electrically powered auto-mobiles appeared but only
occupied a niche market until the turn of the 21st century.

3. What is a chassis?
 An automobile chassis is a basic structure that comprises of various components that are
bare essential for running, controlling and stopping the automobile.
 It may includes the ladder frame, the tires, the braking system, the steering system, the
engine, the transmission, the suspension system, etc.
 Chassis is sub−divided into running gear and power plant.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
 The running gear comprises of the ladder frame, the tires, brakes, steering system and
other components that aid in maneuvering the vehicle.
 While, the power plant means the engine of the vehicle.

4. What is a body?

 A body in an automobile is the structure complementing the chassis whose function is to

provide aesthetic looks, riding comfort or serve any other purpose relating to driving the
vehicle.

5. What is Frame

 A frame is the main structure of the chassis of a motor vehicle. All other components
fasten to it; a term for this design is body-on-frame construction.
 In 1920, other than a few cars based on motorcycles, every motor vehicle had a frame.
Since then, nearly all cars have shifted to unit-body construction, while nearly all trucks
and busses still use frames.

6. Functions of Frame

The main functions of a frame in motor vehicles are:

• To support the vehicle's chassis components and body

• To deal with static and dynamic loads, without undue deflection or distortion.

These include

• Weight of the body, passengers, and cargo loads.

• Vertical and torsional twisting transmitted by going over uneven surfaces.
• Transverse lateral forces caused by road conditions, side wind, and steering the vehicle.
• Torque from the engine and transmission.
• Longitudinal tensile forces from starting and acceleration, as well as compression from
braking.
• Sudden impacts from collisions.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering

7. TYPES OF FRAME

There are three types of frames

(a) Conventional frame,

(b) Semi-integral frame, and
(c) Integral frame (or unit frame).
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering

1. Conventional Frame
It is non-load carrying frame. The loads of the vehicle are transferred to the suspensions
by the frame. This suspension in the main skeleton of the vehicle which is supported on
the axles through springs . The body is made of flexible material like wood and isolated
frame by inserting rubber mountings in between. The frame is made of channel section or
tubular section of box section.
Example: This type of frame is used for trucks.

2. Semi-integral Frame
In this case the rubber mountings used in conventional frame between frame and
suspension are replaced by more stiff mountings. Because of this some of the vehicle
load is shared by the frame also. This type of frame is heavier in construction.
Example : Popular in European and American car.

3. Integral Frame or Frame-less Construction

In this type of construction, there is no frame. It is also called unitized frame-body
construction. In this case, the body shell and underbody are welded into single unit. The
underbody is made of floor plates and channel and box sections welded into single unit.
This assembly replaces the frame. This decreases the overall weight compared to
conventional separate frame and body construction

8.Classification of Automobiles
1. Classification Based on Purpose:

• Passenger Vehicles: These vehicles are designed to transport passengers and include
examples like buses, cars, and passenger trains.
• Goods Vehicles: These automobiles are primarily used for the transportation of goods
and include vehicles such as goods lorries and goods carriers.
• Special Purpose Vehicles: This category encompasses vehicles with unique functions,
including ambulances, fire engines, and military vehicles.

2. Classification Based on Load Capacity:

• Light Duty Vehicles: These are compact motor vehicles such as cars, jeeps, scooters, and
motorcycles.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
• Heavy Duty Vehicles: These larger and bulkier motor vehicles include buses, trucks, and
tractors.

3. Classification Based on Fuel Used:

• Petrol Engine Vehicles: This group comprises automobiles powered by petrol engines,
including scooters, cars, and motorcycles.
• Diesel Engine Vehicles: These are vehicles powered by diesel engines, such as trucks,
buses, and tractors.
• Gas Vehicles: This category includes vehicles that use gas turbines as a power source,
such as turbine-powered cars.
• Electric Vehicles: These automobiles rely on electricity as their power source, like
electric cars and electric buses.
• Steam Engine Vehicles: Vehicles in this category are powered by steam engines and
include steamboats, steam locomotives, and steam wagons.

4. Classification Based on Drive of the Vehicles:

• Left-Hand Drive: These vehicles have the steering wheel on the left-hand side.
• Right-Hand Drive: Vehicles with the steering wheel on the right-hand side.
• Fluid Drive: This category comprises vehicles that employ torque converters, fluid
flywheels, or hydramatic transmissions.

5. Classification Based on Number of Wheels and Axles:

• Two-Wheelers: This includes motorcycles and scooters.

• Three-Wheelers: Examples are tempo and auto-rickshaws.
• Four-Wheelers: These are standard vehicles like cars, jeeps, buses, and trucks.
• Six-Wheelers: Buses and trucks in this category have six tires, with four of them carried
on the rear wheels for additional support.
• Six Axle Wheelers: Examples include vehicles like Dodge with ten tires.

6. Classification Based on Type of Transmission:

• Automatic Transmission Vehicles: These automobiles are capable of changing gear ratios
automatically, such as automatic transmission cars.
• Manual Transmission Vehicles: This category includes vehicles where gear ratios must
be changed manually.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
• Semi-Automatic Transmission Vehicles: These vehicles enable manual gear changing
with a clutch pedal.

7. Classification Based on Suspension System Used:

• Conventional Suspension: This type uses leaf springs.

• Independent Suspension: Examples include coil springs, torsion bars, and pneumatic
suspension.
8. Classification Based on Emission Norms

 BS4 (Bharat Stage 4): A standard for vehicle emissions in India, implemented until 2020.

 BS6 (Bharat Stage 6): The latest standard for vehicle emissions in India, stricter than
BS4.

9.Chassis

 If the frame contains the base components its called as chassis. The
components are like Engine, radiator, clutch, gearbox, silencer, road
wheels, fuel tank, wirings, differential units, etc.

FUNCTIONS OFA CHASSIS

1. Supports or bears the load of the vehicle body.

2. Provide the space and mounting location for various aggregates of vehicle.

3. Supports the weight of varioussystems of the vehicle such as engine, transmission etc.

4. Supports a load of passengers as well as the luggage.

5. With stands the stresses arising due to bad road conditions.

6. With stand stresses during braking and acceleration of the vehicle.

Types of Chassis
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
i. Ladder Chassis

ii. Tubular Chassis

iii. Monocoque Chassis

1. Ladder Chassis
The ladder-frame chassis is one of the oldest chassis types. This chassis is characterised by two
long heavy beams that are supported by two smaller ones. Its quality of being easily
manufactured not only made it contemporarily popular but also eased the way for its mass
production. Since ladder frame chassis is significantly heavy it‘s usually used for vehicles that
transport heavy material.

Benefits

1. Easy to manufacture and easy assembling of the car over it.·

2. Heavy and strong tensile strength.

Drawbacks

1. Poor cornering ability due to weak torsional rigidity

2. Its heaviness doesn‘t make it suitable for performance car sand hatchbacks

Fig. Ladder chassis frame layout

Tubular Chassis
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Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
 Tubular space frame chassis employs dozens of circular-section tubes (some may use
square-section tubes for easier connection to the body panels, though circular section
provides the maximum strength)
 This type of chassisis mostly used while manufacturing racing cars due to the enhanced
safety they offer.

Benefits

 Its crafting allows better contact between the half axle and ground making it preferable for
off-roading.
 A cylindrical tube covering the driveshaft saves it from any damage while off-roading.
 The structure‘s torsional toughness is relatively more supple than ladder chassis.

Drawbacks

 In case the drive shaft fails ,the whole chassis needs to be dismantled as the drive shaft is
covered with the cylindrical tube of the chassis.
 The manufacture of backbone chassis is costly and increases the overall cost of the car.

Fig. Tubular Chassis

Monocoque Chassis
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
 The construction of a monocoque chassis is quite simple in the sense that the entire
structure is one big construction.
 All components or mechanical parts constitute the frame, foundation and body of the car.
 The engine,gear box,suspension,seats and exterior body panels are simply attached to the
construction. This means that the overall construction is very lightweight and compact.
There is quite a lot of safety element to it.
 The applications include all sorts of everyday vehicles ranging from small land compact
hatchbacks to large and heavy SUVs. It must be noted that modern SUVs are using
monocoque construction quite a bit which was not always the case in the past

Benefits

 It‘s safer than both the other chassis due to its cage-like construction.
 The chassis is easy to repair as well.
 It has superior torsional rigidity.

Drawbacks

 The chassis is obviously heavy as it‘s both the frame and chassis as one single entity.
 Producing it in small quantities is not financially feasible and thus it cannot be used for cars
that are not mass-produced.

10.Definition of ‘Engine’
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
An engine is a device, which transforms one form of energy into another form. Normally, most of
the engines convert thermal energy into mechanical work and therefore they are called ‗heat
engines.

Fig. parts of an I.C. Engine

Engine Components

The major components of the engine and their functions are briefly described below.

Cylinder Block:

The cylinder block is the main supporting structure for the various components. The cylinder of a
multi cylinder engine is cast as a single unit, called cylinder block. The cylinder head is mounted
on the cylinder block.
The cylinder head and cylinder block are provided with water jackets in the case of water-
cooling with cooling fins in the case of air-cooling. Cylinder head gasket is incorporated between
the cylinder block and cylinder head. The cylinder head is held tight to the cylinder block by
number of bolts or studs. The bottom portion of the cylinder block is called crankcase. A cover
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
called crankcase, which becomes a sump for lubricating oil is fastened to the bottom of the
crankcase. The inner surface of the cylinder block , which is machined and finished accurately to
cylindrical shape, is called bore or face.

Cylinder:

As the name implies it is a cylindrical vessel or space in which the piston makes a reciprocating
motion. The varying volume created in the cylinder during the operation of the engine is filled
with the working fluid and subjected to different thermodynamic processes. The cylinder is
supported in the cylinder block.

Piston:

It is a cylindrical component fitted into the cylinder forming the moving boundary of the
combustion system. It fits perfectly (snugly) into the cylinder providing a gas-tight space with
the piston rings and the lubricant. It forms the first link in transmitting the gas forces to the
output shaft.

Combustion Chamber:

The space enclosed in the upper part of the cylinder, by the cylinder head and the piston top during
the combustion process, is called the combustion chamber. The combustion of fuel and the
consequent release of thermal energy results in the building up of pressure in this part of the
cylinder.

Inlet Manifold:

The pipe which connects the intake system to the inlet valve of the engine and through which air or
air-fuel mixture is drawn into the cylinder is called the inlet manifold.

Gudgeon Pin:

It forms the link between the small end of the connecting rod and the piston.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
Exhaust Manifold:

The pipe that connects the exhaust system to the exhaust valve of the engine and through which the
products of combustion escape into the atmosphere is called the exhaust manifold.

Inlet and Exhaust Valves:

Valves are commonly mushroom shaped poppet type. They are provided either on the cylinder
head or on the side of the cylinder for regulating the charge coming into the cylinder (inlet valve)
and for discharging the products of combustion (exhaust valve) from the cylinder.

Connecting Rod:

It interconnects the piston and the crankshaft and transmits the gas forces from the piston to the
crankshaft. The two ends of the connecting rod are called as small end and the big end. Small end
is connected to the piston by gudgeon pin and the big end is connected to the crankshaft by
crankpin.

Crankshaft:

It converts the reciprocating motion of the piston into useful rotary motion of the output shaft. In
the crankshaft of a single cylinder engine there is pair of crank arms and balance weights. The
balance weights are provided for static and dynamic balancing of the rotating system. The
crankshaft is enclosed in a crankcase.

Piston Rings:

Piston rings, fitted into the slots around the piston, provide a tight seal between the piston and the
cylinder wall thus preventing leakage of combustion gases

Camshaft:

The camshaft and its associated parts control the opening and closing of the two valves. The
associated parts are push rods, rocker arms, valve springs and tappets. This shaft also provides the
drive to the ignition system. The camshaft is driven by the crankshaft through timing gears.

Cams:

These are made as integral parts of the camshaft and are designed in such a way to open the valves
at the correct timing and to keep them open for the necessary duration.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
Fly Wheel:

The net torque imparted to the crankshaft during one complete cycle of operation of the engine
fluctuates causing a change in the angular velocity of the shaft. In order to achieve a uniform
torque an inertia mass in the form of a wheel is attached to the output shaft and this wheel is called
the flywheel.

11. Heat engines can be broadly classified into two categories:

1. Internal Combustion Engines (IC Engines)

2. External Combustion Engines (EC Engines)

External Combustion and Internal Combustion Engines

External combustion engines are those in which combustion takes place outside the engine whereas
in internal combustion engines combustion takes place within the engine. For example, in a steam
engine or a steam turbine, the heat generated due to the combustion of fuel is employed to generate
high pressure steam, which is used as the working fluid in a reciprocating engine or a turbine. In
case of gasoline or diesel engines, the products of combustion generated by the combustion of fuel
and air within the cylinder form the working fluid.

Application of IC and EC Engines IC Engines

1. Gasoline Engine –Automotive, Marine Aircraft

2. Diesel Engine - Automotive, Marine, Power, Locomative Gas Engines –Industrial Power
3. EC Engines
4. Steam Engines – Locomotives, Marine Steam Turbine – Power, Large Marine

Classification of Internal Combustion Engines

Internal Combustion engines are of two types,

1. Rotary engines
2. Reciprocating engines

• Two stroke & four stroke engines

• Petrol & diesel engines

 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
11. TERMS CONNECTED WITH I.C. ENGINES

Bore: The inside diameter of the cylinder is called bore

Stroke: The linear distance along the cylinder axis between two limiting position s is called stroke.

Top Dead Center ( T.D.C.) : the top most position of the piston towards cover end side of the
cylinder is called T.D.C.

Bottom dead Center ( B.D.C.) : The lowest position of the piston towards the crank end side of
the cylinder is called B.D.C.

Clearance Volume : The volume contained in the cylinder above the top of the piston , when the
piston is at top dead center , is called the clearance volume.

Swept Volume: The volume swept through by the piston in moving between T.D.C. and B.D.C, is
called swept volume or piston displacement

Compression Ratio: It is the ratio of Total cylinder volume to clearance volume

12. PETROL ENGINE:

CONSTRUCTION DETAILS

Basic Engine Components and Nomenclature

PETROL ENGINE:

CONSTRUCTION DETAILS

Basic Engine Components and Nomenclature

Even though reciprocating internal combustion engines look quite simple, they are highly
complex machines. There are hundreds of components that have to perform their functions

satisfactorily to produce output power. There are two types of engines, viz., spark ignition (S1)
and compression-ignition (CI) engine. Let us now go through the important engine components
and the nomenclature associated with an engine.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
Engine Components

The major components of the engine and their functions are briefly described below.

Cylinder Block:

The cylinder block is the main supporting structure for the various components. The cylinder of a
multi-cylinder engine is cast as a single unit, called cylinder block. The cylinder head is mounted
on the cylinder block. The cylinder head and cylinder block are provided with water jackets in
the case of water-cooling with cooling fins in the case of air-cooling. Cylinder head gasket is
incorporated between the cylinder block and cylinder head. The cylinder head is held tight to the
cylinder block by number of bolts or studs. The bottom portion of the cylinder block is called
crankcase. A cover called crankcase, which becomes a sump for lubricating oil is fastened to the
bottom of the crankcase. The inner surface of the cylinder block, which is machined and finished
accurately to cylindrical shape, is called bore or face

Cylinder

As the name implies it is a cylindrical vessel or space in which the piston makes a reciprocating
motion. The varying volume created in the cylinder during the operation of the engine is filled
with the working fluid and subjected to different thermodynamic processes. The cylinder is
supported in the cylinder block.

Piston

It is a cylindrical component fitted into the cylinder forming the moving boundary of the
combustion system. It fits perfectly (snugly) into the cylinder providing a gas-tight space with
the piston rings and the lubricant. It forms the first link in transmitting the gas forces to the
output shaft.

Combustion Chamber

The space enclosed in the upper part of the cylinder, by the cylinder head and the piston top
during the combustion process, is called the combustion chamber. The combustion of fuel and
the consequent release of thermal energy results in the building up of pressure in this part of the
cylinder.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
Inlet Manifold

The pipe which connects the intake system to the inlet valve of the engine and through which air
or air-fuel mixture is drawn into the cylinder is called the inlet manifold.

Exhaust Manifold

The pipe that connects the exhaust system to the exhaust valve of the engine and through which
the products of combustion escape into the atmosphere is called the exhaust manifold.

Inlet and Exhaust Valves

Valves are commonly mushroom shaped poppet type. They are provided either on the cylinder
head or on the side of the cylinder for regulating the charge coming into the cylinder (inlet valve)
and for discharging the products of combustion (exhaust valve) from the cylinder.

Connecting Rod

It interconnects the piston and the crankshaft and transmits the gas forces from the piston to the
crankshaft. The two ends of the connecting rod are called as small end and the big end. Small
end is connected to the piston by gudgeon pin and the big end is connected to the crankshaft by
crankpin.

Crankshaft

It converts the reciprocating motion of the piston into useful rotary motion of the output shaft. In
the crankshaft of a single cylinder engine there is pair of crank arms and balance weights. The
balance weights are provided for static and dynamic balancing of the rotating system. The
crankshaft is enclosed in a crankcase.

Piston Rings

Piston rings, fitted into the slots around the piston, provide a tight seal between the piston and the
cylinder wall thus preventing leakage of combustion gases

Gudgeon Pin

It forms the link between the small end of the connecting rod and the piston.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
Camshaft

The camshaft and its associated parts control the opening and closing of the two valves. The
associated parts are push rods, rocker arms, valve springs and tappets. This shaft also provides
the drive to the ignition system. The camshaft is driven by the crankshaft through timing gears.

Cams

These are made as integral parts of the camshaft and are designed in such a way to open the
valves at the correct timing and to keep them open for the necessary duration.

Fly Wheel

The net torque imparted to the crankshaft during one complete cycle of operation of the engine
fluctuates causing a change in the angular velocity of the shaft. In order to achieve a uniform
torque an inertia mass in the form of a wheel is attached to the output shaft and this wheel is
called the flywheel.

13. Two-stroke Engine

As already mentioned, if the two unproductive strokes, viz., the suction and exhaust could be
served by an alternative arrangement, especially without the movement of the piston then there
will be a power stroke for each revolution of the crankshaft. In such an arrangement,
theoretically the power output of the engine can be doubled for the same speed compared to a
four-stroke engine. Based on this concept, Dugald Clark (1878) invented the two-stroke engine

Figure. Two Stroke Cycle Engine

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Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
In two-stroke engines the cycle is completed in one revolution of the crankshaft. The main
difference between two-stroke and four stroke engines is in the method of filling the fresh charge
and removing the burnt gases from the cylinder. In the four-stroke engine these operations are
performed by the engine piston during the suction and exhaust” strokes respectively. In a two-
stroke engine, the filling process is accomplished by the charge compressed in crankcase or by a
blower. The induction of the compressed charge moves out the product of combustion through
exhaust ports. Therefore, no piston strokes are required for these two operations. Two strokes
are sufficient to complete the cycle, one for compressing the fresh charge and the other for
expansion or power stroke.

Figure shows one of the simplest two-stroke engines, viz., the crankcase scavenged engine. The
air or charge is inducted into the crankcase through the spring loaded inlet valve when the
pressure in the crankcase is reduced due to upward motion of the piston during compression
stroke. After the compression and ignition, expansion takes place in the usual way. During the
expansion stroke the charge in the crankcase is compressed. Near the end of the expansion
stroke, the piston uncovers the exhaust ports and the cylinder pressure drops to atmospheric
pressure as the combustion products leave the cylinder. Further movement of the piston
uncoversthe transfer ports, permitting the slightly compressed charge in the crankcase to enter
the engine cylinder

The top of the piston has usually a projection to deflect the fresh charge towards the top of the
cylinder before flowing to the exhaust ports. This serves the double purpose of scavenging the
upper part of the cylinder of the combustion products and preventing the fresh charge from
flowing directly to the exhaust ports. The same objective can be achieved without piston
deflector by proper shaping of the transfer port. During the upward motion of the piston from B
DC the transfer ports close first and then the exhaust ports close when compression of the charge
begins and the cycle is repeated.

Comparison of Four-stroke and Two-stroke Engines

The two-stroke engine was developed to obtain a greater output from the same size of the engine.
The engine mechanism also eliminates the valve arrangement making it mechanically simpler.
Almost all two-stroke engines have no conventional valves but only ports (some have an exhaust
valve). This simplicity of the two-stroke engine makes it cheaper to produce and easy to
maintain. Theoretically a two-stroke engine develops twice the power of a comparable four
stroke engine because of one power stroke every revolution (compared to one power stroke every
two revolutions of a four-stroke engine). This makes the two-stroke engine more compact than a
comparable four-stroke engine. In actual practice power output is not exactly doubled but
increased by only about 30% because of Reduced effective expansion stroke and Increased
heating caused by increased number of power strokes that limits the maximum speed.
 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
The other advantages of the two-stroke engine are more uniform torque on crankshaft and
comparatively less exhaust gas dilution. However, when applied to the spark-ignition engine the
two stroke cycle has certain disadvantages which have restricted its application to only small
engines suitable for motor cycles, scooters, lawn mowers, outboard engines etc. In the SI engine,
the incoming charge consists of fuel and air. During scavenging, as both inlet and exhaust ports
are open simultaneously for some time, there is a possibility that some of the fresh charge
containing fuel escapes with the exhaust. This results in high fuel consumption and lower
thermal efficiency. The other drawback of two-stroke engine is the lack of flexibility, viz., the
capacity to operate with the same efficiency at all speeds. At part throttle operating condition, the
amount of fresh mixture entering the cylinder is not enough to clear all the exhaust gases and a
part of it remains in the cylinder to contaminate the charge. This results in irregular operation of
the engine. The two-stroke diesel engine does not suffer from these defects. There is no loss of
fuel with exhaust gases as the intake charge in diesel engine is only air. The two- stroke diesel
engine is used quite widely. Many of the high output diesel engines work on this cycle. A
disadvantage common to all two-stroke engines, gasoline as well as diesel, is the greater cooling
and lubricating oil requirements due to one power stroke in each revolution of the crankshaft.
Consumption of lubricating oil is high in two-stroke due to higher temperature.

Figure. Four Stroke Engine

 TULSIRAMJI GAIKWAD-PATIL COLLEGE OF ENGINEERING AND TECHNOLOGY
Wardha Road, Nagpur - 441108
Accredited with NAAC A+ Grade
Approved by AICTE, New Delhi, Govt. of Maharashtra
(An Autonomous Institution Affiliated to RTM Nagpur University, Nagpur)
Department of Mechanical Engineering
14. Fuel Supply system:

1. The Fuel delivery system consists of Fuel tank, fuel pump, fuel filter, Fuel delivery pipe, fuel
injector, fuel pressure regulator and fuel return pipe

2. Fuel is delivered from the tank to the injector by means of an electric fuel pump. The pump is
typically located in or near to the tank. Contaminants are filtered out by a high capacity in line fuel
filter.

3. Fuel is maintained at a constant pressure by means of a fuel pressure regulator. Any fuel which
is not delivered to the intake manifold by the injector is returned to the tank through a fuel return
pipe