3rd Sec B 1

8/13/2019 3rd Sec B 1

1/169

1

AUTOMOBILE HISTORY

First automobiledeveloped in 1860s inEurope.

By 1900 cars gainingsome reliability.

All cars are hand madecosting $10,000.00

Henry Fords better

ideas: I nterchangeable parts

Mass production usinganassembly l ine

8/13/2019 3rd Sec B 1

2/169

Classification of Automobiles

2

1-Purpose

Passenger Cars- ' Bus etc

Goods Carriers- Truck

2-Fuel Used

Petrol vehicle , Diesel Vehicle, Gas Vehicle

Electric Vehicle ,Steam Vehicle.3-Capacity

HTV , LTV, LMV

8/13/2019 3rd Sec B 1

3/169

4.Construction- Single Unit Vehicles

'GF/ ,; & Tractors

5.Drive- LeftHand Drive&RightHand Drive

6. Wheel and Axle

Two wheeler

Three wheelerFour wheeler (4x2) and (4x4)

Six wheeler (6x2) and (6x4)3

8/13/2019 3rd Sec B 1

4/169

4

8/13/2019 3rd Sec B 1

5/169

7.Suspension System:

Conventional Independent

8.Body and Number of Doors:

a)Sedan b)Convertible c)Station wagon

d)Delivery van e)Special purpose vehicle

9.Transmissions

1)Conventional 2) Semiautomatic 3)Automatic

5

8/13/2019 3rd Sec B 1

6/169

6

MASS PRODUCTION OF

AUTOMOBILES

Mass production reduces the cost

of automobiles to $200.00.

There are now 200,000,000

vehicles in the U.S. alone.

8/13/2019 3rd Sec B 1

7/169

7

Four Basic Parts of Vehicles

Chassis or framework

Engine or power plant

Drive Train

Body
http://www.myclassiccar.com/Entertainment/gallery/archives/2001/01-26-01/waynehanning.jpg

8/13/2019 3rd Sec B 1

8/169

8

Automobile Bodies

Most made of

stamped steel parts

A few cars made of

aluminum (NSX

Cadillac Allenta)

Some use composite

materials (Saturn orGM Minivan)

8/13/2019 3rd Sec B 1

9/169

9

Chassis

Classification on basis of

According to its control.

According to fitting of

engine.

According to no. of wheels

and no. of driving wheels.

Acording to wheel base.

8/13/2019 3rd Sec B 1

10/169

According to its control.

Conventional Chassis.

Semi-forward chassis.

Full forward chassis.

10

8/13/2019 3rd Sec B 1

11/169

According to fitting of engine.

Engine at front.

Engine fitted infront infront but crosswise.

Engine fitted at the centre of chassis.

Engine fitted at the back.

11

8/13/2019 3rd Sec B 1

12/169

According to no. of wheels and no. of

driving wheels.

4x2 Drive chassis Vehicle.

4x4 Drive chassis Vehicle



12

8/13/2019 3rd Sec B 1

13/169

CHASSIS FRAME AND BODY

Introduction of Chassis Frame: Chassis is a French term and was

initially usedto denote the frame parts or Basic Structure of the

vehicle.

It is the back bone of the vehicle.

A vehicle with out body is called Chassis. The components ofthe vehicle likePower plant, Transmission System, Axles, Wheels and Tyres, Suspension,

Controlling Systems like Braking, Steering etc., and also electrical system

parts are mounted on the Chassis frame.

It is the main mounting for all the components including the

body. So it is also called as Carrying Unit.

13

8/13/2019 3rd Sec B 1

14/169

Chassis &Components

14

8/13/2019 3rd Sec B 1

15/169

Components of Chassis

The following main components of the Chassis are

1. Frame: it is made up of long two members called side members

riveted together with the help of number of cross members.

2. Engine or Power plant: It provides the source of power

3. Clutch: It connects and disconnects the power from the engine fly

wheel to the transmission system.

4. Gear Box

5. U Joint

6. Propeller Shaft

7. Differential

15

8/13/2019 3rd Sec B 1

16/169

FRAMES

Frame or underbody is the main part ofchassis on which the remaining parts of

chassis are mounted.

Chassis frames are made of steel section

16

8/13/2019 3rd Sec B 1

17/169

FUNCTIONS OF THE CHASSIS FRAME:

1. To carry load of the passengers or goods carried in the body.

2. To support the load of the body, engine, gear box etc.,

3. To withstand the forces caused due to the sudden braking or

acceleration

4. To withstand the stresses caused due to the bad road condition.

5. To withstand centrifugal force while cornering

17

8/13/2019 3rd Sec B 1

18/169

TYPES OF CHASSIS FRAMES:

There are three types of frames

1. Conventional frame

2. Integral frame 3. Semi-integral frame

18

8/13/2019 3rd Sec B 1

19/169

Conventional frame

1. Conventional frame: It has two long side members and 5 to 6

crossmembers joined together with the help of rivets and bolts.

The frame sectionsare used generally.

a. Channel Section - Good resistance to bending

b. Tabular Section - Good resistance to Torsion

c. Box Section - Good resistance to both bending andTorsion

19

8/13/2019 3rd Sec B 1

20/169

Conventional frame

20

8/13/2019 3rd Sec B 1

21/169

Integral Frame:

Integral Frame: This frame is used now a days in most of the cars.

There is no frame and all the assembly units are attached to the

body.

All the functions of the frame carried out by the body itself.

Due to elimination of long frame it is cheaper and due to less

weight most economical also.

It is also called unitized frame-body construction. In this

case, the body shell and underbody are welded into singleunit. The underbody is made of floor plates and channel

and box sections welded into single unit.

Only disadvantage is repairing is difficult. 21

8/13/2019 3rd Sec B 1

22/169

Integral Frame:

22

8/13/2019 3rd Sec B 1

23/169

Semi - Integral Frame

Semi - Integral Frame: In some vehicles half frame is fixed in the

front end on which engine gear box and front suspension is

mounted. It has the advantage when the vehicle is met with

accident the front frame can betaken easily to replace the

damaged chassis frame. This type of frame is used in FIAT cars and some of the European

and American cars.

23

8/13/2019 3rd Sec B 1

24/169

8/13/2019 3rd Sec B 1

25/169

Bodys

25

8/13/2019 3rd Sec B 1

26/169

26

8/13/2019 3rd Sec B 1

27/169

The body of the most vehicle should fulfil the following

requirements:

1. The body should be light.

2. It should have minimum number of components.

3.It should provide sufficient space for passengers and

luggage.

4. It should withstand vibrations while in motion.5.It should offer minimum resistance to air.

6. It should be cheap and easy in manufacturing.

7. It should be attractive in shape and colour.

8. It should have uniformly distributed load.9. It should have long fatigue life

10. It should provide good vision and ventilation.27

8/13/2019 3rd Sec B 1

28/169

VARIOUS LOADS ACTING ON THE

FRAME:

Various loads acting on the frame are

1. Short duration Load - While crossing abroken patch

2. Momentary duration Load - While taking a curve.

3. Impact Loads - Due to the collision of the vehicle. 4. Inertia Load - While applying brakes.

5. Static Loads - Loads due to chassis parts.

6. Over Loads - Beyond Design capacity.oken patch

28

8/13/2019 3rd Sec B 1

29/169

*External combustion engine. *Internal combustion engine.

-Ex: steam engine -Ex: car engine

What is an engine?

Types of engines:

- a machine which converts chemical energy

into mechanical energy

8/13/2019 3rd Sec B 1

30/169

Internal combustion engines

Reciprocating

engine

- 4 stroke engine

- 2 stroke engine

Rotary engine

- Wankel engine

- Turbine engine

8/13/2019 3rd Sec B 1

31/169

*External combustion engine. *Internal combustion engine.

-Ex: steam engine -Ex: car engine

What is an engine?

Types of engines:

- a machine which converts chemical energy

into mechanical energy

Figure source:http://www.tpub.com/machines/12.htm

8/13/2019 3rd Sec B 1

32/169

Internal combustion engines Reciprocating engine

- 4 stroke engine

- 2 stroke engine

Rotary engine

- Wankel engine

- Turbine engine

Reaction engine

- Rocket engine

8/13/2019 3rd Sec B 1

33/169

The very basic of an engine

The ideal gas law: PV = nRT

P:pressure; V: volume; n: mole number; T; temperature

- Gas will expand upon the application of heat.

- The application of heat upon the gas will increase its

pressure (if gas is confined in a volume).

- The compression of the gas will increase its temperature

We try to create heat (through burning) to the gas, so the gas

can push the piston, thereby crank the engine, and output the

movement to useful work.

H i k ?

8/13/2019 3rd Sec B 1

34/169

How engine works?

Air

Fuel

Mixing Combustion

Exhaust

PowerUseful

Work

Carburetor Ignition Valves Flywheel

Crankshaft

8/13/2019 3rd Sec B 1

35/169

Engine Parts, Description, Function,

Construction

8/13/2019 3rd Sec B 1

36/169

Engine Parts, Description, Function, Construction

Cylinder Barrel

Chrome-molybdenum or nickel-molybdenum steel Used to guide and seal piston and to mount cylinder

assembly to head

Barrel threads into head to form cylinder assembly

8/13/2019 3rd Sec B 1

37/169


Cylinder interior wall

Cylinder Walls

i i i i i

8/13/2019 3rd Sec B 1

38/169


Cylinder heads

Constructed of castaluminum

Provides combustion

chamber, and mounting

areas for spark plugs and

valve parts

E i P D i i F i C i

8/13/2019 3rd Sec B 1

39/169


The cylinder head is designed to transfer heat by

conduction to the fins and then from the fins to theair by convection

The exhaust side of the head has the most fins as it

runs the hottest

The head also may incorporate a drain line fitting

to allow excess oil to return to the crankcase

(intercylinder drain lines on radials)

E i P D i i F i C i

8/13/2019 3rd Sec B 1

40/169


Valve Guides

Made of bronze Secured in the head by an

interference (shrink) fit

Valve Seats

Made of chrome steel,

stellite, or brass

Secured by interference fit

8/13/2019 3rd Sec B 1

41/169

Crankcase

The crankcase holds all of the engine parts in

alignment and supports the cylinders and crankshaft It provides a place to mount the engine to the

aircraft

Constructed of aluminum alloy

Divided into sections (radial)

8/13/2019 3rd Sec B 1

42/169

Nose section - Houses prop shaft and bearings

Power section - mount for cylinders

Fuel induction section - intake tubes, blower,manifolds (supercharger)

Accessory section - mounts for magnetos, pumps,

generators (magnesium)

8/13/2019 3rd Sec B 1

43/169

Pistons

Constructed of aluminum alloy

Parts include top, ring grooves, ring lands, skirt,and piston pin boss

Cooling fins on the bottom help the oil carry heat

away from the piston top

8/13/2019 3rd Sec B 1

44/169

Cam ground pistons

diameter of the piston is greater perpendicular to

the piston pin boss

This compensates for uneven expansion during

operation (becomes round at operating

temperature)

8/13/2019 3rd Sec B 1

45/169

Piston head designs

8/13/2019 3rd Sec B 1

46/169

Piston rings (general)

Provide seal between cylinder wall and piston

Rings ride on a thin film of oil Conduct heat from the piston out to the cylinder

and the fins

Material is cast iron or chrome steel

Piston rings (type)

Compression r ingsare located at the top of the

piston and seal the combustion chamber

Types include rectangular, tapered,wedge

8/13/2019 3rd Sec B 1

47/169

Compression rings

8/13/2019 3rd Sec B 1

48/169

Oil control r ings

On bottom of piston below compression rings .

Regulates oil film thickness on cylinder wall. Holes in ring and piston allow excess oil to drain

back to crankcase.

Too much oil film and the engine will use

excessive oil and too little oil causes heat and

insufficient lubrication.

Oil scraper r ings Directs the oil away from or towards the oil control

rings depending upon the requirements of the

engine.

8/13/2019 3rd Sec B 1

49/169

Piston ring end gap

The gap at the end of the rings allows for expansion

and contraction and unevenness in the cylinder wall Butt, step and angle types

Always stagger the end gaps during ring

installation to prevent losing compression

8/13/2019 3rd Sec B 1

50/169

Piston Pins (wrist pins)

Connects the piston to the end of the connecting

rod. Constructed of hardened steel.

The pin is retained in the piston with clips or plugs

to prevent cylinder wall scoring.

Typical Lycoming and Continental pins are free-

floating, meaning the pin is not secured to the

piston or the rod.

8/13/2019 3rd Sec B 1

51/169

Connecting Rod Assembly

8/13/2019 3rd Sec B 1

52/169

g y

The link between the crankshaft and the piston

Normally steel but some low powered engines usealuminum to save weight

Cross section is an H or I

Types include : Plain RodFork and blade rod

Master and articulated

8/13/2019 3rd Sec B 1

53/169

Master and Articulating Rod

Used on radial engines Uses knuckle pins to retain articulated rods to

master

Master Rod

Articulating Rod

8/13/2019 3rd Sec B 1

54/169

Master/Articulating Rod in Action

k h f
http://www.robertsengr.com/radialng.htmhttp://www.robertsengr.com/radialng.htm

8/13/2019 3rd Sec B 1

55/169

Crankshaft

Changes reciprocating motion of pistons into

rotating motion to drive propeller

Constructed of chrome-nickel-molybdenum-steel

May be one piece or as many as three separate

pieces

The propeller mounts to the front of the crankshaft

using a spline, taper, or flange

The crankshaft rotates within the crankcase and issupported by main bearing journals

Crankshaft throws or crankpins are off center and

account for the reciprocating motion of the pistons

8/13/2019 3rd Sec B 1

56/169

Crankshaft Main Bearing Journal, Pin, Arm

8/13/2019 3rd Sec B 1

57/169

C k h ft E d F M ti P ll

8/13/2019 3rd Sec B 1

58/169

Crankshaft Ends For Mounting Propellers

8/13/2019 3rd Sec B 1

59/169

Dynamic Dampers can be mounted to the

crankshaft to reduce vibration (floating) Counterweights are also used to reduce vibration

but they are rigid and do not float

Counterweights and dampers are used in piston

engines because the power pulses and movement of

the pistons create large amounts of vibration

Vibration shortens airframe and engine life and can

lead to premature component failure The engine is also mounted in rubber bushings to

absorb vibration

2 Pi C k h ft With C t i ht

8/13/2019 3rd Sec B 1

60/169

2 Piece Crankshaft With Counterweights

(Single Throw, Single Cylinder)

V l d th V l S t

8/13/2019 3rd Sec B 1

61/169

Valves and the Valve System

Valves control the flow of gases inside the engine

Poppet valves are the most common and get theirname from the popping open and closed during

operation

Intake valves are chrome steel and are cooled by

the incoming air and fuel mixture

Exhaust valves are also alloy steel but are often

filled with metallic sodium for cooling. Valve

faces may be coated with Stellite to reduce wearand corrosion

Valve faces are ground to 30 degrees for intake

(airflow) and 45 degrees (cooling) for exhaust

8/13/2019 3rd Sec B 1

62/169

8/13/2019 3rd Sec B 1

63/169

Val e Springs

8/13/2019 3rd Sec B 1

64/169

Valve Springs

Inner and outer springs are used to prevent bounce,

provide redundancy, and increase valve closing

pressure

Held in place by retainer washers on the top and

bottom of the spring

Split key or keeper holds the retainers andsprings in place on the valve stem

Valve Lifter or Tappet

8/13/2019 3rd Sec B 1

65/169

Valve Lifter or Tappet

May be solid, roller, or hydraulic The lifter follows the cam lobes and pushes on the

pushrod

Solid and roller lifters require adjustable rocker

arms

Hydraulic type lifters fill with oil and lengthen to

compensate for any clearances in the valve system

8/13/2019 3rd Sec B 1

66/169

Camshaft

8/13/2019 3rd Sec B 1

67/169

Camshaft

Turns at 1/2 the speed of the crankshaft

Must be mechanically coupled to the crankshaft fortiming purposes (gears, belts, chains)

The camshaft consists of bearing journals and lobes

spaced along the shaft

Each lobe is positioned to open and close a valve at

a specific time

Lobe

8/13/2019 3rd Sec B 1

68/169

8/13/2019 3rd Sec B 1

69/169

Valve clearance adjustment

Valve clearance measurement

Rocker Arm

8/13/2019 3rd Sec B 1

70/169

Rocker Arm

Adjustable in solid lifter engines and fixed in

engines with hydraulic lifters

One end rests on the valve stem and the other on

the pushrod

Rocking motion opens and closes the valves

Roller rocker arms incorporate a roller that reduces

friction and are used in some radials and

experimental engines

Propeller Reduction Gearing

8/13/2019 3rd Sec B 1

71/169

Propeller Reduction Gearing

Purpose is to reduce propeller rpm to its optimalspeed and to increase engine rpm to its optimal

speed.

Propeller always turns slower than the engine

Spur Gears

8/13/2019 3rd Sec B 1

72/169

Spur Gears

Simple drive and driven gear system.

Number of teeth on gear and gear diameters determine

reduction ratio.

Large gear would be mounted to propeller as it turns theslowest

Planetary Gears

8/13/2019 3rd Sec B 1

73/169

Planetary Gears

Ring gear, Planet gear, Sun gear

Large gear reductions possible

Compact and versatile

Common in large radials and turbine engines

8/13/2019 3rd Sec B 1

74/169

Engine Lubrication And

Cooling

8/13/2019 3rd Sec B 1

75/169

Lubrication and Cooling

System in an Engine

Th f i h d

8/13/2019 3rd Sec B 1

76/169

There are a few safetyprecautions that need to

be followed when checking the lubrication and

cooling systems in an engine

1. The engine should be cold before you start.

2. The cap on the top of almost every car or truckradiator (or on the separate coolant reservoir) isdesigned for safetyfirst letting any built- up

pressure escape slowlybefore the cap iscompletely removed.

3. Dont touch the oil because it maybe hot.4. Wear gloves or use a rag.

5. Wear safety glasses.

Can anyone give me another?

8/13/2019 3rd Sec B 1

77/169

D k h i f

8/13/2019 3rd Sec B 1

78/169

Does anyone know the importance of

lubrication and cooling systems in an engine?

The lubrication and cooling system of an

internal- combustion engine is very important.If the lubricating system should fail, not only

will the engine stop, but many of the parts are

likely to be damage beyond repair. Coolant

protects your engine from freezing oroverheating.

Wh t l b i ti t d f i

8/13/2019 3rd Sec B 1

79/169

What lubrication system does for an engine.

1. The job of the lubrication system is to distribute oil to the moving parts toreduce friction between surfaces which rub against each other.

2. An oil pump is located on the bottom of the engine.

3. The pump is driven by a worm gear off the main exhaust valve camshaft.

4. The oil is pumped to the top of the engine inside a feed line.

5. Small holes in the feed line allow the oil to drip inside the crankcase.

6. The oil drips onto the pistons as they move in the cylinders, lubricating thesurface between the piston and cylinder.

7. The oil then runs down inside the crankcase to the main bearings holdingthe crankshaft.

8. Oil is picked up and splashed onto the bearings to lubricate these surfaces.9. Along the outside of the bottom of the crankcase is a collection tube which

gathers up the used oil and returns it to the oil pump to be circulated again.

8/13/2019 3rd Sec B 1

80/169

8/13/2019 3rd Sec B 1

81/169

Proper lubrication of an engine is a

complex process.Motor oil must perform many functions under many different operating conditions. The

primary functions of oil are listed below:

1. Provide a barrier between moving parts to reduce friction, heat buildup, and wear.2. Disperse heat. Friction from moving parts and combustion of fuel produce heat thatmust be carried away.

3. Absorb and suspend dirt and other particles. Dirt and carbon particles need to becarried by the oil to the oil filter where they can be trapped.

4. Neutralize acids that can build up and destroy polished metal surfaces.

5. Coat all engine parts. Oil should have the ability to leave a protective coating on allparts when the engine is turned off to prevent rust and corrosion.

6. Resist sludge and varnish buildup. Oil must be able to endure extreme heat withoutchanging in physical properties or breaking down.

7. Stay fluid in cold weather; yet remain thick enough to offer engine

What the cooling system does for an

8/13/2019 3rd Sec B 1

82/169

What the cooling system does for an

engine.1. Although gasoline engines have

improved a lot, they are still notvery efficient at turning chemicalenergy into mechanical power.

2. Most of the energy in the gasoline(perhaps 70%) is converted into

heat, and it is the job of thecooling system to take care of thatheat. In fact, the cooling system ona car driving down the freewaydissipates enough heat to heat twoaverage-sized houses!

3. The primary job of the coolingsystem is to keep the engine fromoverheating by transferring thisheat to the air, but the coolingsystem also has several otherimportant jobs.

4. The engine in your car runs best ata fairly high temperature.

5. When the engine is cold,components wear out faster, andthe engine is less efficient andemits more pollution.

6. So another important job of thecooling system is to allow theengine to heat up as quickly aspossible, and then to keep theengine at a constant temperature.

8/13/2019 3rd Sec B 1

83/169

8/13/2019 3rd Sec B 1

84/169

Cooling systems consist of three main parts:

1. Pumping

Your cooling system'spumping function is handled

by its water pump, which

keeps the coolant mixture

moving.

The main water pump is gear-

or belt-driven but, in many

cars, a secondary electricwater pump is used for

improved flow and cooling.

8/13/2019 3rd Sec B 1

85/169

Cooling systems consist of three main parts:

2. Piping

Your cooling system's piping consistsof all hoses, any control valves, theheater core, the radiator and theexpansion tank. Because of the

materials used and the constantcontact with coolant, all parts in thissystem deteriorate more from timethan use.

Maintenance of cooling system pipingconsists of scheduled coolantreplacement, replacement of all hoses

on a regular basis and replacement ofany plugged or leaking parts.

All hoses should be checked at leasttwice a year for abrasions, cracks,flexibility and evidence of leakage.Whenever the coolant is drained forreplacement or during engine repairs,any suspect hoses should be replaced.All hoses should be replaced at least

every few years. Radiators, expansion tanks, heatercores and control valves are normallyonly replaced due to leakage orplugging. The condition of these partsshould be assessed by a professionalsince proper functioning is critical to

many other systems within your car.

Cooling systems consist of three main

8/13/2019 3rd Sec B 1

86/169

Cooling systems consist of three main

parts:

3. Temperature Control

Your cooling system's temperature controls include all coolant temperature sensors,thermostat, radiator or expansion tank cap, cooling fan(s) and fan clutch (ifequipped). These cooling system parts function primarily independent of the engine

but control the engine either through cooling or by sending control signals to yourcar's electronic systems.

The thermostat is a spring-loaded valve that opens and closes based on thetemperature of the coolant flowing through it. A high temperature reading followedby a drop to normal temperature (or a continuously low temperature) is a commonfirst sign of a sticking thermostat. However, many other conditions may cause thesesymptoms, so you need to know how to eliminate each possibility.

The radiator or expansion tank cap is also a spring-loaded valve reacting to systempressure. It serves to maintain proper system coolant level at predeterminedpressures. It must always be replaced with an exact replacement cap with the samepressure setting. Never use other caps except for short-term emergencies!

8/13/2019 3rd Sec B 1

87/169

8/13/2019 3rd Sec B 1

88/169

Liquid Cooled System

In a liquid cooled system, heat is carried away by theuse of a heat absorbing coolant that circulates throughthe engine, especially around the combustionchamber in the cylinder head area of the engine

block. The coolant is pumped through the engine,then after absorbing the heat of combustion iscirculated to the radiator where the heat is transferred

to the atmosphere. The cooled liquid is thentransferred back into the engine to repeat the process.

8/13/2019 3rd Sec B 1

89/169

8/13/2019 3rd Sec B 1

90/169

Maintenance of your cooling system

Maintenance of your cooling system sensors is

virtually impossible since there's nothing really to

"maintain". Keeping them clean both internally

(coolant replacement) and externally (engine

cleaning) is the best way to ensure trouble-free

driving. Checking and replacing all parts at the

factory-recommended time or mileage limits helps aswell.

Is there any questions?

8/13/2019 3rd Sec B 1

91/169

Lubrication and Cooling System

The lubrication system of aninternal-combustion engineis very important. If thelubricating system shouldfail, not only will the enginestop, but many of the partsare likely to be damaged

beyond repair.

The only purpose of theengine's cooling system is toremove excess heat from theengine, to keep the engineoperating temperature at itsmost efficient level, and toget the engine up to thecorrect temperature as soonas possible after starting. Acooling system is also

required to prevent theinternal engine parts frommelting from the heat of the

burning fuel.

8/13/2019 3rd Sec B 1

92/169

Engine Failures

Does anyone know

the how many engine

failures are attributed

to cooling systemfailure?

-Over 50% of engine

failures can be

attributed to coolingsystem failure.

8/13/2019 3rd Sec B 1

93/169

Thing needed to repair a cooling system

Can anyone list some of the things needed to repair a cooling system?

- Coolant- Water Pump- Water Pump Drive Belt (timing, V-, or flat)- Hoses (upper & lower radiator, bypass, heater, manifold coolant,

etc.)- Radiator- Expansion Tank- Heater Core- Control Valves- Temperature Sensors- Radiator Cap and/or Expansion Tank Cap- Fan Clutch

Can anyone tell me how important a lubrication system is in an engine?

8/13/2019 3rd Sec B 1

94/169

1) What does an Oil Pump do?

2) What does an Oil Pan do? 3) What does an Engine Oil Cooler do?

4) What does an Oil Filter do?

5) What does a Water Pump do? 6) What does a fan do?

7) What does a Radiator do?

8) What does the Transmission Oil Filter do?

9) What does the Transmission Oil Cooler do?

10) What does the Liquid Cooling system do?

8/13/2019 3rd Sec B 1

95/169

1) http://www.autohausaz.com/html/cooling_systems.html

2) http://auto.howstuffworks.com/cooling-system.htm

3) http://science.howstuffworks.com/engine12.htm

4)http://www.tpub.com/content/fc/14104/css/14104_115.htm

5) http://www.tpub.com/content/constructionforklifts/TM-

10-3930-660-10/css/TM-10-3930-660-10_22.htm
http://www.autohausaz.com/html/cooling_systems.htmlhttp://auto.howstuffworks.com/cooling-system.htmhttp://science.howstuffworks.com/engine12.htmhttp://www.tpub.com/content/fc/14104/css/14104_115.htmhttp://www.tpub.com/content/fc/14104/css/14104_115.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/constructionforklifts/TM-10-3930-660-10/css/TM-10-3930-660-10_22.htmhttp://www.tpub.com/content/fc/14104/css/14104_115.htmhttp://www.tpub.com/content/fc/14104/css/14104_115.htmhttp://science.howstuffworks.com/engine12.htmhttp://auto.howstuffworks.com/cooling-system.htmhttp://auto.howstuffworks.com/cooling-system.htmhttp://auto.howstuffworks.com/cooling-system.htmhttp://www.autohausaz.com/html/cooling_systems.html

8/13/2019 3rd Sec B 1

96/169

Engine Lubrication And Cooling

Principles of Engine Lubrication

Primary purpose is to reduce friction betweenmoving parts.

Liquid lubricants (oil) are used universally inaircraft.

No metal to metal contact occurs.

Friction and wear held to a minimum.

8/13/2019 3rd Sec B 1

97/169



Oil film acts as a cushion between metal parts.

Crankshaft and connecting rods

Shock-loading parts

i i i A C i

8/13/2019 3rd Sec B 1

98/169



Absorbs heat from the parts.

Pistons and cylinder walls.

Forms a seal between the piston and the cylinderwall.

Reduce abrasive wear.

Picks up foreign particles and carries them to the

filter.

8/13/2019 3rd Sec B 1

99/169

E i L b i i A d C li

8/13/2019 3rd Sec B 1

100/169


Requirements & Characteristics Of Lubricants

The Most important characteristic is its

viscosity.

The resistance of an oil to flow.

High viscosity is oil that flows slow.

Low viscosity is oil that flows freely.

E i L b i ti A d C li

8/13/2019 3rd Sec B 1

101/169


Lubricating Oil Types

Straight Mineral Oil

Ashless Dispersant

Synthetic


8/13/2019 3rd Sec B 1

102/169


Straight Mineral oil

Used in engines after overhaul or when new to

facilitate wear-in or seating of piston rings.

Often forms sludge when exposed to

temperatures higher than normal.


8/13/2019 3rd Sec B 1

103/169


Ashless Dispersant (AD)

Replaces mineral oil after the piston rings haveseated.

Less tendency to oxidize to carbon, or form ashdeposits.

Particles dont clump together, forming sludge.

Better lubricating properties than mineral oils.


8/13/2019 3rd Sec B 1

104/169


Oil Compatibility

Can different brands and grades of the same oiltype be mixed?


8/13/2019 3rd Sec B 1

105/169


Internal Lubrication Of Reciprocating Engines

Three Methods used

Pressure

Splash

Combination Splash-And-Pressure


8/13/2019 3rd Sec B 1

106/169


Pressure-Lubrication

A mechanical pump supplies oil under pressure

to the bearings throughout the engine.

Splash-Lubrication

Used in addition to pressure lubrication onaircraft engines.


8/13/2019 3rd Sec B 1

107/169


Advantages of pressure lubrication system

Positive introduction of oil to the bearings.

Cooling effect caused by the large quantities of

oil which can be circulated through a bearing.

Satisfactory lubrication in various attitudes offlight.

8/13/2019 3rd Sec B 1

108/169

From Reservoir To Filter


8/13/2019 3rd Sec B 1

109/169


Lubrication Systems

Wet-Sump System

Dry-Sump System


8/13/2019 3rd Sec B 1

110/169


Wet-Sump

System consist of a sump or pan, in which the

oil supply is contained.

The sump or pan is attached to the bottom of

the engine case.


8/13/2019 3rd Sec B 1

111/169


Wet-Sump

Disadvantages

Oil supply limited by sump.

Cooling is difficult.

Higher operating temperatures.

Not adaptable to inverted flying

Advantages

Requires no external parts and fittings to

complicate installation.

No second (scavenge pump) required.

Can be operated in much cooler temperatures.


8/13/2019 3rd Sec B 1

112/169


Dry-Sump

Oil supply is carried in a separate tank.

Scavenger pumps used to return the oil to the

tank.

Used in radial engines and engines capable ofsustained inverted flight.

Dry-Sump

8/13/2019 3rd Sec B 1

113/169


8/13/2019 3rd Sec B 1

114/169


Lubrication

System


8/13/2019 3rd Sec B 1

115/169


Engine Cooling Systems

Why is excessive heat undesirable in internal

combustion engines?


8/13/2019 3rd Sec B 1

116/169


Affects the behavior of the combustion of the

fuel/air charge.

It weakens and shortens the life of engine parts.

It impairs lubrication.


8/13/2019 3rd Sec B 1

117/169


Engine Cooling Systems

About one-fourth of the heat released in an engine ischanged into useful power.

Half of the heat goes out the exhaust, and the other isabsorbed by the engine.

Oil picks up some heat and transfers it to theairstream.

The engine cooling system takes care of the rest.


8/13/2019 3rd Sec B 1

118/169


Cooling Fins

Cooling fins increase the surface of a cylinder.

This arrangement increases the heat transfer by

radiation (from a jug to a barrel).

Cylinders are normally replaced when aspecified number of square inches of fins are

missing.


8/13/2019 3rd Sec B 1

119/169


Cowling and baffles

Designed to force air over the cylinder cooling

fins.

Direct the air close around the cylinders and

prevent it from forming hot pools.

Blast tubes direct jets of cooling air onto the

bottom spark plug elbows.


8/13/2019 3rd Sec B 1

120/169



8/13/2019 3rd Sec B 1

121/169


Temperature Controls

Controls the air circulation over the engine.

Keeps the engine from overheating on take off

and getting too cold in high-speed low-power

letdowns.

Cowl Flaps, Augmenters


8/13/2019 3rd Sec B 1

122/169


Cylinder Head Temperature Indicating System

Consists of and indicator, electrical wiring, and

a thermocouple.

Thermocouple consists of two dissimilar metals

connected by wiring to an indicating system. A

voltage is produced when the temperature of the

junction is different from the temperature

where the dissimilar metals are connected.


8/13/2019 3rd Sec B 1

123/169


Thermal Shock

Occurs when engine parts that are operating at

high temperatures are quickly cooled.

Idle power, high airspeed, cool or cold air.

Some parts are cooled much more rapidly thenothers. These parts shrink in size faster then

the warmer, surrounding metals.

INTRODUCTION

8/13/2019 3rd Sec B 1

124/169

INTRODUCTION The power out put of an engine depends

upon the amount of air inducted per unittime and the degree of utilization of thisair and the thermal efficiency of theengine.Indicated engine Power

IP=P*L*A*n*K/60000 ..(1)Where, IP= indicated power (kW)

P=indicated mean effective pressure(N/m2

)L=length of stroke

A= area of piston

n= no of power stroke, for 2-s engine-N and for 4-s engine N/2, N= rpm

K= No of cylinders

Three possible methods utilized to increase the air

8/13/2019 3rd Sec B 1

125/169

pconsumption of an engine are as follows:

Increasing the piston displacement: This increases the size

and weight of the engine, and introduces additional cooling

problems.

Running the engine at higher speeds: This results in

increased mechanical friction losses and imposes greater

inertia stresses on engine parts.

Increasing the density of the charge: This allows a greatermass of the charge to be inducted into the same volume.

Definition

8/13/2019 3rd Sec B 1

126/169

DefinitionThe most efficient method of increasing the power

of an engine is by supercharging, i.e. increasing

the flow of air into the engine to enable more fuel

to be burnt.

A Superchargeris run by the mechanical drive,powered by engine power .

A turbochargeruses the otherwise unused

energy in the exhaust gases to drive a turbinedirectly connected by a co-axial shaft to a rotary

compressor in the air intake system.

SUPERCHARGERS

8/13/2019 3rd Sec B 1

127/169

SUPERCHARGERS

FUEL/AIRMIXTURE

EXHAUST

GASES

8/13/2019 3rd Sec B 1

128/169

Emission Controls
http://www.hunter.com/pub/undercar/index.htmhttp://www.hunter.com/pub/undercar/index.htm

8/13/2019 3rd Sec B 1

129/169

129

Emission Controls

emission control system Purpose: control emissions and exhaust from
http://www.hunter.com/pub/undercar/index.htmhttp://www.hunter.com/pub/undercar/index.htm

8/13/2019 3rd Sec B 1

130/169

130

pvehicle

Turn the harmful gases the car manufactures intoharmless ones that don't ruin the environment

Problem gases :

hydrocarbons (unburned) HCcarbon monoxide CO

nitrogen oxides NOx

sulfur dioxide SO2

phosphorus P

lead and other metals Pb

Three (major) Pollutants

8/13/2019 3rd Sec B 1

131/169

131

Three (major) Pollutants

Hydrocarbons (HC) Un-burnt Gasoline

Carbon Monoxide (CO)

CO results from the incomplete combustion FuelOxides of Nitrogen (NOx)

NOx results from air being overheated.

HC

8/13/2019 3rd Sec B 1

132/169

132

HC

HC results from gasoline that is not burned

in the engine. This can be due from

misfires, burning rich, open loop operation,

or excessive cranking.

CO

8/13/2019 3rd Sec B 1

133/169

133

COCOresults from the incomplete combustion

of organic materials.

gasoline, kerosene, natural gas, propane,

coal, wood, charcoal, diesel fuel, heating

oil and almost any other combustible

material, such as tobacco and paper.

NOx Nitrogen oxides (NOx) are reactive gases

8/13/2019 3rd Sec B 1

134/169

134

Nitrogen oxides (NOx) are reactive gases

Cause a host of environmental concerns impacting adversely on

human health and welfare. Nitrogen dioxide (NO2), in particular, is a brownish gas that has

been linked with higher susceptibility to respiratory infection,increased airway resistance in asthmatics, and decreased pulmonaryfunction.

Other effects:

Principle cause of ground-level ozone formation

Contribute to acid deposition, which can damage trees at highelevations and increases the acidity of lakes and streams, which can

severely damage aquatic life Contribute to increased levels of particulate matter by changing into

nitric acid in the atmosphere and forming particulate nitrate

combustion temperature gets above 2,500 degrees F

8/13/2019 3rd Sec B 1

135/169

135

Evaporation from the fuel tank. 5%

Blow-by gases which escape from the crankcase.

20-25%

Tail pipe emissions. 60-75%

Carburetor evaporation from the float bowl on

old cars.

8/13/2019 3rd Sec B 1

136/169

Three Ways to Control Pollution

8/13/2019 3rd Sec B 1

137/169

137

y

1Improve combustion

2Capture the vapors and re-burn them.

3Treat the exhaust.

Ways to Combat Pollution

8/13/2019 3rd Sec B 1

138/169

138

y

Capture the vapors and burn them

EGR

Charcoal Canister

Improve the combustion

Monitor mixture

Less Power

Treat the exhaust

Fewer Emission

Manifold Heat Control

8/13/2019 3rd Sec B 1

139/169

139

improves vaporization

improves mixture distribution

As engine warms up, the thermostatic spring

is heated and loses tension

allows counterweight to change position ofheat control valve gradually so that, at higher

driving speeds with a thoroughly warmed

engine, exhaust gases pass directly to theexhaust pipe and muffler

Exhaust Gas Recirculation

(EGR)

8/13/2019 3rd Sec B 1

140/169

140

(EGR) Used to send some of

the exhaust gas back

into the cylinders

Reduce combustiontemperatures

Reduces NOx gases

AIR INJECTION SYSTEMS

P i Air Pump

8/13/2019 3rd Sec B 1

141/169

141

Pump air

Exhaust manifold Catalytic converter

Air Pump

Diverter Valve One-way Valves

Air Switching Valve

Hoses & Tubing

Catalytic Converter

8/13/2019 3rd Sec B 1

142/169

142

y

One of the most

important emission

controlson the car.

Literally burns uppollution in the

exhaust system.

Catalytic Converter Contains precious al min m o ide platin m

8/13/2019 3rd Sec B 1

143/169

143

Contains precious

metals

Down Stream O2

Re-burner

2 way

3 way

3 way w/air

aluminum oxide, platinum

and palladium

carbon monoxide and

hydrocarbons to change

into water vapor and

carbon dioxide

2 way Two Way Catalyst:

oxidize CO and HC to CO2 and

8/13/2019 3rd Sec B 1

144/169

144

2 way oxidize CO and HC to CO2 andH2O.

Temperature of 200C for catalyst

to "light off".

Above 450C, oxidation of SO2 to

SO3 occurs, combines with water to

form sulfuric acid.

Leads to the formation of sulfates.

(acid rain)

2-way catalyst may reduce NOx by

10-20 %.

3 way Reactions between CO, HC, and NOx result in the

l f ll th j h t ll t t

8/13/2019 3rd Sec B 1

145/169

145

removal of all three major exhaust pollutants.

In order to get high conversions of CO and NOx,the air-to-fuel mixture should be held close to thestoichiometric requirement.

If not, conversion of either NOx or CO willdeteriorate.

Requires monitoring the oxygen in the exhaust gasand using it in a feedback loop to adjust the fuel toair ratio.

Makes the 3-way closed loop system more

expensive than an open loop 2-way, or an openloop 3-way system.

Some latest catalysts have a NOx reduction of 70-75%.

3 way with air

8/13/2019 3rd Sec B 1

146/169

146

Uses air tube after Rhodium sub straight

Air helps reduce HC & CO

8/13/2019 3rd Sec B 1

147/169

GOOD NEWS

8/13/2019 3rd Sec B 1

148/169

148

Emission controls have reduced carbon

monoxide and hydrocarbon emissions by

about ninety-six percent from pre-control

vehicles. That's almost a hundred percent!

8/13/2019 3rd Sec B 1

149/169

149

BAD

O2sensors

EPA EMISSION STANDARDS

8/13/2019 3rd Sec B 1

150/169

150

EPA EMISSION STANDARDS

1968-1971 HC 900 ppm CO 9.0%

1972-1974 HC 800 ppm CO 8.0% 1975-1979 HC 700 ppm CO 7.0%

1980 HC 300 ppm CO 3.0%

1981- on HC 220 ppm CO 1.2%

I.M. 240 Test

TURBOCHARGERS The major disadvantage of a supercharger

8/13/2019 3rd Sec B 1

151/169

The major disadvantage of a supercharger

is its reliance on engine power to drive theunit.

By connecting a centrifugal supercharger

to a turbine drive wheel and installing it inthe exhaust path, the lost engine

horsepower is regained to perform other

work and the combustion heat energy lost

in the engine exhaust (as much as 40% to

50%) can be harnessed to do useful work.

TURBOCHARGERS

8/13/2019 3rd Sec B 1

152/169

The turbochargers mainadvantage over a

mechanically driven

supercharger is that the

turbocharger does not drain

power from the engine.

In a naturally aspirated

engine, about half of the

heat energy contained in the

fuel goes out the exhaustsystem.

FIGURE 19-7A turbocharger

uses some of the heat energy

that would normally bewasted.

TURBOCHARGERS

8/13/2019 3rd Sec B 1

153/169

FIGURE 19-8A turbine wheel is turned by the

expanding exhaust gases.

TURBOCHARGERSTurbocharger Design and Operation

8/13/2019 3rd Sec B 1

154/169

Turbocharger Design and Operation

A turbocharger consists of two chambersconnected by a center housing.

The two chambers contain a turbine wheel

and a compressor wheel connected by ashaft which passes through the center

housing.


8/13/2019 3rd Sec B 1

155/169


FIGURE 19-9The exhaust drives the turbinewheel on the left, which is connected to the

impeller wheel on the right through a shaft. The

bushings that support the shaft are lubricated

with engine oil under pressure.


8/13/2019 3rd Sec B 1

156/169


If properly maintained, the turbochargeralso is a trouble-free device.

However, to prevent problems, the

following conditions must be met:The turbocharger bearings must be constantly

lubricated with clean engine oil

turbocharged engines should have regular oilchanges at half the time or mileage intervals

specified for nonturbocharged engines.


8/13/2019 3rd Sec B 1

157/169


Dirt particles and other contamination must bekept out of the intake and exhaust housings.

Whenever a basic engine bearing (crankshaft or

camshaft) has been damaged, the turbochargermust be flushed with clean engine oil after the

bearing has been replaced.

If the turbocharger is damaged, the engine oil

must be drained and flushed and the oil filterreplaced as part of the repair procedure.

TURBOCHARGERSTurbocharger Size and Response Time

8/13/2019 3rd Sec B 1

158/169

Turbocharger Size and Response Time

A time lag occurs between an increase inengine speed and the increase in the speedof the turbocharger.

This delay between acceleration and turboboost is called turbo lag

To minimize turbo lag, the intake andexhaust breathing capacities of an enginemust be matched to the exhaust and intakeairflow capabilities of the turbocharger.

8/13/2019 3rd Sec B 1

159/169

TURBOCHARGERS

8/13/2019 3rd Sec B 1

160/169

COMPRESSES AIR

GOING INTOCOMBUSTION

CHAMBER

DEPENDS ONRAPID EXPANSION

OF EXHAUST

GASES LEAVING

COMBUSTIONCHAMBER

TURBO LAG IS A

CHARACTERISTIC

TURBOCHARGER PARTS

8/13/2019 3rd Sec B 1

161/169

TURBINE SHAFT

COMPRESSOR

WASTEGATE ACTUATOR

CENTER HOUSING

CONTAINS

COOLING SECTION

222C

TURBO CYCLE223C

8/13/2019 3rd Sec B 1

162/169

EXHAUST GAS FORCES TURBINE TO

ROTATE

COMPRESSOR FORCES (PACKS) CREATING

A DENSE AIR-FUEL MIXTURE

CREATES A POSITVE PRESSURE BOOST

BOOST PRESSURE

CONTROL

8/13/2019 3rd Sec B 1

163/169

CONTROL

WASTEGATEDIAPHRAGM

CONTROLS BOOST

PRESSURE MECHANICAL OR

ELECTRONICALLY

CONTROLS

WASTEGATEOPERATION

224C

TURBOCHARGER COOLING

8/13/2019 3rd Sec B 1

164/169

EXHAUST FLOW PASTTURBINE WHEEL

CAUSES HIGH TEMPS

WATER COOLING

OIL COOLING

OIL SEALS

MUST LET TURBO

COOL DOWN ONSHUTOFF

HEAVY DUTY APPLICATION

8/13/2019 3rd Sec B 1

165/169

SAME PRINCIPLEAS SMALLER ONES

BOOST PRESSURE

SLIGHTLY HIGHER

COOLING A LOT

MORE IMPORTANT

DIESEL TRUCK,

LOCOMOTIVE,HEAVY

EQUIPMENT

ROTARY RACING ENGINE

8/13/2019 3rd Sec B 1

166/169

MAINTENANCE /

PROBLEMS

8/13/2019 3rd Sec B 1

167/169

PROBLEMS

LACK OF OIL

DIRTY OIL

MECHANICAL DAMAGE OF VANE

WHEELS

WASTEGATE CONTROL PROBLEMS

OIL CAKING

DIAGNOSISPAGE 302 LAB

8/13/2019 3rd Sec B 1

168/169

OIL LEAKS, HOSES, LINKAGES

BLUE SMOKE

EXCESSIVE NOISE

EXHAUST LEAKS

TEST BOOST PRESSURE

TURBO R & R REQUIRES PRE-LUBING

8/13/2019 3rd Sec B 1

169/169

THEEN

3rd Sec B 1

Documents

Transcript of 3rd Sec B 1