INTERNAL COMBUSTION ENGINES

Diesel Engine Construction and Operation

Dr. P S RANJIT
University of Petroleum & Energy Studies
Dehradun
 Diesel Engine Construction and Operation
C. I. Engine : Basic Features

• Air alone is inducted & Fuel is injected directly into the engine
cylinder just before combustion is required to start

• Load control is achieved by varying the amount of fuel injected

each cycle

• Air flow at a given engine speed is unchanged

• Variety of C. I . Engine designs available for wide range of

applications
Cars, Trucks, Locomotives, marine, & power generation, etc.
 Diesel Engine Construction and Operation
C. I. Engine : Types of Intake Air Charging

• Naturally aspirated : atmospheric air is inducted

• Turbocharged : inlet air is compressed by an exhaust driven

turbine-compressor combination

• Supercharged : air is compressed by mechanically driven

pump or blower

Turbocharging / Supercharging increase engine out-put by

increasing air mass flow rate per unit displaced volume,
thereby allowing increase in fuel flow
 Diesel Engine Construction and Operation
Electro-Motive Two-Stroke Cycle Uniflow Diesel Engine
Diesel Engine Construction and Operation
Four-Cylinder, Naturally Aspirated, Indirect Injection, 4-Stroke
Automobile Diesel Engine
 Diesel Engine Construction and Operation
Direct-Injection, Four-Stroke Cycle, 6-Cylinder,
Turbocharged Diesel Engine
Diesel Engine Construction and Operation
A View of I. C.Engine with Principal Parts
Diesel Engine Construction and Operation
Different Parts of Diesel Engine

1. Cylinder 2. Cylinder head 3. Piston

4. Piston rings 5. Gudgeon pin 6. Connecting rod

7. Crankshaft 8. Crank 9. Engine bearing

10. Crankcase 11 Flywheel 12. Governor

13. Valve and valve operating mechanisms

14 Fuel pump 15 Injector

 Diesel Engine Construction and Operation
Engine Cylinder

• Engine Cylinder is contained in cylinder block

• It is in direct contact with products of combustion, contains
gas under pressure, guides piston
• Consists of a cylinderical barrel or removable cylinderical
sleeves replaced when worn
• Upper end consists of a combustion chamber or clearance
space
 Diesel Engine Construction and Operation
Engine Cylinder
Sections of Air & Water Cooled Cylinders
 Diesel Engine Construction and Operation
Cylinder Head
Features
- Cylinder head closes / seals one end of cylinder and is
removable
- Inside cavity forms main combustion space ( chamber )
Its shape controls the direction & rate of combustion
- Accommodate Valves & its mechanism
- Contains Fuel Injector
- It is strong & rigid to distribute gas forces uniformly
- Passages leading to & from valves are called ports
- Common pipe connecting ports is called manifold
 Diesel Engine Construction and Operation
Valves and Valve Mechanism
Features
- Inlet valves admit air ( fuel ! ) & Exhaust valves
discharge products of combustion
 Diesel Engine Construction and Operation
Valves and Valve Mechanism
Features
- Inlet valve may have provision for guiding air motion
- Exhaust valve have provision for enhanced cooling
- Valve stem moves in valve guide
- Valve seats may be cut in head or block
- Valve spring attached to valve stem with washer & split
keeper holds valves closed
- Camshafts with cams are used for opening or closing
the valves
-Camshafts are gear, belt or chain driven from crankshaft
 Diesel Engine Construction and Operation
Valves and Valve Mechanism
Features
- Camshaft turns 0ne-half of crankshaft speed in 4- stroke engine
- lifters / tappets ride on cam & transmit motion to valve stem
 Diesel Engine Construction and Operation
Piston, Piston Rings & Gudgeon Pin
Features of Piston Rings
- Seals against gas leakage & control oil flow
- Upper Rings are Compression rings
- Lower rings scrape lubricating oil from cylinder

COMPRESSION RING OIL RING

 Diesel Engine Construction and Operation
Piston, Piston Rings & Gudgeon Pin
Features of Piston
- Seals the cylinder
- Transmit combustion generated gas pressure to crank pin
- Piston is fitted with Rings in grooves cut in the piston head
 Diesel Engine Construction and Operation
Piston, Piston Rings & Gudgeon Pin
Working of Piston Rings
- Piston rings are split at one point so that they can be
slipped over the piston into ring grooves
- Rings fit tightly against the sides of ring grooves &
cylinder walls to provide good seal
- Rings can expand or contract as they heat and cool &
still make good seal and able to slide up & down freely
- Figure shows how rings hold compression/combustion
pressure
- Arrows show pressure above the piston passing
 Diesel Engine Construction and Operation
Piston, Piston Rings & Gudgeon Pin
Working of Piston Rings
through clearance between piston & cylinder walls.
- It presses down against the top & back of piston rings
& pushes piston ring firmly against the bottom of piston
ring groove. Higher the pressure better is the sealing
 Diesel Engine Construction and Operation
Gudgeon Pin [ Wrist Pin or Piston Pin ]
Features
- These are hardened steel parallel spindles fitted
through piston bosses and small end bushes
- It allow connecting rod to swivel
 Diesel Engine Construction and Operation
Connecting Rod
Features
- Connecting rod connects piston to the crank

- It transmit piston load to the crank

- Crank end of the connecting rod is called “big end”

and the piston end is called “small end”

- Big end bearing of connecting rod attached to crank

pins on each throw turns / rotates crankshaft
 Diesel Engine Construction and Operation
Crank & Crankshaft

Features

• The reciprocating motion is converted into a rotary motion by

the crank & crankshaft

• All auxiliary mechanisms with mechanical transmission are

geared in one way or another to the crankshaft

• Crankshaft mounts in bearings encircled with journals & rotates

freely
 Diesel Engine Construction and Operation
Parts & Assembly : Piston-Connecting rod-crank
 Diesel Engine Construction and Operation
Parts & Assembly : Crankshaft
 Diesel Engine Construction and Operation
Engine Bearings
Features
• Bearings are used to support rotary action
• The purpose of bearings is to reduce friction and allow parts to
move freely
• Bearings are lubricated with oil
• Crankshaft is supported by bearings
• Connecting rod big end is attached to crank pin by a bearing
• Piston pin rides in bearing
 Diesel Engine Construction and Operation
Crankcase
Features
• Main body of engine to which cylinders are attached
and which contains crankshaft, etc. is called
Crankcase
• It holds other parts of the engine in alignment and
resists explosion & inertia forces
• It protects engine parts from dirt
• It acts as lubricating oil reservoir
• It is ventilated to remove blow-by-gases
 Diesel Engine Construction and Operation
Flywheel
Features
• Flywheel is secured on crankshaft
• It brings mechanism out of dead centers
• It stores energy to rotate shaft during starting
• It makes crankshaft rotation more uniform
 Diesel Engine Construction and Operation
Governor
Features
• Governor is defined as a device for regulating
automatically out put of a machine by regulating the
supply of working fluid
• The function of governor is to control the fluctuations
of engine speed due to change in load
• Types of Governors :
- Centrifugal governor : In these governors the
centrifugal force due to revolving masses is balanced
by either Gravity or Spring force
 Diesel Engine Construction and Operation
Governor
• Types of Governors :
- Inertia & Flywheel governor : These governors are fitted
to crankshaft or flywheel of engine
• Description
Centrifugal types governors are generally used in I. C.
Engines. The balls of the governor are so arranged that
inertia force caused by angular acceleration or
retardation of the shaft tends to alter their position.
Amount of displacement of balls is controlled by
suitable springs, and alters the fuel supply to the
engine
 Diesel Engine Construction and Operation
Fuel Pump for diesel engines
 Diesel Engine Construction and Operation
Fuel Atomiser or
Injector
Diesel Engine Construction and Operation
Diesel Engine Construction and Operation
A Sequential Description of C. I. Engine Operation
• Intake : During intake stroke air is inducted under ambient
conditions (press. & temp.) & compressed to a pressure of
about 4MPa (600 psi ) and temperature of about 800 k during
compression stroke.
• Fuel Injection : At about 20 CA btdc, fuel injection commences.
• Mixture Preparation : Liquid fuel jet atomizes into drops &
entrains air. Liquid fuel evaporates and fuel vapors then mixes
with air to within combustible proportions. The air temp. &
press. Are above fuels ignition point.
• Combustion : After a short delay period, spontaneous ignition
(auto ignition) of parts of non-uniform fuel-air mixture initiates
combustion process. Cylinder press. Rises above the non-
firing engine level. The flame spreads rapidly through that
portion of the injected fuel which has already mixed with
sufficient air to burn.
Diesel Engine Construction and Operation
A Sequential Description of C. I. Engine Operation
• Output : As expansion process proceeds, mixing between fuel,
air, and burning continues, accompanied by further
combustion. At full load, the mass of fuel injected is about 5%
of mass of air in the cylinder. Increasing level of black smoke in
the exhaust limit the amount of fuel that can be burned
efficiently
• Exhaust : At about two - thirds of the way through expansion
stroke, the exhaust valve start to open. The cylinder press. Is
greater than exhaust manifold press. And exhaust blowdown
process occurs. The burned gases flow through exhaust till
press. Equilibrate and finally piston displaces.
At the end of exhaust stroke, the cycle starts again.