Whoever loves discipline loves

knowledge,
But he who hates reproof is stupid.
prov 12:1

Mechanical Engineering- Gitam University

INTRODUCTION
We know that in case of Internal Combustion engines,
combustion of air and fuel takes place inside the engine
cylinder and hot gases are generated. The temperature of
gases will be around 2300-2500C.
This is a very high temperature and may result into burning
of oil film between the moving parts and may result into
seizing or welding of the same.
About 20-25% of total heat generated is used for
producing brake power
(useful work).
Cooling system is designed to remove 30-35% of total
heat.
Remaining heat is lost in friction and carried away by
exhaust gases.

Air Cooled System

Air cooled system is generally used in small engines say up
to 15-20 kW and in aero plane engines.
In this system fins or extended surfaces are provided on the
cylinder walls,
cylinder head, etc.
The amount of heat dissipated to air depends upon :
Amount of air flowing through the fins.
Fin surface area.
Thermal conductivity of metal used for fins.

Advantages of Air Cooled System:

Radiator/pump is absent hence the system is light.
In case of water cooling system there are leakages, but in
this case
there are no leakages.
Coolant and antifreeze solutions are not required.
This system can be used in cold climates, where if water is
used it
may freeze.

Disadvantages of Air Cooled System

Comparatively it is less efficient.
It is used in aero planes and motorcycle engines where the
engines are
exposed to air directly.

Thermo Siphon System

In this system the circulation of water is due to difference in
temperature (i.e. difference in densities) of water. So in this
system pump is not required but water is circulated because of
density difference only

Pump Circulation System

In this system circulation of water is obtained by a pump. This
pump is driven by means of engine output shaft through Vbelts

Fan
It is driven by the engine output shaft through same belt that
drives the pump. It is provided behind the radiator and it blows
air over the radiator for cooling purpose.

Pump
Pump consists of an impeller
mounted on a shaft and enclosed in
the pump casing.
The pump casing has inlet and
outlet openings.
The pump is driven by means of
engine output shaft only through
belts. When it is
driven water will be pumped.

Thermostat valve
It is a valve which prevents flow of water from the engine to
radiator, so that engine readily reaches to its maximum
efficient operating temperature. After
attaining maximum efficient operating temperature, it
automatically begins functioning. Generally, it prevents the
water below 70C.

Antifreeze Mixture
In western countries if the water used in the radiator freezes
because of cold
climates, then ice formed has more volume and produces
cracks in the cylinder
The ideal
antifreeze
solutions
should
have the
following
blocks,
pipes,
and radiator.
So,
to prevent
freezing
antifreeze
properties
mixtures
or :solutions are added in the cooling water.
It should dissolve in water easily.
It should not evaporate.
It should not deposit any foreign matter in cooling system.
It should not have any harmful effect on any part of cooling
system.
It should be cheap and easily available.
It should not corrode the system.
No single antifreeze satisfies all the requirements.
Normally following are used as antifreeze solutions :
Methyl, ethyl and isopropyl alcohols.
A solution of alcohol and water.
Ethylene Glycol.
A solution of water and Ethylene Glycol.

ENGINE LUBRICATION SYSTEM

Lubricants
Lubricant is substance that reduces friction and wear at the interface of two
materials. The lubricant at interface reduces the adhesive friction by lower the
shear strength of interface. Based on the shear strength of lubricant or
molecular state, lubricants are classified in four categories.

Gaseous lubricants
Liquid lubricants
Semi-solid lubricants
Solid lubricants

PURPOSE OF LUBRICATION SYSTEM

Lubricate: Reduces Friction by creating a thin film(Clearance)between
moving parts (Bearings and journals).
Seals
The oil helps form a gastight seal
between piston rings and cylinder walls
(Reduces Blow-By) Internal oil leak
(blow-by) will result in BLUE SMOKE
at the tale pipe.
Cleans
As it circulates through the engine, the
oil picks up metal particles and carbon,
and brings them back down to the pan.

PURPOSE OF LUBRICATION SYSTEM

Cools
Picks up heat when moving through the engine and then drops into the cooler
oil pan, giving up some of this heat.
Absorbs shock
When heavy loads are imposed on the bearings, the oil helps to cushion the
load.
Absorbs Contaminants
The additives in oil helps in absorbing the contaminants that enter the
lubrication system.

Types of Lubrication system

There are various types of lubrication system for
lubricating the automobile engines.
Petroil system.
Splash system.
Pressure system.
Wet sump system.
Dry sump system.
Semi pressure system.

VISCOSITY
Viscosity is a measure of oils resistance to flow.
A low viscosity oil is thin and flows easily
A high viscosity oil is thick and flows slowly.
As oil heats up it becomes more viscous (Becomes thin)

If the oil is too thin(has very low viscosity) it will be forced out from between
the moving parts, resulting in rapid wear.
If the oil is too thick(has very high viscosity)it will flow very slowly to engine
parts, especially when the engine and the oil are cold, resulting in rapid wear.
Viscosity Index is the measure of how much the viscosity of an oil changes
with temperature. (20 W) Viscosity number is set by SAE (Society of
Automotive Engineers)
Single viscosity oils SAE 5W, SAE 10W (Winter) and SAE 20, SAE30
(Summer)
Multiple viscosity oils SAE 10W-30. This means that the oil is same as SAE
10W when cold and SAE30 when hot.
The higher the number the higher the viscosity(thickness)of oil.

Properties of oil
Corrosion and Rust Inhibitor : Displaces water from metal surfaces, to prevent
corrosion.
Foaming Resistance: Rotating crankshaft tends to cause bubbles (Foam)in the
oil and bubbles in oil will reduce the effectiveness of oil to lubricate.
Synthetic Oils : Made by chemical process and do not necessarily come from
petroleum.

Service Rating of Oil

Oil SA, SB, SC, SD,.. SJ SA and SB oils are not recommended for use in
todays Automobile engines.

Parts
Oil Pumps Driven by camshaft, crankshaft (Rarely rebuild by an auto
technician)
Rotor Pump(Two star shaped rotors pumps the oil)
Gear oil Pump

Oil Pan
Stores the oil and helps in cooling the oil Pan gasket splits if over tightened.
Pressure Relief Valve :
To prevent the buildup of high Pressure
Good oil pressure is 40-60 psi

Oil Pressure Indicator

Light or a Gauge
The light turns on or gauge reads low when the pressure drops below 10psi.
Common causes of low oil pressure are:
Low oil level
Worn out pump
Low oil pressure Safety system will shuts down the car by cutting the ignition
System(Spark).

Oil Filter:
Filters the oil Some particles are too small for the filter Element (paper in the
filter) to trap.

Oil Pressure sending unit electrically sends the signal to the Light or Gauge
mounted on the dash . If the wires get shorted the light will come on or the
gauge will read high.

Positive Crankcase ventilation Valve

Pollution prevention
Blow-by back into the intake
Prevent sludge in the engine.

OIL CHANGE
Every 5000Km
3 months
Ignoring regular oil change intervals will shorten engine life and
performance.