AUTOMOBILE IC ENGINE

DESIGN

Contents

Introduction

Chassis Design & Types

Engine and its classification

Differences

Power transmission

Hand on practice

Software distribution & installation

Designing of some engine components

Competition

Certificate distribution

INTRODUCTION

WHAT IS AN ENGINE ?

ORIGINALLY CALLED HORSELESS CARRIAGES.

AUTOMOTIVE ENGINEERING INCLUDES:

Mechanical Engineering

Vehicle Dynamics

Engine Design

Drive Train Engineering

HISTORY & Advancements

Thomas Saverybuilds a steam-powered waterpumpfor pumping water out of mines in year 1698.

1712 Thomas Newcomenbuilds apiston-and-cylinder steam-powered water pump for pumping

water out of mines.

First steam engine built by James watt in year 1769

The first car was built by Joseph Cugnot in 1769.

Nicolas August Otto built the first four cylinder IC engine in 1877.

Dugald Clark in year 1878 invented a two stroke engine.

In 1886 Gottlieb Daimler designed the first four wheeled automobile. They also created the first vslanted engine.

Rudolf Dieselpatents theDiesel enginein year 1892.

Karl Benz is the first to build an automobile powered by an gasoline fueled internal combustion
engine.

Henry Ford, manufacturing over 15 million Models by 1927.

Ferdinand Porschecreates the firsthybrid vehicle.

As problems with environment and gas process continue, Hybrids are now a hot commodity in the
market place and are now the new wave of future cars

Indian Automobile Market

The world's third largest by 2016, with currently being the world's second largest
two-wheeler manufacturer.
Two-wheeler production is projected to rise from 18.5 million in FY15 to 34 million
by FY20. passenger vehicle production is expected to increase to 10 million in FY20
from 3.2 million in FY15.

 The government aims to develop India as a global manufacturing as well as a

research and development (R&D) hub. It has set up National Automotive Testing
and R&D Infrastructure Project (NATRIP) centres as well as a National
Automotive Board to act as facilitator between the government and the industry.
No. Of Motor Vehicles in Major CitiesGross turnover of Automobile manufacturers in INDIA

Some of the key highlights of the Automotive Mission Plan

2026 are

Indian automotive industry to grow 3.5 to 4 times of the current

value of USD 74 billion to USD 260 billion to 300 billion.

Contribute over 12 percent to India's GDP.

Generate 65 million more jobs.

AMP aims to make Indian automotive industry to be the engine of

'Make in India' initiative.

Auto Component to grow to Rs 593,500 crore - Rs 732,000 crore.

By 2026, passenger vehicles likely to increase between 9.4 - 13.4

million units, commercial vehicle between 2.0 - 3.9 million units,
two wheeler to grow to 50.6 - 55.5 million, and tractors to 1.5 1.7 million units.

ENGINE PERFORMANCE PARAMETERS

Indicated Thermal Efficiency

Brake Thermal Efficiency

Mechanical Efficiency

Volumetric Efficiency

CHASSIS

LADDER CHASSI
Longitudinal members :- Main
stress(Acceleration and
Braking) bearing members.

Lateral members :Resistance to forces during

Cornering and increase in
torsional rigidity.

 TUBULAR SPACE FRAME CHASSI

3 Dimensional design.
Circular and Square section
tubes.
Complex Structure.
Very High Torsional
Rigidity.
Very strong in any direction.
High Rigidity/weight ratio.
High end Sports cars.
Formula SAE Cars.
Difficult access to cabin.

 MONOCOQUE FRAME CHASSI

One piece structure

defining overall
shape of car.

99% of overall cars,

low production cost
and easy to weld
through robots.

Good crash
protection and space
efficient.

Rigidity to weight
ratio is low.

Impossible for small

volume production.

 ULSAB MONOCOQUE CHASSI

(Ultra Light Steel Auto Body)

Use of Hydroform
parts.

Developed by Porsche
Engineering Services.

Stronger and lighter

then conventional
monocoque without
increasing production
cost.

cannot be used in
everywhere because it
needs adhesive
bonding or riveting
instead of welding.

Opel Astra and BMW 3Series.

 BACKBONE FRAME CHASSI

Colin Chapman, the

founder of Lotus, invented
backbone chassis.

A strong tubular backbone

(usually in rectangular
section) connects the front
and rear axle and provides
nearly all the mechanical
strength.

Strong enough for smaller

sports cars.

most space-saving other

than monocoque chassis.

cheap for low-volume

production.

 ALUMINIUM SPACE FRAME

Audi A8 is the first mass

production car featuring
Aluminium Space Frame
chassis

Audi claimed A8's ASF is

40% lighter yet 40%
stiffer than contemporary
steel monocoque.

Made of high-strength
aluminium alloy.

It's quite complex and

production cost is far
higher than steel
monocoque.

Lighter than steel

monocoque. As space
efficient as it.

 CARBON FIBRE MONOCOQUE

Carbon fiber called

Kevlar offer highest
rigidity to weight ratio.

Kevlar can also be found

in the body panels of
many exotic cars.

Building in F1.

Very expensive and

complex manufacturing
process.

ENGINE
External

combustion Engines.

Internal

combustion Engines.

Classification of Engines
On The Basis Of Engine Designs
Rotary Engines
Reciprocating Engines

On The Basis Of Type Of Cooling

Air-Cooled Engine
Water-Cooled Engine

On The Basis Of Working Cycle

Two Stroke Engines
Four Stroke Engines

On The Basis Of Fuel Used

Petrol Engine
Diesel Engine

On The Basis Of Ignition

Spark Ignition
Compression Ignition

On The Basis Of Method Of Charging

Naturally Aspirated Engines
Supercharged Engines

ENGINE PARTS(Petrol Engine)

Cylinder Head

Cylinder Block

Crank case and Crank Shaft

Cam shaft

Rocker shaft and Rocker Arm

Piston and Gudgeon Pin

Connecting Rod

Push Rods

Valve Train(Intake and Exhaust

Valves)

Flywheel

Spark Plugs

Sump or Oil pan

TRANSMISSION SYSTEM
The

mechanism that transmits the power developed by the engine of

automobile to the engine to the driving wheels is called the
TRANSMISSION SYSTEM (or POWER TRAIN). It is composed of :-

Clutch

Gear Box

Propeller Shaft

Universal Joints

Rear Axle

Differential

Wheels

Tyres

REQUIREMENTS OF TRANSMISSION
SYSTEM : Provide

means of connection and disconnection of engine with rest of power

train without shock and smoothly.

Provide

a varied leverage between the engine and the drive wheels.

Provide

means to transfer power in opposite direction.

Enable

power transmission at varied angles and varied lengths.

Enable

speed reduction between engine and the drive wheels in the ratio of

5:1.
Enable

diversion of power flow at right angles.

Provide
Bear

means to drive the driving wheels at different speeds when required.

the effect of torque reaction , driving thrust and braking effort effectively.

TYPES OF TRANSMISSION
SYSTEM
HYDRAULIC TRANSMISSION SYSTEM

MECHANICAL TRANSMISSION SYSTEM

TORQUE CONVERTOR

MANUAL TRANSMISSION

FLUID COUPLING

CONTINIOUSLY VARIABLE
TRANSMISSION
AUTOMATIC
TRANSMISSION

CLUTCH

A clutch is a mechanism which enables the rotary motion of one shaft to be

transmitted at will to second shaft ,whose axis is coincident with that of
first.

Clutch is located between engine and gear box. When the clutch is engaged,
the power flows from the engine to the rear wheels through the transmission
system and the vehicle moves . when the clutch is disengaged ,the power is
not transmitted to the rear wheels and the vehicle stops, while the engine is
still running.

Clutch is disengaged when

Starting the Engine

Shifting the Gears

Idling the Engine

clutch is engaged only when the vehicle is to

move and is kept engaged when the vehicle is
moving.

FUNCTIONS OF A CLUTCH
To permit engagement or disengagement of a gear when the
vehicle is stationary and the engine is running.
To transmit the engine power to the road wheels smoothly
without shock to the transmission system while setting the
wheel in motion.
To permit the engaging of gears when the vehicle is in motion
without damaging the gear wheels.

Principle of Operation Of a Clutch

o The clutch principle is based on friction . when two friction surface are brought
in contact with each other and pressed they are united due to friction between
them. If one is revolved the other will also revolve . The friction between the two
surfaces depends upon Area :
i. Area of the surface,
ii. Pressure applied upon them,
iii. Coefficient of friction of the surface materials

UNIVERSAL JOINTS

Auniversal joint is ajointorcouplingin a rigid rod that allows the rod to 'bend' in any
direction, and is commonly used in shafts that transmitrotary motion. It consists of a pair
ofhingeslocated close together, oriented at 90 to each other, connected by a cross shaft.