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MOUNT ZION COLLEGE OF ENGINEERING AND

TECHNOLOGY, PUDUKKOTTAI
1

DEPARTMENT OF MECHANICAL ENGINEERING


(REGULATION 2013)
III YEAR/6TH SEMESTER- A&B
ME 6602 AUTOMOBILE ENGINEERING

MOUNT ZION COLLEGE OF ENGINEERING & TECHNOLOGY


ME 6602 AUTOMOBILE ENGINEERING
SYLLABUS PLAN
UNIV ALLOTED HOURS: 45 Hrs PLANNED HOURS: 45 Hrs
2

UNIV.
UNIT PLANNED
UNIT TITLES ALLOTED TEACHING AIDS
NO. HOURS
HOURS

1 VEHICLE STRUCTURE AND ENGINES 9 9 PPT, SMART BOARD, VIDEOS, FIELD VISIT

2 ENGINE AUXILIARY SYSTEMS 9 9 PPT, SMART BOARD, DEMO, VIDEOS

3 TRANSMISSION SYSTEMS 9 9 PPT, SMART BOARD, DEMO, FIELD VISIT

STEERING, BRAKES AND SUSPENSION


4 9 9 PPT, SMART BOARD, FIELD VISIT
SYSTEMS

5 ALTERNATIVE ENERGY SOURCES 9 9 PPT, VIDEOS

TOTAL HOURS 45 Hrs.

MOUNT ZION COLLEGE OF ENGINEERING & TECHNOLOGY


UNIT 1- VEHICLE STRUCTURE AND ENGINES
UNIT PLAN
Univ. Alloted: 9 Hrs. Planned:9 Hrs
3

LECTURE PLANNED
TOPICS TLP NO. TEACHING AIDS
HOUR HOURS

1 INTRODUCTION 1.1 PPT, VIDEOS, SMART BOARD


1
2 TYPES OF AUTOMOBLIES 1.2 PPT, VIDEOS, SMART BOARD

VEHICLE CONSTRUCTION AND


3 1.3 1 PPT, VIDEOS, SMART BOARD
DIFFERENT LAYOUTS

4 CHASSIS, FRAMES AND BODY 1.4 2 PPT, VIDEOS, SMART BOARD

5 VEHICLE AERODYNAMICS 1.5 1 PPT, VIDEOS, SMART BOARD

6 IC ENGINES – INTRODUCTION, TYPES 1.6 PPT, VIDEOS, SMART BOARD


3
COMPONENTS – FUNCTION AND
7 1.7 PPT, VIDEOS, SMART BOARD
MATERIALS
VALVE TIMING DIAGRAM – VARIABLE
8 1.8 1 PPT, VIDEOS, SMART BOARD
VALVE TIMING

MOUNT ZION COLLEGE OF ENGINEERING & TECHNOLOGY


LECTURER HOUR – 1
1.1 Introduction
• Automobile engineering is the one of the stream of
mechanical engineering. It deals with the various types of
automobiles, their mechanism of transmission systems
and its applications. Automobiles are the different types
of vehicles used for transportation of passengers, goods,
etc.
• Basically all the types of vehicles works on the principle
of internal combustion processes or some times the
engines are called as internal combustion engines.
1.1 Introduction
• Different types of fuels are burnt inside the cylinder at
higher temperature to get the transmission motion in the
vehicles.
• Most of the automobiles are internal combustion engines
vehicles only.
• Therefore, every mechanical and automobile engineer
should have the knowledge of automobile engineering its
mechanism and its various applications.
1.1 Definition
• Automobile is a vehicle driven by an internal combustion
engine and it is used for transportation of passengers and
goods on the ground.
• Automobile can also be defined as a vehicle which can
move by itself.
• Examples : Car, jeep, bus, truck, scooter, etc.
1.2 Classification of Vehicles

• Automobiles or vehicles can be classified on different


bases as given below :
• On the Basis of Load :
– Heavy transport vehicle (HTV) or heavy motor vehicle
(HMV),e.g. trucks, buses, etc.
– Light transport vehicle (LTV) e.g. pickup, station
wagon, etc.
– Light motor vehicle (LMV), e.g. cars, jeeps, etc.
1.2 Classification of Vehicles

• On the Basis of Wheels :


– Two wheeler vehicle, for example : Scooter,
motorcycle, scooty, etc.
– Three wheeler vehicle, for example : Auto rickshaw,
three wheeler scooter and tempo, etc.
– Four wheeler vehicle, for example : Car, jeep, trucks,
buses, etc.
– Six wheeler vehicle, for example : Big trucks with two
gear axles each having four wheels.
1.2 Classification of Vehicles

• On the Basis of Fuel Used


– Petrol vehicle, e.g. motorcycle, scooter, cars, etc.
– Diesel vehicle, e.g. trucks, buses, etc.
– Electric vehicle, e.g. battery drive
– Steam vehicle, an engine which uses steam.
– Gas vehicle, LPG and CNG vehicles, where LPG is
liquefied petroleum gas and CNG is compressed
natural gas.
1.2 Classification of Vehicles

• On the Basis of Body


– Sedan with two doors
– Sedan with four doors
– Station wagon
– Convertible, e.g. jeep, etc.
– Van
– Special purpose vehicle,
1.2 Classification of Vehicles

• Transmission
– Conventional vehicles with manual transmission, e.g.
car with 5 gears.
– Semi-automatic
– Automatic : In automatic transmission, gears are not
required to be changed manually. It is automatically
changes as per speed of the automobile.
1.2 Classification of Vehicles

• Position of Engine
– Engine in Front :Most of the vehicles have engine in
the front. Example : most of the cars, buses, trucks in
India.
– Engine in the Rear Side: Very few vehicles have engine
located in the rear. Example : Nano car.
LECTURER HOUR – 2
1.3 Vehicle construction and
Different layouts
1.3 Vehicle construction and
Different layouts
1.3 Vehicle construction and
Different layouts
LECTURER HOUR – 3
1.3 Vehicle construction and
Different layouts
• It contains the source of power, i.e. engine, the frame,
which supports the engine, wheels, body, transmission,
the braking system and the steering. It also gives support
to suspension system and springs.
Introduction….
 Chassis is the significant structure of an
automobile
 A skeletal frame with various mechanical
parts like engine, tires, brakes, steering and
axle assemblies
 Usually made of a light metal or composite
plastic which provides strength needed for
supporting vehicle components and load on it
• Chassis is a French term and was initially used to 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 of the vehicle like Power 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.
Types of chassis….

 Ladder frame chassis


 Tubular space frame chassis
 Monocoque frame chassis
 Ulsab monocoque chassis
 Back bone frame chassis
 Alluminium space frame
 Carbon fibre monocoque
Ladder chassis
 One of the oldest form of chassis that is still
used by most of the SUVs till today
 Resembles a shape of ladder which having
two longitudinal rails interlinked by several
lateral and cross braces
 The lateral and cross members provides
rigidity to the structure
it has no much advantage these days….
Easy and cheap for hand built

Since two dimensional structure…. Torsional rigidity is


much lower than other chassis especially with vertical
loads or bumps

Most SUVs , classic cars ,lincoln town car, ford crown victoria
etc…..
Backbone chassis
 Has a rectangular tube like a backbone and
simple in structure
 made of glass fibre is used for joining front
and rear axle and responsible for the strength.
 Space within structure used for positioning
drive shaft in case of rear wheel drive.
 Drive train, engine and suspensions are
connected at the ends of the chassis
Strong enough for smaller sports
cars and most space saving other
than monocoque chassis

Does not provide protection against side impact or off-set


crash and not strong for high speed cars

Lotus Esprit, Elan Mk2, TVR, Macros


Monocoque chassis
 Most modern cars use this type
 A single piece of frame work that give shape
to the entire car and built by welding several
pieces together
 Demand for monocoque chassis is increased
because it is suitable for robotized production
Inherently good crash protection
and it is space efficient and cheap
for mass production

Heavy , impossible for small volume production

Nearly all mass production cars, all current porche


Tubular space frame chassis
 A 3-dimensional design employing number of
circular and square section tubes
 Tubes are positioned in different sections to
provide mechanical strength against forces
from anywhere
 Tubes are welded together and form a
complex structure
 Very strong when compared with ladder and
monococoque chassis of the same weight
Very strong in
any direction

Very complex, time consuming to built and engages a lot


of space , raise the door sill and results in difficult
accessto the cabin

All ferrari before the 360m ,Lamborghini Diablo, Jaguar


Xj220 ,caterham
Ulsab monocoque chassis
 Traditional steel monocoque chassis
becomes heavier than ever ,as a result car
makers turned to replace steel with
aluminium
 More cars use aluminium in body panels
 American steel manufacturers hired Porsche
Engineering services to develop a new
kind of steel monocoque technology calls
Ultra Light Steel Auto Body (ULSAB)
Stronger and lighter than conventional
monocoque without increasing
production cost

Still not strong enough for best sports car

Opel Astra and BMW 3series


Carbon fibre monocoque
chassis
 Carbon fibre is the most sophisticated
material using in aircrafts, spaceships and
racing cars
 Because of its superior rigidity to weight
ratio
 Several carbon fibres used in motor industry
like Kelvar which has rigidity to weight ratio
among them and can be found in body
panels of many exiotic cars
Lightest and
stiffest chassis

The most expensive

McLaren F1 ,Bugatti EB110SS, Ferrari F50


Aluminium space frame
chassis
 ASF consists of extruded aluminium sections,
vacuum die cast components and aluminium
sheets of different thickness
 Highly stressed corners and joints and
extruded sections are connected by complex
aluminium die casting
 40% lighter yet 40% stiffer than contemporary
steel monocoque
 Its quite complex
Lighter than steel monocoque
and space effecient

Still expensive for mass production

Audi
1.4 Chassis
• It is the main mounting for all the components including
the body. So it is also called as Carrying Unit.
Classification of a vehicle chassis is based on the
position of the engine on the chassis.
1. Full forward
2. Semi Forward
3. Engine at centre
4. Engine at the back
5. Conventional chassis

Chassis also classified based on reference to drive


1. Rear wheel drive
2. Front wheel drive
3. Four wheel drive
Full Forward:
Mostly poweris given to the front
wheels hence reduces components
Problem of visibility & Costly because of transaxle
Part of Chassis portion can not
be utilized for carrying
passengers and goods
Semi Forward:
Half portion of the engine is in the driver cabin
and remaining half is outside the cabin such as
in tata trucks
In this arrangement a part of the chassis is
utilized for carrying extra passengers
Engine at Centre:
Drive is given to the rear.
Full space of the chassis floor can be used
(Royal tiger world master buses in Delhi)
If used in cars it limits the car to
be a two seater.
Luxury/Sports cars use this layout.
Engine at the rear/back:
Reduced components
Costly because of transaxle
With elimination of propeller shaft the centre of
gravity lowered giving stable driving
Better adhesion on road specially
when climbing hill.
CONVENTIONAL CHASSIS

Chassis of a Truck
Chassis of a Truck
Rear wheel Drive:
Good traction obtained while climbing the hill.
Good distribution of braking force.
Large bulge in the region of gear box and due to
propeller shaft.
-Lighter in weight, because the driveshaft is
shorter, meaning better fuel economy.
-No floor hump in the passenger compartment, for
the same reason.
-Less weight in the drive train overall, resulting in
even more fuel economy.
1.4 Chassis
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
LECTURER HOUR – 4
It is the foundation on which the power plant
and the body are carried and which in turn is
supported on the wheels through axles and
springs
Cross Section of Frame:
a.Channel Section - Good resistance to bending
b.Tabular Section - Good resistance to Torsion
c.Box Section - Good resistance to
both bending
and Torsion

Cross sections of Frame


• The various steels used for conventional pressed frame
are mild steel, carbon sheet steel and sheet nickel alloy
steel

•Carbon - 0.25-0.35%
•Manganese -0.35-0.725%
•Silicon -0.30% (maximm)
•Nickel -3%
•Phosphorous -0.05% (max.)
•Sulphur -0.5% (max)
1.5 Frame and body
• Frame: It is made up of long two members called side
members riveted together with the help of number of
cross members.
• TYPES OF CHASSIS FRAMES:
• There are three types of frames
– Conventional frame
– Integral frame
– Semi-integral frame
1.5 Frame and body
• Conventional frame: It has two long side members and
5 to 6 cross members joined together with the help of
rivets and bolts.
Conventional Semi Integral

Integral
1.5 Frame and body
• 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. Only disadvantage is repairing is
difficult.
1.5 Frame and body
• 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 be
taken easily to replace the damaged chassis frame. This
type of frame is used in FIAT cars and some of the
European and American cars.
1.5 Frame and body
• VARIOUS LOADS ACTING ON THE FRAME:
– Short duration Load - While crossing a broken patch.
– Momentary duration Load - While taking a curve.
– Impact Loads - Due to the collision of the vehicle
– Inertia Load - While applying brakes.
– Static Loads - Loads due to chassis parts.
– Over Loads - Beyond Design capacity.
1.5 Frame and body
• The Automobile bodies are divided in two groups
– Passenger body
– Commercial body
1.5 Frame and body
1.5 Frame and body
• REQUIREMENTS OF BODIES FOR VARIOUS TYPES OF
VEHICLE:
• The body should be light.
• It should have minimum number of components.
• It should provide sufficient space for passengers and
luggage.
• It should withstand vibrations while in motion.
• It should offer minimum resistance to air.
1.5 Frame and body
• REQUIREMENTS OF BODIES FOR VARIOUS TYPES OF
VECHILE:
• It should be cheap and easy in manufacturing.
• It should be attractive in shape and colour.
• It should have uniformly distributed load.
• It should have long fatigue life.
• It should provide good vision and ventilation.
LECTURER HOUR – 5
1.6 Vehicle Aerodynamics
 Aerodynamics is itself a part of fluid dynamics, which is
the study of the properties of a solid object displace a
fluid such as air.
 For the performance of a typical passenger car,
aerodynamics is an important consideration in the
achievement of maximum fuel economy, as well as in
creating auto body styling that is visually appealing.
1.6 Vehicle Aerodynamics
• Terms to Know- Aerodynamics
– Fluid
– Mass
– Aerodynamics
– Drag
– Lift
– Rear Suction
– Down Force
– Frontal Area
1.6 Vehicle Aerodynamics
• Air-
– Is a type of fluid such as water that can be directed or
displaced;
– Has mass and is measured in terms of pressure;
– Applies direct and frictional forces to objects in
motion
1.6 Vehicle Aerodynamics
One should be aware of four aerodynamic principles
• Drag
• Lift/Down Force
• Drag Coefficient
• Frontal Area
1.6 Vehicle Aerodynamics
• Drag is a combination of two forces that will work against
the acceleration of your car.
– Frontal Pressure occurs when tiny molecules of air hit
the front of your car and is forced away to make room
for other molecules to hit it.
– Rear Suction occurs when an empty pocket of air is
created in the back of your car resulting in a vacuum
cleaner effect that tries to pull your car backward.
1.6 Vehicle Aerodynamics
• Lift and Down Force
• Lift is similar to rear suction in that a thin empty pocket
occurs as air passes over a flat surface causing the car to
lift.
• Down Force is due to high pressure in curved surfaces
that causes the car to be pushed down.
• Drag Coefficient
• Drag Coefficient is a way of expressing how slippery a car.
• The drag coefficient (CD) is a measure of the vehicle's
aerodynamic efficiency.
1.6 Vehicle Aerodynamics
• Frontal Area
Frontal Area is the total of all surfaces in the front of
your vehicle which cause drag.
Area = Length x Width
1.6 Vehicle Aerodynamics
1.6 Vehicle Aerodynamics
LECTURER HOUR – 6
INTRODUCTION
◦ An Engine is a device which transforms the
chemical energy of a fuel into thermal energy
and uses this thermal energy to produce
mechanical work.
◦ Engines normally convert thermal energy into
mechanical work and therefore they are called
heat engines.
◦ Heat engines can be broadly classified into :
i) External combustion engines ( EC
Engines)
ii) Internal combustion engines ( IC
Engines )
HISTORY
◦ Internal combustion engines date back to 1876 when Otto first
developed the spark- ignition engine and 1892 when Rudolf
Diesel invented the compression-ignition engine.
◦ Since that time these engines have continued to develop as our
knowledge of engine processes has increased, as new
technologies became available, as demand for new types of
engine arose, and as environmental constraints on engine use
changed.
◦ Internal combustion engines, and the industries that develop and
manufacture them and support their use, now play a dominant
role in the fields of power, propulsion, and energy.
CLASSIFICATION OF HEAT ENGINES
Heat
Engines

Open Wan Gasoli Dies Stea Stirli Stea Closed


cycleg kel ne el m ng m Cycle 5
as engin engine engi engi engin turbi gas
HEAT ENGINE
A heat engine is a system that
converts heat or thermal energy to mechanical
energy, which can then be used to do
mechanical work
Working Process of 4-stroke engine

A four-stroke engine is an internal combustion (IC)


engine in which the piston completes four separate
strokes while turning a crankshaft. A stroke refers to
the full travel of the piston along the cylinder, in either
direction. The four separate strokes are termed:
Intake(suction) stroke
Compression stroke
Power (working) stroke
Exhaust stroke
Intake Stroke

Intake: This stroke of the piston begins at top dead center (T.D.C.) and ends
at bottom dead center (B.D.C.). In this stroke the intake valve must be in the
open position while the piston pulls an air-fuel mixture into the cylinder by
producing vacuum pressure into the cylinder through its downward motion.
Compression stroke

Compression: This stroke begins at B.D.C, or just at the end of the suction
stroke, and ends at T.D.C. In this stroke the piston compresses the air-fuel
mixture in preparation for ignition during the power stroke (below). Both the
intake and exhaust valves are closed during this stage.
Working stroke

Power: This is the start of the second revolution of the four stroke cycle.
At this point the crankshaft has completed a full 360 degree revolution.
While the piston is at T.D.C. (the end of the compression stroke) the
compressed air-fuel mixture is ignited by a spark plug (in a gasoline
engine) or by heat generated by high compression (diesel engines),
forcefully returning the piston to B.D.C. This stroke produces mechanical
work from the engine to turn the crankshaft.
Exhaust stroke

Exhaust: During the exhaust stroke, the piston once again returns from
B.D.C. to T.D.C. while the exhaust valve is open. This action expels the
spent air-fuel mixture through the exhaust valve.
Working Process of 4-stroke engine
Applications of IC Engines
I.C. engines have many applications, including:
 Road vehicles(e.g. scooter , motorcycle , buses
etc.)
Aircraft
 Motorboats
 Small machines, such as lawn mowers,
chainsaws and portable engine-generators
Advantages of IC engine
 An internal combustion engine is compact and
lighter.
 An internal combustion engine can be started
immediately.
 An internal combustion engine is quite safe to
use.
 An internal combustion engine has higher
efficiency than external combustion engine.
FOUR STROKE PETROL ENGINE
LECTURER HOUR – 7
FOUR STROKE DIESEL ENGINE
TWO STROKE ENGINE
1.7 IC Engines
ENGINE
1.8 Components of IC Engines
o This is the main block of the engine.
o This contains the cylinder and provides housing for the
crank, crank shaft and other engine parts.
o This is the basic frame for the engine and the parts fitted
on it.
o Material: Hard Grade cast iron or Aluminium alloys
 This is the top most part of the engine which covers
the cylinder.
 It is bolted with the engine block at the top.
 Provides combustion chamber, and mounting areas for
spark plugs and valve parts
 Material: Hard Grade cast iron or Aluminium alloys
 Gasket are used so that a gas tight joint is
formed.
 These joints will withstand high pressure and
heat developed in the combustion chambers.
 This is usually cast as a single piece.
 Material: Soft copper and asbestos sheet
 Used to guide and seal piston and to mount
cylinder assembly to head.
 It contains gas under pressure during
combustion

Prepared By: K. Rajesh, AP/Mech, RMK Coll of


Engg & Tech

 Material: Chromium plated mild steel

Prepared By: K. Rajesh, AP/Mech, RMK Coll of


Engg & Tech
o The piston is the most active part of the engine.
o The movement of the piston changes
the volume inside the cylinder and provides
combustion space.

o Material : cast iron, aluminium alloy, nickel-iron


alloy, cast steel, etc.
Piston designs
 To provide a good sealing fit between the piston
and cylinder.
 There are two type of rings
1. COMPRESSION RINGS - Prevents gases
leaking from combustion chamber. These rings
are located at the top of the piston

2. OIL RINGS -
prev
ents lubricant entering into the combustion
chamber.
Too much oil film and the engine will use excessive
oil and too little oil causes heat and insufficient
lubrication
 The link between the crankshaft and the piston

 The connecting must withstand heavy thrust

 Cross section is an “H” or “I”


 It has passage for transfering lubricating oil from
the big end bearing to the small end bearing.
Dynamic Dampers can be mounted to the
crankshaft to reduce vibration
 Changes reciprocating motion of pistons into
rotating motion to drive propeller

 The propeller mounts front of the


to the
crankshaft using a spline, taper, or flange
The crankshaft rotates within the
crankcase and is supported by main
bearing journals

Dynamic Dampers can be mounted to


the crankshaft to reduce vibration
 Counterweights are also used to reduce vibration
 Counterweights and dampers are used in piston
engines because the power pulses and
movement of the pistons create large amounts of
vibration

 The engine is also mounted in rubber bushings to


absorb vibration

 Material: Plain carbon steel, Al alloy, nickel


alloy steels
 Turns at 1/2 the speed of the crankshaft

 Must be mechanically coupled to the crankshaft


for timing 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

 Material:Plain carbon steel, Al alloy,


nickel alloy steels
 Valves control the flow of gases inside the engine
 Poppet valves are the most common and get their
name 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 wear and
corrosion
 Valve faces are ground to 30 degrees for intake
(airflow) and 45 degrees (cooling) for exhaust
Prepared By: K. Rajesh, AP/Mech, RMK Coll of
Engg & Tech
LECTURER HOUR – 9
Actual Valve Timing Diagram
1.9 Variable Valve Timing
• This engine has a variable valve timing system, which
adjusts the opening and closing timings of the intake
valves optimally by continuously changing the phase
angle of the camshaft sprocket relative to the camshaft.

• The ECM determines the optimal cam angle relative to


the crank angle by making reference to the engine speed,
vehicle speed, throttle opening and other relevant
parameters.
1.9 Variable Valve Timing
• Under the control of the ECM, the oil flow control valve
moves its spool to switch the hydraulic passage to/from
the advance and retard chambers that are formed in the
camshaft sprocket to change continuously the phase
angle between the camshaft sprocket and camshaft.
1.9 Variable Valve Timing
1.9 Variable Valve Timing
• Advantages:
• Improved torque
• Reduced nitrogen and hydrocarbon emission
• Improve fuel and battery economy
Assignment
• Comparison between four stroke and two stroke engine.
• Comparison between SI and CI engine.

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