7th Project Report

GTU INNOVTIONA COUNCIL
SELF-DECLARATION (by a student/ team of students) of each IDP/UDP SELF DECLARATION (by a student/ team of students) I/We No Name Enroll No
1 2 3 4
PATEL HARDIK K. THANKI MEHUL M. GHELANI JANAK T. GANDHI BRIJESH A.
100163102003 100163102009 100163102010 080160102018
The student(s) of AUTOMOBILE Branch enrolled at GOVERNMENT ENGINEERING COLLEGE, MODASA hereby certify and declare the following: I/we have defined my/our project based on input at AAROHI MOTORS PVT.LTD, (EICHER MOTORS.) users name / industry/any other user like faculties or any other organizations) and each of us will make significant efforts to make attempt to solve the challenges . I /we will attempt the project work at my college or at any location under the direct and consistent monitoring of PROF. KUNAL V FADADU SIR _(guides name/industry/user). We shall adopt all ethical practices to share credit amongst all the contributors based on their contributions during the project work. (We will work on the project work under the direct and consistent monitoring of Industry mentors and Faculty Guides) I /we have not purchased the solutions developed by any 3rd party directly and the efforts are made by me/us under the guidance of guides. The project work is not copied from any previously done projects directly. (The same problem can be attempted done in new ways.)
The project work submitted by me/us is prepared by me/us and I/we fully understand the contents. We will make best efforts to solve the problems given by the user/ industry. If the project is in relay model (kho-kho) we will share credits with the initial contributors. AAROHI MOTORS PVT.LTD, (EICHER MOTORS.) _ (Name of industry) to the best of my knowledge is a genuine industry, engaged in the professional service/social organizations. I/we understand and accept that the above declaration if found to be untrue, it can result in punishment/cancellation of project definition to me/we including failure in the subject of project work. Name PATEL HARDIK K. THANKI MEHUL M. GHELANI JANAK T. GANDHI BRIJESH A. Date: Contact No. 9601272497 9662061913 8530096157 9427791952 Sign
Place: MODASA
IDP / UDP Project Statement Form

TITLE OF PROBLEM/PROJECT DEFECT OCCURS ON THE PISTON IN THE CYLINDER DURING THE RUNNING OPERATION OF ENGINE DUE TO THE BLOW BY EFFECT DICIPLINARY/ INTER-DICIPLINRY DICIPLINARY DISCIPLINE/S
AUTOMOBILE ENGG.
STUDENT PARTICULARS NO NAME MOBILE NO EMAIL ID PATEL HARDIK K. hardik6004@gmail.com 9601272497 1. THANKI MEHUL M. mehul.thanki31@gmail.com 9662061913 2. GHELANI JANAK T. janakghelani7@gmail.com 8530096157 3. GANDHI BRIJESH A. brijesh1109@gmail.com 9427791952 4. COLLAGE NAME Government Engineering College, Modasa-383315 COLLAGE CODE 016 BRANCH Automobile SEMESTER VII YEAR 2012-13 TEAM CODE GA 1214 SIGNATURE OF STUDENTS INDUSTRY PARTICULARS/USERS DETAIL INDUSTRY DETAILS NAME ADDRESS
AAROHI MOTORS PVT.LTD, (EICHER MOTORS.) BLOCK NO .738 TULSI AVENUE, NATIONAL HIGHWAY NO.8, ASLALI, AHMEDABAD.
CONTACT NO. OFFICE MOBILE NAME OF INDUSTRIAL ESTATE COMPANY LOGO(optional) INDUSTRY GUIDE DETAILS GODHANI BHAGVANJI J. NAME. 9879113775 MOBILE NO. BHAGWANJI@AAROHIMOTORS.COM EMAIL ID

1 2 3 4
THANKI MEHUL M. GHELANI JANAK T. GANDHI BRIJESH A. PATEL HARDIK K.
100163102009 100163102010 080160102018 100163102003
The student(s) of AUTOMOBILE Branch enrolled at GOVERNMENT ENGINEERING COLLEGE, MODASA hereby certify and declare the following: I/we have defined my/our project based on input at AAROHI MOTORS PVT.LTD, (EICHER MOTORS.) users name / industry/any other user like faculties or any other organizations) and each of us will make significant efforts to make attempt to solve the challenges . I /we will attempt the project work at my college or at any location under the direct and consistent monitoring of PROF. KUNAL V. FADADU SIR _(guides name/industry/user). We shall adopt all ethical practices to share credit amongst all the contributors based on their contributions during the project work. (We will work on the project work under the direct and consistent monitoring of Industry mentors and Faculty Guides) I /we have not purchased the solutions developed by any 3rd party directly and the efforts are made by me/us under the guidance of guides. The project work is not copied from any previously done projects directly. (The same problem can be attempted done in new ways.)
The project work submitted by me/us is prepared by me/us and I/we fully understand the contents. We will make best efforts to solve the problems given by the user/ industry. If the project is in relay model (kho-kho) we will share credits with the initial contributors. AAROHI MOTORS PVT.LTD, (EICHER MOTORS.) _ (Name of industry) to the best of my knowledge is a genuine industry, engaged in the professional service/social organizations. I/we understand and accept that the above declaration if found to be untrue, it can result in punishment/cancellation of project definition to me/we including failure in the subject of project work. Name THANKI MEHUL M. GHELANI JANAK T. GANDHI BRIJESH A. PATEL HARDIK K. Date: Contact No. 9662061913 8530096157 9427791952 9601272497 Sign
Place: MODASA

AUTOMOBILE ENGG.
STUDENT PARTICULARS NO NAME MOBILE NO EMAIL ID THANKI MEHUL M. mehul.thanki31@gmail.com 9662061913 1. GHELANI JANAK T. janakghelani7@gmail.com 8530096157 2. GANDHI BRIJESH A. brijesh1109@gmail.com 9427791952 3. PATEL HARDIK K. hardik6004@gmail.com 9601272497 4. COLLAGE NAME Government Engineering College, Modasa-383315 COLLAGE CODE 016 BRANCH Automobile SEMESTER VII YEAR 2012-13 TEAM CODE GA 1214 SIGNATURE OF STUDENTS INDUSTRY PARTICULARS/USERS DETAIL INDUSTRY DETAILS NAME ADDRESS

1 2 3 4
GHELANI JANAK T. GANDHI BRIJESH A. PATEL HARDIK K. THANKI MEHUL M.
100163102010 080160102018 100163102003 100163102009
The project work submitted by me/us is prepared by me/us and I/we fully understand the contents. We will make best efforts to solve the problems given by the user/ industry. If the project is in relay model (kho-kho) we will share credits with the initial contributors. AAROHI MOTORS PVT.LTD, (EICHER MOTORS.) _ (Name of industry) to the best of my knowledge is a genuine industry, engaged in the professional service/social organizations. I/we understand and accept that the above declaration if found to be untrue, it can result in punishment/cancellation of project definition to me/we including failure in the subject of project work. Name GHELANI JANAK T. GANDHI BRIJESH A. PATEL HARDIK K. THANKI MEHUL M. Date: Contact No. 8530096157 9427791952 9601272497 9662061913 Sign
Place: MODASA

AUTOMOBILE ENGG.
STUDENT PARTICULARS NO NAME MOBILE NO EMAIL ID GHELANI JANAK T. janakghelani7@gmail.com 8530096157 1. GANDHI BRIJESH A. brijesh1109@gmail.com 9427791952 2. PATEL HARDIK K. hardik6004@gmail.com 9601272497 3. THANKI MEHUL M. mehul.thanki31@gmail.com 9662061913 4. COLLAGE NAME Government Engineering College, Modasa-383315 COLLAGE CODE 016 BRANCH Automobile SEMESTER VII YEAR 2012-13 TEAM CODE GA 1214 SIGNATURE OF STUDENTS INDUSTRY PARTICULARS/USERS DETAIL INDUSTRY DETAILS NAME ADDRESS

1 2 3 4
GANDHI BRIJESH A. PATEL HARDIK K. THANKI MEHUL M. GHELANI JANAK T.
080160102018 100163102003 100163102009 100163102010
The project work submitted by me/us is prepared by me/us and I/we fully understand the contents. We will make best efforts to solve the problems given by the user/ industry. If the project is in relay model (kho-kho) we will share credits with the initial contributors. AAROHI MOTORS PVT.LTD, (EICHER MOTORS.) _ (Name of industry) to the best of my knowledge is a genuine industry, engaged in the professional service/social organizations. I/we understand and accept that the above declaration if found to be untrue, it can result in punishment/cancellation of project definition to me/we including failure in the subject of project work. Name GANDHI BRIJESH A. PATEL HARDIK K. THANKI MEHUL M. GHELANI JANAK T. Date: Contact No. 9427791952 9601272497 9662061913 8530096157 Sign
Place: MODASA

TITLE OF PROBLEM/PROJECT DEFECT OCCURS ON THE PISTON IN THE CYLINDER DURING THE RUNNING OPRARITON OF ENGINE DUE TO THE BLOW BY EFFECT DICIPLINARY/ INTER-DICIPLINRY DICIPLINARY DISCIPLINE/S
AUTOMOBILE ENGG.
STUDENT PARTICULARS NO NAME MOBILE NO EMAIL ID GANDHI BRIJESH A. brijesh1109@gmail.com 9427791952 1. PATEL HARDIK K. hardik6004@gmail.com 9601272497 2. THANKI MEHUL M. mehul.thanki31@gmail.com 9662061913 3. GHELANI JANAK T. janakghelani7@gmail.com 8530096157 4. COLLAGE NAME Government Engineering College, Modasa-383315 COLLAGE CODE 016 BRANCH Automobile SEMESTER VII YEAR 2012-13 TEAM CODE GA 1214 SIGNATURE OF STUDENTS INDUSTRY PARTICULARS/USERS DETAIL INDUSTRY DETAILS NAME ADDRESS
PROBLEM SUMMARY
As I visited AAROHI MOTORS PVT.LTD which are the authorized service Station of EICHER MOTOR PVT. LTD. We have observed that during the working cycle of engine some of the unburnt gases escape from the combustion chamber to the crankcase. This phenomenon is called BLOW BY.
Thus Blow-by occurs when the explosion that occurs in engine's combustion chamber causes fuel, air and moisture to be forced past the rings into the crankcase. Engine's rings must maintain an excellent fit in order to contain the pressure.
The amount of blow by depends on many variables, including design, components used and age (or wear) of the engine. The older and more worn the rings and cylinder walls of an engines gets the more likely it will allow greater Blow By.
During our visit we come to know that excessive cylinder wear tends to increase the rate of blow by. One of the primary reasons of cylinder wear is the dust particle that enters into the cylinder via engine air intake system.
DETAILED DESCRIPTION OF PROBLEM

Blow-by is the gas that enters an engines crankcase during a normal combustion event or compression stroke. It is composed of unburnt fuel, air and combustion by-product.
Note that at this stage it does not contain any oil. Incidentally, the combustion by-products contained in blow-by gas are corrosive, which is why it is a bad idea to paint the underside of truck withholds engine oil as a cheap under seal substitute.
Blow-by happens because the seal around cylinder is not perfect. It is composed of closely matched metal parts - the piston, rings and cylinder bore. The close sliding fit and tangential load pressing the rings into the bore wall creates a good (and variable, as we will see later on) seal, but by necessities there are gaps, and gas will get through them (see figure 1). If left unchecked, this gas entering the crankcase will eventually pressurize it and can cause oil to be blown past the crankshaft and camshaft seals.
Figure 1: Blow-by flow paths
There are other sources of blow-by: Air leaking into the cam cover via the valve guides and seals in pressure-charged engines. However it is very small amount and hence it can be neglected.
Blow By is detrimental for several reasons

As Blow By increases, horsepower decreases because you are losing some of the high pressure mixture pushing on the piston.
Contaminates from incomplete combustion are not kept inside the combustion chamber they make their way into the oil inside the crank case. This will cause oil contamination and dilution.
Blow By can "blow" lubrication off the cylinder wall causing high wear.
As Blow By increases significantly, it can actually allow oil to leak into the combustion chamber (by the rings) and reduce the octane rating of the mixture. This can cause Detonation and cause severe destruction of the piston and chamber.
As Blow By increases significantly, the leakage of hot gasses by the edge of the piston can actually "torch out the piston" (like a cutting torch, cut the edge off the piston).
Blow By is also a pollutant. In older vehicles Blow By was taken care of by simply allowing the pressure generated inside the crankcase created by Blow By to be vented into the atmosphere by way of the crankcase vent tube. But eventually (in the 60s) the EPA mandated that these vented gasses where detrimental to the quality of the air in the U.S. That is when the PCV (Positive Crankcase Ventilation) valve came into play.
Typically, the higher the torque an engine makes or the larger the displacement, the higher the potential for Blow By. Blow By typically does not increase drastically with RPM, but is highest at the engine's torque peak. Thus we can say that the amount of blow by is higher in transport truck then a car.
Possible causes of blow by
1. Worn Cylinder Walls

As the diesel engine gets older, the cylinder walls wear out by constant piston and piston ring scraping. Over time, the cylinder bore becomes bigger by this constant scraping. The end effect is that "slop" or a gap is created between the piston and cylinder. The gap between the piston and the cylinder wall becomes significant; and as a result, compressed gases are free to go around the piston.
2. Worn Pistons
Worn pistons cause blow by. Just as the cylinder walls wear out and the bore becomes bigger, the piston becomes worn and becomes slightly smaller. Bear in mind that aluminum is a soft metal, and grit accumulation in the combustion chamber carves grooves into the piston. These grooves are an ideal place for the compressed fuel/air mixture to escape into the crankcase.
Figure 2:-Effect of blow by on piston
3. Worn Rings
Researchers at the Helsinki University of Technology ran extensive studies of piston rings and concluded that worn rings are a source of blow by. What happens is the constant scraping of rings back and forth in the cylinder eventually wears them down, and their sealing capabilities fail. Blow by happens in front of the ring, but the gases also "sneak" around the backside of the ring when the sidewalls become worn.
4. PCV Valve
The Positive Crankcase Ventilation valve is designed to vent excess pressure out of engine and valve cover areas. PCV valves have to be periodically serviced and replaced, or they will become blocked. If PCV valve quits functioning, pressure is building up in engine with no way to escape. When enough pressure builds up, it may force oil and air out in the form of blow-by.
5. Pressure
The bottom line on engine blow-by is that it is caused by pressure. Any time more pressure builds up inside engine or valve areas than it can release, the pressure is forced through the weakest point of engine and causes blow-by
6. Air intake system

The air intake system is also one of the main factors affecting the rate of blow by. Though it will not affect the blow by effect. When atmospheric air is suck into the air cleaner, if dust particle are not remove from air then dust enters into the cylinder. It will make surface uneven. Hence the gap between cylinder and piston ring will increase and blow by will occur.
Figure-3 Effect of dust on cylinder wall
Importance of breather system
We know that an internal combustion engine produces gases that enter the crankcase via leakage past the piston rings. This gas flow can be considerable (up to 100 liters per minute in a normally aspirated engine).
If left unchecked, this would cause a buildup of pressure in the crankcase, the result of which would be oil being pushed past the shaft seals at the front and rear of the crankshaft. Also, since the cylinder head and cam cover are linked to the crank case by oil drain galleries which allow lubrication oil from the valve train to return to the oil pan under gravity, this pressure can also pressurize the cylinder head and push oil past the camshaft seals. In extreme cases, the pressure can rise to a point where it is sufficient to push these seals out of their housings. The section deals with the system that prevents this from happening the closed breather system.
The obvious solution to pressure build up in the crank case is simply to incorporate an atmospheric vent into the cam cover, and up until about 1960 this is exactly what was done the so-called open breather system. Unfortunately for the environment, blow-by gases contain a proportion of unburned fuel, oil and combustion products, which would get dumped into the atmosphere. As soon as legislation to govern vehicle emissions started to come into play, the open breather systems days were numbered.
Thus the closed breather system was born. The hose that was previously routed to atmosphere was connected to the engines air intake so that the engine effectively ingested its own blow-by gases and all that they contained.
Over the years, the closed breather system has evolved into a complex part of the modern-day engine.
A simple closed breather system:

In any breather system the crankcase (where the blow-by gases are created) is linked to the cam cover via either a chimney cast into the crankcase and cylinder head, or an external pipe. This chimney has two functions: Firstly, it allows blow-by gases to leave the crankcase to equalize pressure in the top and bottom of the engine. Secondly, it gives any oil that may be being carried along with the gas time to drop out and return to the oil pan under gravity. Note that depending upon the dimensions of the chimney, the velocity of the blow-by gases can be quite high. For this reason, it is bad practice to use a cylinder head oil drain as a blow-by chimney, as the oil and gas moving in opposite directions can interfere with each other more on this later.
Once the blow-by gas has made its way up into the cam cover, it needs to be fed back into the intake system. The obvious way to do this is to link the cam cover to the intake plenum with a small pipe. In this way, the vacuum in the plenum will draw the gases off and maintain the crankcase at slightly below atmospheric pressure. In practice things are not quite so simple.
At low engine loads, the throttle plate will be almost fully closed, leading to a low pressure in the plenum. This is ideal for drawing the blow-by gases out of the cam cover. However, at high engine speeds and low loads (i.e. on the overrun this vacuum can be very high to high in fact for the purposes of just maintaining the crankcase at slightly below atmospheric pressure. The solution is to introduce a restriction (typically about 1 to 2mm in diameter) into the link pipe between cam cover and plenum to limit this vacuum.
Figure 3: Low blow-by / low load breather flow.
Conversely, at high engine loads, the throttle plate will be almost fully open and so the plenum will be at almost atmospheric pressure no good for a vacuum source. Therefore, a second connection off the cam cover is used which uses the pressure drop across the air filter as a vacuum source.
Figure 4: High blow-by / low load breather flow. This is the essence of the closed breather system a restricted connection into the plenum which creates a vacuum under part throttle, and a second connection upstream of the throttle plate which creates a vacuum at wide open throttle (WOT). These two connections are referred to by various names, but we will call them the part-throttle breather and the WOT breather.
EXPECTED OUTCOME
Breather systems equalize the crank case pressure created by blow by, and maintain the crankcase at slightly below atmospheric pressure to ensure that blowby gases and oil cannot enter the atmosphere.
Blow-by gases contain oil mist, which in excess, can get carried over into the intake system.
Oil separation is required in the breather system to remove carry over oil and prevent it from re-entering the engine.
There are three main types of oil separator: Volumes, labyrinths and centrifuges.
Separated oil can be either returned to the oil pan or held in a catch can.
The designs of oil separators and oil catch cans are necessarily different, principally in the location of the entry and exit pipes.
The other main reason of blow by is dust particles. The amount of dust particles can be reduced by using oil bath type air cleaner.
OTHER DESCRIPTION (IF ANY)
REFERENCES
Breather system MKIVSupra.net
by
Written
by Digsy
for
Vortex-Power.co.uk
and
Automobile Engineering by R.B.Gupta Satya Prakashan, New Delhi.
http://www.ehow.com/list_5939480_causes-exhaust-blow_by.html
http://www.bobistheoilguy.com/blowby.html
http://performancetrends.com/Definitions/Blow-By.html

7th Project Report

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GTU INNOVTIONA COUNCIL

PATEL HARDIK K. THANKI MEHUL M. GHELANI JANAK T. GANDHI BRIJESH A.

100163102003 100163102009 100163102010 080160102018

GTU INNOVTIONA COUNCIL

IDP / UDP Project Statement Form

GTU INNOVTIONA COUNCIL

THANKI MEHUL M. GHELANI JANAK T. GANDHI BRIJESH A. PATEL HARDIK K.

100163102009 100163102010 080160102018 100163102003

GTU INNOVTIONA COUNCIL

IDP / UDP Project Statement Form

GTU INNOVTIONA COUNCIL

GHELANI JANAK T. GANDHI BRIJESH A. PATEL HARDIK K. THANKI MEHUL M.

100163102010 080160102018 100163102003 100163102009

GTU INNOVTIONA COUNCIL

IDP / UDP Project Statement Form

GTU INNOVTIONA COUNCIL

GANDHI BRIJESH A. PATEL HARDIK K. THANKI MEHUL M. GHELANI JANAK T.

080160102018 100163102003 100163102009 100163102010

GTU INNOVTIONA COUNCIL

IDP / UDP Project Statement Form

DETAILED DESCRIPTION OF PROBLEM

Figure 1: Blow-by flow paths

Blow By is detrimental for several reasons

Possible causes of blow by

1. Worn Cylinder Walls

Figure 2:-Effect of blow by on piston

6. Air intake system

Figure-3 Effect of dust on cylinder wall

Importance of breather system

A simple closed breather system:

Figure 3: Low blow-by / low load breather flow.

OTHER DESCRIPTION (IF ANY)

Breather system MKIVSupra.net

Automobile Engineering by R.B.Gupta Satya Prakashan, New Delhi.

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