Automobile Engineering

Unit 1
BY
Prof. Dr. S.D.Ambekar
Classification of Automobiles:
Classification of Automobiles:
Automobiles can be classified into several types based on many criteria. A brief
classification of automobiles is listed below:

1. Based on Purpose :
Passenger vehicles: These vehicles carry passengers. e.g: Buses, Cars, passenger trains.

Goods vehicles: These vehicles carry goods from one place to another place. e.g: Goods
lorry, Goods carrier.

Special Purpose: These vehicles include Ambulance, Fire engines, Army Vehicles.

2. Based on Load Capacity:

Light duty vehicle: Small motor vehicles. eg: Car, jeep, Scooter, motorcycle

Heavy duty vehicle: large and bulky motor vehicles. e.g: Bus, Truck, Tractor
3. Based on fuel used:
Petrol engine vehicles : Automobiles powered by a petrol engine. e.g:
scooters, cars, motorcycles.

Diesel engine vehicles : Automobiles powered by diesel engine. e.g: Trucks,

Buses, Tractors.

Gas vehicles : Vehicles that use gas turbine as a power source. e.g: Turbine
powered cars.

Electric vehicles : Automobiles that use electricity as a power source. e.g:

Electric cars, electric buses.

Steam Engine vehicles : Automobiles powered by steam engine. e.g:

Steamboat, steam locomotive, steam wagon.
4. Based on Drive of the vehicles:
Left-Hand drive : Steering wheel fitted on the left-hand side.

Right-Hand drive : Steering wheel fitted on the right-hand side.

Fluid drive : Vehicles employing torque converter, fluid flywheel or hydramatic

transmission.

5. Based on number of wheels and axles:

Two wheeler : motorcycles, scooters
Three-wheelers : Tempo, auto-rickshaws
Four wheeler : car, Jeep, Bus, truck
Six-wheelers : Buses and trucks have six tires out of which four are carried on the
rear wheels for additional reaction.
Six axle wheeler : Dodge(10 tire) vehicle
6. Based on type of Transmission:
Automatic transmission vehicles: Automobiles that are capable of
changing gear ratios automatically as they move. e.g: Automatic Transmission
Cars.

Manual transmission vehicles: Automobiles whose gear ratios have to

be changed manually.

Semi-automatic transmission vehicles: Vehicles that facilitate manual

gear changing with a clutch pedal.

7. Based on Suspension system used:

Convectional – Leaf Spring

Independent – Coil spring, Torsion bar, Pneumatic.

Based on type:
CHASSIS

Introduction

Chassis frame is the basic frame work of the automobile.

It supports all the parts of the automobile attached to it.It is

made of drop forged steel.

All the parts related to automobiles are attached to it only.

All the systems related to automobile like

powerplant,transmission, steering, suspension, braking system etc
are attached to and supported by it only
Components of Chassis

The chassis includes the following major components.

(i) A steel frame, which is a major part.

(ii) In case of a passenger car, the whole body is also an integral

part of the chassis. However, in commercial vehicles like trucks
and buses, the body is not a part of the chassis. Therefore, a
chassis is almost a complete vehicle except the body and other
accessories, which are not involved in the movement of the
vehicle.

(iii) Other major components include engine, transmission system,

front and rear axle, steering system, suspension system, wheels,
tyres and brakes.
Functions of Chassis

The functions of the chassis includes

(i) carrying the weight of the vehicle and its passengers,

(ii) withstanding the engine and transmission torque and thrust

stresses, as well as accelerating and braking torque,

(iii)withstanding the centrifugal force while taking a turn and

(iv) withstanding the bending load and twisting due to the rise
and fall of the front and rear axles.
LAYOUT TYPES

1. Front Engine Rear Wheel Drive :

Rear wheel drive places the engine in the front of the vehicle and
the driven wheels are located at the rear, a configuration known as
front-engine, rear-wheel drive layout.

In this layout a front mounted engine-clutch-gear box unit drives

a beam type rear axle supported on leaf springs through a
propeller shaft with two universal joints.

With the help of coil springs, the front Wheels are independently
sprung.
Front Engine Rear Wheel Drive
Some of the advantages provided by this system are :

(a) Even weight distribution: Balanced weight distribution

between the front and the rear wheels providing good handling
characteristics.
(b) For easy front wheel steering movement enàne occupies the
reduced width between the wheel arches.
(c) Large luggage space is provided behind the rear seat.

Disadvantages :

1. Reduces back seats leg room space,

2. A tunnel is needed for the propeller shaft,
3. Reduces boot space,
2. Rear Engine Rear Wheel Drive :

This layout consists of placing the engine, clutch and

gearbox in the back.

So taking the space of the boot. In these type of layout

more than 50% of the weight is on the rear axle.

The necessity of the propeller shaft is completely

eliminated. The clutch, gear box and engine and final drive
form a single unit.
Rear Engine Rear Wheel Drive
Advantages :

1. Excellent traction is available while climbing hills.

2. A larger passenger space is available for the given length of
body.
3. Very compact and accessible power and transmission
assembly is provided.

Disadvantages :

1. At high speed, relatively high proportions of weight at the

rear axle will make the car unstable at speed. There is a strong
tendency for the vehicle to oversteer.
2. The space at the front has to be reduced to allow for the
steering lock of the front wheel.
3. Space utilized for engine compartment is wasted.
3. Front Engine Front Wheel Drive :

 This type ofarrangement provides optimum passenger space

and a flat floor line resulting in a transverse under floor-
longitudinal engine position.

 The propeller shaft length is reduced or neglects the propeller

shaft.

 Good grip with road surface due to engine weight at front.

 Power required for the cooling is reduced. When the vehicle is

to be ‘steer in’ to the curve, it provide ‘under-steer’
characteristics, which is always preferred.
Front Engine Front Wheel Drive
4. Mid-Engine, Rear Wheel Drive :
This type of engine layout places the engine between the two
axles and the rear wheels are driven. weight is equally
distributed between front and rear wheel
Advantages :

1. Good acceleration because of back weight transfer.

2. Efficient braking.
3. Neutral handling.

Disadvantages :

1. When accelerating some steering is lost.

2. Require more space.
3. No back seats.
4. Difficulties with the cooling system.
5. Four Wheel Drive :
In this arrangement all the four wheels of the vehicle are driven
by the engine thus making the entire vehicle weight available for
traction.

These four wheel drive vehicles are very useful on Hill station if
one of the wheel slipping or skidding then the other axle wheel
transmit the tractive force to the vehicle.

The steering of the four wheel drive is hard to operate

compared with other type of drive.
Advantages :

1. Traction is nearly doubled compared to a two-wheel drive

layout.
2.Handling characteristics in normal conditions can be configured
to emulate or R WD.
3.Gives sufficient power, this results in unparalleled acceleration
and drivability on surfaces with less than ideal and superior engine
braking on loose surfaces.

Disadvantages :

1.The manufacturing cost of the vehicle is high.

2.More component and complicate transmission.
3.Increased power-train mass, rotational inertia and power
transmission losses.
Working of all drive systems
Different types of car frames.
Different types of car frames.
ENGINE
Components

An engine is complex unit in which different components are

assembled together, and fuel is burned to produce power or energy.

The engine converts chemical energy (heat energy) into mechanical

energy, which is then utilised for vehicular movement

There are different processes of fuel combustion. When the fuel is

burned within the engine, it is called an Internal Combustion (IC)
engine, and when it is burned externally and the produced
steam is used for the mechanical movement, it is called an External
Combustion (EC) engine.
On the basis of the process of ignition, the automobile engines
are classified into spark ignition engine (petrol or gas) and
compression ignition engine (diesel).

In an IC engine, the reciprocating motion of the piston is

converted into rotary motion of the crankshaft and the produced
power is then transmitted to move the vehicle.

In case of a rotary engine or Wankel engine, the rotor rotates and
completes the process of combustion and produces the power,
which helps the vehicular movement.
 Spark Ignition Engine (Petrol or Gas Engine)

The spark ignition engine uses

a highly volatile fuel, such as
gasoline, which turns into vapour
easily.
The fuel is mixed with air
before it enters in the
combustion chamber, and forms
a combustible air-fuel mixture.
This mixture then enters the cylinder and gets compressed
with the help of a piston. An electric spark is produced by the
ignition system which ignites the combustible air-fuel mixture. T

The combustible gases burn and expand, which forces the

piston downwards for generating power.
Compression Ignition Engine(Diesel Engine)
In the compression ignition engine or diesel engine, only fresh air
enters the cylinder, which is compressed to a very high pressure and
temperature, which could go up to 1000°F (538C).
The diesel is then injected or sprayed into the engine combustion
chamber.
This spray contains very fine and tiny particles of diesel in
an atomised form.
The hot air or heat of compression ignites the fuel and generates
the power stroke.
Components of an IC Engine

1. Cylinder:
The cylinder or cylinder liner of an IC engine is fitted in the
cylinder block, which is a single casted unit and is considered to be
the main body of an engine.

The block has cylinder liners. The piston reciprocates up and

down from Top Dead Centre (TDC) to Bottom Dead Centre (BDC) to
generate power.

The cylinder liner and the cylinder block have to withstand very
high pressure (about 70 bar) and temperature (about 700 C) during
power stroke.
2.Cylinder Head:
The cylinder head is also singlecasted unit and bolted the top
portion of the cylinder block.

The combustion chamber is a part of the cylinder head, where

the combustion of gases takes place. The water passages are
provided to remove the heat from the cylinder head.

In latest engines, the cylinder head also houses the camshaft
which has the inlet and exhaust valves with supportive valve
mechanism.

This provision is made to fix spark plug in SI engines and nozzle in

CI engines.
3. Piston and Piston Rings:
Piston is a cylindrical unit, used to compress the charge during
compression stroke and to transmit the gas force to the connecting
rod and then to the crankshaft during power stroke.

The pistons of IC engines are usually made of aluminium alloy,

which has high thermal conductivity and is light in weight.

The material of piston must have the ability for higher heat
transfer.

The piston moves up and down (from TDC to BDC) and assists in
completing the engine cycle.
4. Connecting Rod:
It is usually manufactured by using drop-forged steel. It is made in
the shape of ‘I’ so as to reduce its weight and to withstand strength.

Its small end is connected to the piston with the help of gudgeon
pin and the big end is connected to the crankpin with shell bearings.

It has a passage for the transfer of lubricating oil from the big end
bearing to the small end bearing (gudgeon pin).

The major function of the connecting rod is to convert the

reciprocating motion of piston to the rotary motion of the
crankshaft.
5. Crank and Crankshaft:
The crankshaft is called the backbone of an engine because it
converts the reciprocating motion of piston into the rotary motion
of the crankshaft.

The crankshaft is a single casted unit and is made of drop-forged

steel main journals which are placed and supported in the crank
case.

The main journal and connecting journals are machined to a

smooth finish to reduce friction and shell bearings are used for
smooth rotation of crankshaft.

Front end of the crankshaft will transmit drive to the camshaft

and also to the timing gear, whereas the flywheel is bolted to the
flange at rear end of the crankshaft.
Basic Components of IC ENGINE
6. Piston Pin or Gudgeon Pin
This unit connects the piston and small end of the connecting
rod and passes through the piston (Fig. 3.6).

Circlips are fitted into recesses in the piston to prevent the

gudgeon from touching the cylinder wall.

The needle bearing or bronze bushing is press fitted into the

connecting rod, due to this the gudgeon pin provides bearing for
the oscillating small end of the connecting rod.
7. Inlet Valve:
The major role of the inlet valve is to submit fresh charge in to the
cylinder during the suction stroke.

8. Exhaust Valve:
The exhaust valve removes out the burnt gases from the
combustion chamber after power stroke.

9. Valve Spring:

The valve spring (Fig. 3.7)plays an important role to close the valve
and also provides air tight compartment to seal the combustible
gases during power stroke and also maintain the self-centering
movement of the valve.
VALVE Spring
10. Inlet Manifold:
The fuel air mixture is carried from the carburettor to the
cylinder through a separate pipe through inlet manifold in a
carbureted engine.

11. Exhaust Manifold:

It is a set of pipes and muffler, which is used to remove the

exhaust gases from the exhaust ports. Engines oxygen sensors
and catalic convertors are used to reduce sound and air pollution,
respectively
Inlet and Exhaust Manifold
12. Camshaft:
The major function of the camshaft is to operate the intake and
exhaust valves through the cam lobe, the gear drive transmits the
power for the rotation of oil pump, therefore the oil pump sucks the
oil from the oil sump and transits the same to the oil gallery .

13. Cam Lobe and Tappet:

The cam lobe (see Fig. 3.10) of the camshaft is placed directly
above the bucket tappet, such that the lobe comes around it and
pushes down the bucket tappet and the valve, thus opening the
valve.

In an overhead camshaft with rocker arm, the cam lobe comes
under the valve lifter, and causes the rocker arm to rock or turn the
lobe and pushes down the valve steam and it moves down to open.
14. Push Rod and Rocker Arm:
The motion of the cam lobe pushes the valve lifter upwards. This
movement pushes the push rod and the rocker turns the upward
motion of the push rod to the downward movement of the valve
stem resulting in opening of the valve.

15. Crank Case:

The crank case is an integrated part of the cylinder block. The
casing is provided to hold the crankshaft. The crankshaft is allowed
to rotate freely and transmit the power to the flywheel.
15. Crank Case:
The crank case is an integrated part of the cylinder block. The
casing is provided to hold the crankshaft. The crankshaft is
allowed to rotate freely and transmit the power to the flywheel .

16. Water Pump and Water Jacket:

The function of water pump is to draw water from the radiator
and supply it to the water passages provided in the cylinder block
and cylinder head with certain pressure. The circulation of
coolant removes the excessive heat from an engine.
Water Pump and Water Jacket
17. Radiator:
The major function of the radiator is to radiate the heat from the
coolants. It has two tanks located at the top and bottom. The upper
tank is connected to the lower tank with the core through the
passages for easy radiation of the heat.

18. Flywheel:
It is a wheel mounted on the crankshaft which stores the energy
during the power stroke and transmits the energy to the
transmission system, the clutch and then to the gear box
Radiator

Flywheel
19. Governor :
It is run by drive from the crankshaft. The function of the
governor is to regulate the charge in case of petrol engine and
amount of fuel in case of diesel engine to maintain the speed of
the engine constant, when the load requirement varies.

20. Carburettor:
The major function of the carburetor is to supply carburised fuel
as per speed and the engine load. In petrol engines the carburettor
is mounted on the induction pipe or on the induction manifold.
Governor
Carburettor
21. Spark Plug:
The function of the spark plug is to ignite the fuel air mixture after
completion of the compression stroke in an engine. It is generally
placed in the combustion chamber of the cylinder head. This is only
used in petrol engine.

22. Fuel Injection Pump:

In case of diesel engine the diesel oil from the fuel tank is sucked
by the fuel feed pump. The pump first sends the diesel oil to the fuel
filter and then to the transfer pump. The transfer pump increase the
pressure of the fuel.
Spark Plug
Fuel Injection Pump
23. Fuel Injector:
The function of fuel injector (Fig. 3.20) is to break the fuel into
fine spray (atomised condition) as it enters the combustion
chamber of diesel engine.
Firing Order
The firing sequence of internal combustion engines is the
sequence of ignition for the cylinders in spark ignition, eg. For
gasoline/petrol engines, the firing order corresponds to the order in
which the spark plugs operate.
In diesel engines, the firing order corresponds to the order in
which fuels are injected into each cylinder.
Four-stroke engines must also time the valve openings relatives to
the firing order, as the valves do not open & close on every stroke.
Why Do We Need Firing Order?
As we all know that the four-stroke engine we are using today
works on an autocycle or diesel cycle, which includes suction,
compression, power and exhaust, four strokes, or reciprocating.

This is accomplished in four movements of the piston, and

when it comes to engines with more than one cylinder, the
process becomes quite complex.

Hence the need for a pre-determined sequence of combustion

or firing of the fuel like- When it comes to more than 1-piston the
load on the crankshaft increases as all the pistons are connected
to a single crankshaft and if proper firing order is not provided to
the engine the crankshaft will likely fail.
The proper firing sequence of the engine provides maximum
power, smooth running, and high life to the engine and also
protects the engine from unwanted vibrations.

Improper firing order can affect engine and crankshaft balance

due to uncontrolled stress generation resulting in harsh running,
unwanted sound, and unwanted vibrations from the engine,
which can suddenly break any component of the engine and is
quite a dangerous operator or people around.
The firings order of 2, 3, 4, and 6 cylinders in tabular form are given
below:
Sr. No Number of cylinders Firings Order

1 2 1-2

1-2-3,
2 3
1-3-2
1-3-4-2

1-2-4-3
3 4
1-3-2-4

1-4-3-2
1-5-3-6-2-4
1-4-3-6-2-5
1-6-5-4-3-2
1-2-3-4-5-6
1-4-2-5-3-6
1-4-5-2-3-6
4 6 1-6-3-2-5-4
1-6-2-4-3-5
1-6-2-5-3-4
1-4-2-6-3-5