INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING-AHMEDABAD

Reg.No:

Automotive Engines
LABORATORY MANUAL
B.E. Fifth SEMESTER 2010-11

INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING AUTOMOBILE ENGINEERING DEPARTMENT AHMEDABAD

INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING-AHMEDABAD

CERTIFICATE

This is to certify that Mr./Ms.____________________________ Reg.No._________________of __________________________ Class has satisfactory completed the course in ____________________________________________________ at INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING, Rancharda, Ahmedabad. Date of Submission: ____________________________ Concern Faculty: ______________________________ Head of Department: __________________________

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INDEX
Sr. No 1. 2. 3 4. 5. 6. 7. 8. 9. 10. 11. Title Page From Engine components and Engine operating cycles. Performance test on Two stroke, Single cylinder Petrol engine Performance test on Four stroke, Four cylinder Diesel engine Performance test on Four stroke, Four cylinder Petrol engine Morse test on four stroke, four cylinder petrol engine Experimental study of smoke meter Air Pollution from IC Engines Ignition systems Lubrication systems Fuel injection systems use in S.I.Engine and C.I.Engine Cooling systems To Date of Start Completion date Initial of faculty Gr

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* INSTRUCTIONS *

Your writing should be neat and clean. Get checked your manual at the end of the performance of each practical. Practical & Tutorials that cannot be read or are not presented in a professional engineering style will not receive credit (Higher Grades).

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Teaching and Examination Scheme

* Syllabus * (As per Gujarat Technological University) B.E. SEM-V (AUTOMOBILE) AUTOMOBILE ENGINES
Subject Code Teaching Scheme Theory Lab/ Pract Exam Sessional University Examination Scheme Theory Theory Pract Paper Marks TW Total

Automotive Engines

Course content 1. Engine: Classification of engine types (including construction of two stroke and four stroke engines), Engine parts/aggregates and their functions & operations. Phenomena of scavenging.
2. Modern Power Plants:

Stratified charged engine, Wankel engine, Multi-fuel engine, Sterling engine.

3 Fuels:

Types of fuel, properties. Fuel supply system in SI engine Fuel supply system layout, Fuel feed pump, Filters, Carburetion, Types of carburetors, Mixture requirements, Idling, Cold starting, Economy, Power and acceleration, Chokes petrol injection, Multi-point fuel injection. Fuel supply system in CI engine Fuel injection pump, fuel feed pump, injectors, nozzles, cold starting devices (glow plugs), types of governors, Common Rail Diesel Injection (CRDI) System. Modern Fuels Biogas, Biodiesel, Hydrogen, LPG, CNG and alcohols.
4 Process of Combustion in Engines:

Flame propagation, Combustion phenomena, Types of combustion chambers, Detonation, knocking, Knocking parameters, Knock ratings, Antiknock agents, Preignition, Dual Timing Spark Ignition system. 5. Engine Cooling Systems: Types of cooling systems (water & air cooling), Types of cooling fans, Water pump, Radiators, Thermostat, Coolant/anti freeze solution. 6 Lubrication System: Functions & types of lubrication systems and its components including Engine Lubrication circuit, Types of Lubricating pumps, Oil coolers, Types of oils, Lubricant properties and additives for lubricants, Big end & small end bearings, Bush bearings, Thrust bearings and bimetallic bearings.

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7.Intake and Exhaust System: Exhaust/Intake systems, Types of air cleaners, Supercharger, Turbo charger, Silencers, Catalytic convertor. 8.Air Pollution: Emission norms, Exhaust gas emission constituents and analysis, Orsat apparatus, Modern methods and Gas chromatography. 9.Engine Performance and Testing: Study of various performance parameters, Valve timing, Friction losses, Ignition timing, Compression ratio, Inlet temperature etc., Measurement of power, Fuel consumption, Airfuel ratio, Efficiency, Heat balance sheet, Engine troubleshooting.

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* Units *
SI base units
Name Symbol
Newton joule watt Pascal N J W Pa

Quantity
Force, Weight Energy, Work, Heat Power Pressure, Stress

Expression in terms of other units

mkg/s2 Nm J/s N/m2

Expression in terms of SI base units

mkgs2 m2kgs2 m2kgs3 m1kgs2

Some Important Derived Units

Name square metre cubic metre metre per second metre per second squared radian per second Newton second Newton meter second Newton meter kilogram per cubic meter cubic meter per kilogram Mass Moment of Inertia Symbol m2 m3 ms1 ms2 rads1 Ns Nms Nm kgm3 kg1m3 kgm2 Quantity area volume speed, velocity acceleration angular velocity momentum, impulse angular momentum torque, moment of force density, mass density specific volume Mass Moment of Inertia Expression in terms of SI base units m2 m3 ms1 ms2 s1 kgms1 kgm2s1 kgm2s2 kgm3 kg1m3 kgm2

INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING-AHMEDABAD

PRACTICAL: 1
ENGINE COMPONENTS AND ENGINE OPERATING CYCLES

AIM: - Study of Engine components and Engine operating cycles. RELAVANCE: - To make conversant with various components of engine and operating cycles on which gasoline and diesel engine works. Carry out study of following engine Parts: Stationary parts Moving parts Auxiliary parts Carry out study of following engine operating cycles: Otto cycle Diesel cycle Dual cycle. QUESTIONS: 1. 2. 3. 4. Give the name and Function of every components of Engine. Draw the p-V and T-s diagram for otto and diesel cycle. Compare Otto and Diesel cycles for the same compression ratio and heat input. Compare Otto and Diesel cycles for the same Max. Pressure and heat rejection.

CONCLUSION:

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PRACTICAL: 2
PERFORMANCE TEST - TWO STROKE PETROL ENGINE.

AIM: - Performance Test On Two Stroke, Single Cylinder Petrol Engine.

RELAVANCE: - To understand working & construction of an engine and to make students conversant with different components and their materials. Two stroke Petrol engines are widely used as a source of mechanical power. Because of their less weight to power ratio, they are popularly used for two wheelers (light vehicles) and Marine Engine. ENGINE SPECIFICATIONS:Engine Bore & Stroke (D Compression ratio Maximum output Engine cooling L) : 57 mm 57 mm : 7.4: 1 : 6.3 BHP@ 5200 RPM : Air cooling by centrifugal fan

EXPERIMENTAL SETUP:- Draw the Schematic diagram of Test rig. PROCEDURE: - Write the procedure as per the lab work.
DATA:-

Pulley Diameter (d) : 0.30 m Rope thickness (t) : 0.005 m Brake pulley effective Diameter : 0.305 m Orifice diameter : 0.014 m Coefficient of discharge of orifice: 0.65 Density of Fuel ( f) : ___________ (Approx. - 700 Kg / m3 ) Calorific value of Petrol (CV):___________ (Approx.-52,200 KJ / Kg)

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OBSERVATION TABLE:Sr No Load On Engine W=(T1-T2) Kg 1 2 3 4 Time measured for 10 CC Fuel Consumption (t) Sec Manometer Reading (hw) m Speed (N) RPM

CALCULATION:1. 2. 3. 4 5 6 7 8 Net torque T = W 9.81 Brake pulley effective radius , N-m Brake Horse Power Fuel Consumption BP = 2 FC = (10 N T / 60000 , KW
3

10-6) / time in Sec , m /sec

f

Total fuel consumption (TFC) = FC x Heat Input = TFC x CV , KJ/sec

, Kg/sec

Brake Specific Fuel Consumption = TFC x 3600 / BP Brake thermal efficiency = [BP / Heat Input] Air Flow rate Va = 100 , %

Kg/hr-KW

cd A 2 gha

m3/s

cd =Coefficient of discharge of orifice , A =area of orifice m2

ha
w a

w a

hw
3

= density of water = _____________ kg/m = density of air = _________ kg/m

a ,

Mass of air intake (actual) = Va x 9 10

Kg/sec

Air fuel ratio = Mass of air in kg per sec / Fuel consumption in kg per sec. Volumetric efficiency= Actual mass of air intake/Theoretical mass of air intake Theoretical mass of Air intake= ( /4 x D2 x L) (N /60) x
a

Kg/sec

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RESULT TABLE:Sr

No

S Load On Engine W=(T1-T2) Kg

Engine Out Put

B.S.F.C.

Brake Thermal Efficiency %

Volumetric Efficiency

A:F Ratio

BP

Kg/hr-KW %

1 2 3 4 PLOT THE GRAPHS OF :1. 2. 3. 4. Load Vs B.S.F.C. Load Vs Brake Thermal Efficiency Load Vs Volumetric Efficiency Load Vs A:F ratio

QUESTIONS: 1. 2. 3. 4. Why air tank is provided? How Brake power is measured? What kind of ignition system is provided in an engine? Why one should maintain constant speed during the performance?

CONCLUSION:Conclude the performance of engine on basis of result table and graph plotted

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INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING-AHMEDABAD

PRACTICAL: 3
PERFORMANCE TEST FOUR STROKE FOUR CYLINDER DIESEL ENGINE

AIM: - Performance Test on Four stroke, Four cylinder Diesel Engine RELAVANCE: - To make conversant with working & construction of engine, various engine systems and determine various performance parameters. The experimental set up consists of a 4 stroke, 4 cylinder diesel engine coupled with a hydraulic dynamometer. This type of engine is best suitable for vehicles which operate at varying speed. SPECIFICATIONS:Bore (D) Stroke (L) Capacity BHP : 73 mm : 90 mm : 1500 CC : 10 HP@ 1500 rpm

EXPERIMENTAL SETUP:- Draw the Schematic diagram of Test rig. PROCEDURE: - Write the procedure as per the lab work. OBSERVATIONS:1. Specific gravity of fuel 2. Calorific value of fuel (CV) 3. Orifice Diameter (d) 4. Engine water inlet temp. ( T1) : 5. Engine water outlet temp. ( T2) : 6. Calorimeter water inlet temp.( T3) 7. Calorimeter water outlet temp.( T4) 8. Exhaust gas inlet temp.( T5) 9. Exhaust gas outlet temp.( T6) : 10. Engine cooling water flow rate ( Qe) 11. Calorimeter cooling water flow rate ( Qc) 12. Mass rate of Engine cooling water(Me) : 13. Mass rate of Calorimeter cooling water(Mc): : : : 0.035

KJ/Kg m

: : : : : Kg/sec Kg/sec m3/sec m3/sec

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14. Coefficient of Discharge (Cd)

: 0.62

OBSERVATION TABLE:Load (W) Sr. No. Kg Time for 10 Cc of Fuel (t) Temperature (T) Centigrade Engine Cooling water
T1 T2

Calorime ter Water

T3 T4

Exha. gas from calo.

T5 T6

Manometer Reading (hw) Amb. Temp.

T7

Speed

Sec

RPM

1 2 3 4 CALCULATION :1. Fuel consumption ( FC) = (10 x 10 -6 ) / t , m3/sec

2. Total fuel consumption (TFC) = FC x Specific gravity of fuel , Kg/sec 3 Heat Input = TFC x CV , KJ/sec

4 Engine Output (Brake Power) = ( W x N ) / (2000 x 1.36) , KW 5. Brake specific fuel consumption = TFC x 3600/ BP , kg/hr-KW 6. Volume of air Intake Va = Cd x A x ( 2 x g x ha )0.5 , m /sec Area of orifice A = (ha) = (hw x Where
a w

d2 / 4
a w= a

)/

= ____________ Kg / m3,

__________ Kg / m3

8. Mass of air intake (Actual) (Ma) = Va x

, Kg/ sec

9. Volume of Theoretical air intake ( Vt ) = ( /4 x D2 x L x n ) (N/2 x 60) , m3 / sec Where n= No. of cylinder 10. Volumetric efficiency (
Vol)

= Va / Vt

11. Brake thermal efficiency (

BTh)

= [ BP / Heat Input ] 100 , %

12. A : F ratio = Mass of air intake(actual) / TFC 13. Mass of exhaust gas Mg = Ma + TFC , Kg/sec

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14. Heat loss in Engine cooling system = Me x Cp water x (T2-T1) , KJ / sec 15. Heat lost by Exhaust gas to calorimeter = Heat gained by water in Calorimeter Mg x Cpgas x (T5 - T6) = Mc x Cp water x ( T4 - T3) Cpgas =______________ KJ/Kg K 16. Heat lost in Engine Exhaust system = Mgas x Cp gas x ( T5-T7) KJ / sec

RESULT TABLE:-

Sr.No. 1 2 3 4

Load W

Power KW

Bsfc Kg/Hr.KW

BTh

Air- Fuel ratio

HEAT BALANCE SHEET:HEAT SUPPLIED HEAT EXPENDITURE 1. Heat converted to work(brake power)= ________ KW Heat Input = 2. Heat loss in Engine cooling system = ________ ________KW 3. Heat lost in Engine Exhaust system = ________ KW 4. Unaccountable heat loss = Heat Input ( 1+2+3 ) = ___________ KW GRAPHS:Plot the graph of followings. Study the nature of curve and give your comments on it. 1. Plot BP vs volumetric efficiency 2. Plot BP vs Brake thermal efficiency KW % OF INPUT

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3. Plot BP vs brake specific fuel consumption and comment. 4. Plot BP Vs A/F ratio result. QUESTIONS: 1. 2. 3. 4. How hydraulic dynamometer is used to measure the output of an engine? What is the purpose of exhaust gas calorimeter provided in the test rig? What do you understand by unaccounted heat? Evaluate Thermal efficiency increases with increase in Load.

CONCLUSION:Conclude the performance of engine on basis of result table and graph plotted

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PRACTICAL: 4
PERFORMANCE TEST FOUR STROKE FOUR CYLINDER PETROL ENGINE
AIM: - Performance test on Four stroke, Four cylinder Petrol engine RELAVANCE:- To make student conversant with working & construction of engine, various engine systems and various engine performance parameters. The engine is Ambassador brand & is a 4 stroke, 4 cylinder engine developing 10 H.P at 1500 rpm. This type of engine best suitable for automobiles which operate at varying speed. The engine is fitted on a rigid body & is coupled through a flexible coupling to a hydraulic dynamometer that acts as the loading device. SPECIFICATIONS:Bore Stroke Capacity Speed BHP : 73 mm : 90 mm : 1500 CC. : 1500 rpm. : 10 @ 1500 rpm.

EXPERIMENTAL SETUP:- Draw the Schematic diagram of Test rig. PROCEDURE: - Write the procedure as per the lab work. OBSERVATIONS:1. Specific gravity of fuel 2. Calorific value of fuel (CV) 3. Orifice Diameter (d) 4. Engine water inlet temp. ( T1) : 5. Engine water outlet temp. ( T2) : 6. Calorimeter water inlet temp.( T3) 7. Calorimeter water outlet temp.( T4) 8. Exhaust gas inlet temp.( T5) 9. Exhaust gas outlet temp.( T6) : 10. Engine cooling water flow rate ( Qe) 11. Calorimeter cooling water flow rate ( Qc) : : : 0.035

KJ/Kg m

: : : : : m3/sec m3/sec

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12. Mass rate of Engine cooling water(Me) : 13. Mass rate of Calorimeter cooling water(Mc): 14. Coefficient of Discharge (Cd) OBSERVATION TABLE:Load (W) Sr. No. Kg Time for 10 Cc of Fuel (t) Temperature (T) Centigrade Engine Cooling water
T1 T2

Kg/sec Kg/sec : 0.62

Calorime ter Water

T3 T4

Exha. gas from calo.

T5 T6

Manometer Reading (hw) Amb. Temp.

T7

Speed

Sec

RPM

1 2 3 4 CALCULATION :1. Fuel consumption ( FC) = (10 x 10 -6 ) / t , m3/sec

2. Total fuel consumption (TFC) = FC x Specific gravity of fuel , Kg/sec 5 Heat Input = TFC x CV , KJ/sec

6 Engine Output (Brake Power) = ( W x N ) / (2000 x 1.36) , KW 5. Brake specific fuel consumption = TFC x 3600/ BP , kg/hr-KW 6. Volume of air Intake Va = Cd x A x ( 2 x g x ha )0.5 , m /sec Area of orifice A = (ha) = (hw x Where
a w

d2 / 4
a w= a

)/

= ____________ Kg / m3,

__________ Kg / m3

17. Mass of air intake (Actual) (Ma) = Va x

, Kg/ sec

18. Volume of Theoretical air intake ( Vt ) = ( /4 x D2 x L x n ) (N/2 x 60) , m3 / sec 19. Volumetric efficiency (
Vol)

= Va / Vt

20. Brake thermal efficiency (

BTh)

= [ BP / Heat Input ] 100 , %

21. A : F ratio = Mass of air intake(actual) / TFC 22. Mass of exhaust gas Mg = Ma + TFC , Kg/sec

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23. Heat loss in Engine cooling system = Me x Cp water x (T2-T1) , KJ / sec 24. Heat lost by Exhaust gas to calorimeter = Heat gained by water in Mg x Cpgas x (T5 - T6) = Mc x Cp water x ( T4 - T3) Cpgas =______________ KJ/Kg K 25. Heat lost in Engine Exhaust system = Mgas x Cp gas x ( T5-T7) KJ / sec RESULT TABLE:Sr.No. 1 2 3 4 Load W Power KW Bsfc Kg/Hr.KW
v BTh

Air- Fuel ratio

HEAT BALANCE SHEET:HEAT SUPPLIED % OF INPUT

HEAT EXPENDITURE 1. Heat converted to work(brake power)= ________ KW

Heat Input = 2. Heat loss in Engine cooling system = ________ ________KW 3. Heat lost in Engine Exhaust system = ________ KW 4. Unaccountable heat loss = Heat Input ( 1+2+3 ) = ___________ KW GRAPHS:Plot the graph of followings. Study the nature of curve and give your comments on it. 1. 2. 3. 4. Plot Plot Plot Plot BP vs volumetric efficiency BP vs Brake thermal efficiency BP vs brake specific fuel consumption. BP Vs A/F ratio result. KW

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5.

Plot Brake power in KW Vs Total fuel consumption in g/sec ,and Find Friction power by extend curve in Negative side (Willans Line Method).and compare it with morse test method (Practical-5)

QUESTIONS: 1. How fuel consumption is measured? 2. Write major differences of petrol and diesel engine test rigs? 3. Which type of injection system provided with engine? On which principle it works? CONCLUSION:Conclude the performance of engine on basis of result table and graph plotted

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PRACTICAL: 5 MORSE TEST

AIM: - Morse test on Four stroke, Four cylinder Petrol Engine. RELAVANCE:- To make student conversant with working & construction of engine, various engine systems and find Indicated Horse Power. The engine is Ambassador brand & is a 4 stroke, 4 cylinder engine developing 10 H.P at 1500 rpm. For perform morse test on this engine cut off are provided on high voltage spark line. SPECIFICATIONS:Bore Stroke Capacity Speed BHP : 73 mm : 90 mm : 1500 CC. : 1500 rpm. : 10 @ 1500 rpm.

EXPERIMENTAL SETUP:- Draw the Schematic diagram of Test rig. PROCEDURE: - Write the procedure as per the lab work. OBSERVATION TABLE:Speed of engine =___________ rpm Dynamometer Load Sr. No. Condition Kg 1 2 3 4 5 All cylinders working 1st cylinder cut-off 2nd cylinder cut-off 3 cylinder cut-off 4th cylinder cut-off
rd

Power Output (WxN) (2000 x 1.36) KW A=___________ B=___________ C=___________ D=___________ E=___________

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CALCULATION:1. Power output BP = ( W x N ) / (2000 x 1.36) , KW 2. Indicated Horse Power IP For 1st cylinder For 2nd cylinder For 3rd cylinder For 4th cylinder (IP)1 (IP)2 (IP)3 (IP)4 =A-B =A-C =A-D =AE

Total IP of engine = Summation of power produced by all cylinders. 3. Mechanical Efficiency = Total BP of Engine / Total IP of engine 4. Friction Power RESULT TABLE:Sr.No. 1 2 3 4 GRAPHS:Plot the graph of followings. Study the nature of curve and give your comments on it. 1 2 Plot Load Vs Indicated Horse Power Plot Load Vs Fiction Power Load(W) Kg Power Output KW Indicted Horse Power Friction Power FP = Total IP of engine - Total BP of Engine

QUESTIONS: 1. What is the purpose of the Morse test? 2. What are other methods which can be used for the same purpose? 3. Explain the motoring test. CONCLUSION:Conclude the performance of engine on basis of result table and graph plotted

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PRACTICAL: 6 SMOKE METER

AIM: - Experimental Study of Smoke meter. RELAVANCE: - To make conversant with smoke meter and to understand that how it can be used for the analysis of exhaust products from I.C engines. EXPERIMENTAL SETUP:- Draw the Schematic diagram of Equipment use to perform practical. PROCEDURE: - Write the procedure as per the lab work. RESULT TABLE:Attach Xerox copy of Result printed from smoke meter QUESTIONS: 1. 2. 3. 4. 5. What is the working principle of smoke meter? What are the main constituents of exhaust from Diesel engine? What are the main constituents of exhaust from Petrol engine? Which equipment is use to measure petrol engine emission? On which principle it work? How government interfere to control Emission from Vehicles? Give the brief detail of various norms use to control emission. 6. Which are the technologies use to reduce emission from Petrol and Diesel Vehicles 7. What is the mechanism of smoke formation?

CONCLUSION: Give your comments on Result. Find that this engine is falling in which norms?

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PRACTICAL: 7 AIR POLLUTION FROM I.C. ENGINE

AIM: - Study of air pollution from I.C. engine.
RELAVANCE: - To make conversant with various sources of air pollution and various pollutants and also to study that how air pollution can be controlled. QUESTIONS: 1 2 3 4 5 6 What are the major emissions that come out of engine? What are particulates? Describe in detail how particulate emissions are caused. Give a brief account of emission from CI engines. What do you understand by the term EGR? Explain how EGR reduces NOx emission. Explain with neat sketches how non exhaust emission are controlled. What are catalytic convertors? How are they helpful in reducing HC, CO, and NO x emissions?

CONCLUSION:

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PRACTICAL: 8 IGNITION SYSTEMS

AIM: - Study of ignition systems RELAVANCE: - To make student conversant with various Ignition systems, their construction and working. Carry out study of following Ignition systems: Battery Ignition system. Magneto Ignition system. Modern Ignition systems. QUESTIONS:1. 2. 3. 4. With net sketch explain the battery ignition system. Explain TCI and CDI ignition system with suitable diagram. Why spark advance is required? Explain advance mechanism use in vehicle What is firing order? What is its significance?

CONCLUSION:

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PRACTICAL: 9 LUBRICATION SYSTEM

AIM: - Study of lubrication systems RELAVANCE: - To make student conversant with various Lubrication systems, their construction and working. Carry out study of following Lubrication systems: Mist lubrication system. Splash lubrication system. Dry sump-Full force feed lubrication system Wet sump-Force feed system QUESTIONS:1. What are the various components to be lubricated in an engine and how it is accomplished? 2. Explain different types of lubrication system with sketch. 3. Discuss the function and properties of the lubricants.

CONCLUSION:

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PRACTICAL: 10 FUEL INJECTION SYSTEMS USE IN S.I. ENGINE AND C.I. ENGINE

AIM: - Study of fuel injection systems use in S.I. Engine and C.I. Engine RELAVANCE: - To make students with conversant with various injection systems use in I.C engine. QUESTIONS: 1. Draw the general arrangement of fuel supply system 2. What do you understand by stoichiometric Air Fuel ratio? Briefly discuss the air fuel ratio requirements of a petrol engine from no load to full load. 3. Explain the principle of carburetion. 4. How are the injection system classified? With a net sketch explain the various components of a fuel feed system of a CI engines. 5. With a neat sketch explain the working principle of a Distributor type Rotary fuel injection pump. 6. Describe briefly the D-MPFI and L-MPFI system with a neat sketch. 7. What is a common rail system? Explain. CONCLUSION:

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PRACTICAL: 11 COOLING SYSTEMS

AIM: - Study of Cooling systems RELAVANCE: - To make student conversant with various Cooling systems, their construction and working. Carry out study of following Cooling systems: Water cooling system. Air cooling system. QUESTIONS:1 2 3 Why engine cooling is necessary? Explain the two type of cooling systems and compare them. Discuss different methods of water cooling in I. C. engines.

CONCLUSION:

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Manual Prepared By
B.R.PATHAK B.M.DOGRA (Lecturer in Automobile Engineering)

Approved by Prof. V. K. Manglik

H.O.D.- Automobile Engineering

AUTOMOBILE ENGINEERING DEPARTMENT INDUS INSTITUTE OF TECHNOLOGY & ENGINEERING

AHMEDABAD

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