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AUTOMOTIVE ENGINEERING
INTERNAL COMBUSTION
ENGINES (ICE) - 1
Djoko W. Karmiadji

COURSE GOALS

This course has two specific goals:

i. To introduce students to basic concepts of
automotive engineering to develop the design
method of engine and power trains.
ii. To develop analytical skills relevant to the areas
mentioned in (i) above in the field of
mechanical engineering.

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COURSE OBJECTIVES

Upon successful completion of this course, students should

be able to:
1. Determine the solution of automotive engineering
problems.
2. Familiarize the standard method of automotive
technology.
3. Analyze the problem solution induces in automotive
engineering systems by emphasizing the regulation and
standard of automotive.
4. Apply sound analytical techniques and logical procedures
in the solution of automotive development problems.

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TEACHING STRATEGIES

■ The course will be taught via Lectures and

Tutorial Sessions, the tutorial being designed
to complement and enhance both the
lectures and the students appreciation of the
subject.
■ Course work assignments will be reviewed
with the students.
Attendance at Lectures and Tutorials is
Compulsory

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TASK OF AUTOMOTIVE
ENGINEERING

1. Create a paper/project design related to the topic of

"Development of Automotive Engine/Power Train"
2. Down load scientific articles/standards related to
automotive engine/power train (in English) and
translate into Indonesian language. Furthermore, the
topics should be presented. Each student is 1 topic
and should not be the same.

Note: Duty is submitted / sent via email to: dkarmiadji@yahoo.com

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DESIGN PROPOSAL

– Introduction to topic
– Literature Review
– Design Research
Methodology
– Proposed Approach
– Design Research Schedule
– References
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INTERNAL COMBUSTION
ENGINES (ICE)
1. INTRODUCTION

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Introduction to Internal Combustion Engines.

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Introduction to Internal Combustion

Engines.
The internal combustion engine is a heat engine that converts
chemical energy in a fuel into mechanical energy

This thermal energy raises the temperature and pressure of the gases
within the engine, and the high-pressure gas then expands against the
mechanical mechanisms of the engine. This expansion is converted by the
mechanical linkages of the engine to a rotating crankshaft, which is the
output of the engine.
Internal combustion engines are reciprocating engines having pistons
that reciprocate back and forth in cylinders internally within the engine.

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Introduction
- Reciprocating piston-cylinder geometry (since late 1800s)
- Thermal efficiency increased from 10-20% (20th century) to
50% today
- Corporate Average Fuel Economy (CAFE)=> 27.5 mpg (1990-
2010), 35.5 mpg (2016), & 54.5 mpg (2025)
- In 1900, +/- 4,200 automobiles
were sold, (40% steam powered,
38% battery/electric & 22%
gasoline engine powered)
- In 2010, +/- 220 million motor
vehicles in USA alone
- ICE range 0.01 to 20 x 103 kW
- Current ICE is 5% lower emission
than 40 years ago

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Historical Background
- 1858, J. Lenior (1822-1900), Belgian engineer => two-stroke
engine (6 hp, efficiency 5%).
- 1872, George Brayton (1830-1892), American mechanical
engineer=> patented and commercialized a constant pressure
internal combustion engine. Automobile in 1878.
- 1876 Nikolaus Otto (1832-1891), a German engineer=> ‘‘Otto
Silent Engine’’, 1st practical four-stroke engine with in-cylinder
compression. (CR 2.5, 2 hp at 160 rpm, brake efficiency 14%).

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Historical Background
- 1878, Sir Dugald Clerk (1854-1932), a Scottish mechanical
engineer=> first practical two-stroke engine.
- 1883, Gottlieb Daimler (1834-1900), German engineer => high-
speed four-stroke gasoline-fueled engine. 1886=>first four-
wheeled automobile.
- 1885, Karl Benz (1844--1929), German engineer, =>3.5 hp
liquid fueled two-stroke engine carburetor & spark ignition.
1886, the first ‘‘horseless carriage”.
- 1889 Joseph day designed the crankcase-compression two-
stroke engine as it is widely known today

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Historical Background
- 1890, Gottlieb Daimler and Wilhelm Maybach, start the first
automobile company, the Daimler Motor Company. Otto’s son
Gustav=>BMW
- 1896 Henry Ford (1863-1947) builds his first
car, called the Quadricycle.
- 1897, Rudolph Diesel (1858--1913), a
German engineer, => 1st practical four-stroke
engine using direct injection of liquid fuel
into the combustion chamber. Bore 250 mm,
stroke 400 mm, 20 L displacement, speed 170
rpm, 18 hp, efficiency 27% at full load.

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Historical Background
- Sir Harry Ricardo (1885-1974), English mechanical engineering
=>spherical prechamber, increase the fuel--air mixing rate, high-
speed, 2000 rpm and higher.
- 1924, 1st multi-cylinder diesel engines for trucks & 1936, first
diesel-powered automobiles.
- 1908 Ford Model T introduced. (1909 Henry Ford sold over 10,000 Model
Ts -a staggering figure in those days. By using mechanical-driven conveyors, Ford
introduced the moving assembly line and further improved his production processes.
While Model T sales soared to almost a quarter million cars in 1914, Ford gradually
reduced the price from $950 to $490. By 1925 the basic price of his car had been
lowered to $290. By 1927 1.5 Million were produced)
- Henry Ford’s Model T engine of 1908, and the Wright Brother’s
Flyer engine of 1903 used natural convection water cooling

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INTERNAL COMBUSTION
ENGINES (ICE)
2. BASIC ENGINES

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Principles of Engine Operation

■ Converts chemical energy into mechanical

energy
■ Gasoline engine is an internal combustion (the
burning of a fuel within an enclosed space)
engine
■ Gasoline must ignite easily and burn quickly
■ Energy produced by burning gasoline must be
controlled

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Gasoline Must Be Atomized

■ The more surface area exposed to air, the more
vapor will be given off
■ More vapor leads to faster burning
■ Gasoline must be atomized
■ Atomization (process of breaking gasoline into
tiny droplets and mixing it with air to produce the
rapid burning required in an engine)
– Increased burning area
– Explosive release of heat energy

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Elementary Engine

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Two- and Four-Stroke Engines

■ Engines identified by number of piston strokes
(movement of a piston in the cylinder from one
end of its travel to the other) required to
complete one operating cycle
■ Each stroke is either toward the rotating
crankshaft or away from it
– Bottom dead center (the lowest point of
piston travel. Abbreviation is BDC)
– Top dead center (the point at which the
piston is at its upper most position on the
compression stroke)
■ Strokes identified by job they perform
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Four-Stroke Engine

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Basic Components of Four-Stroke Engines

■ A. Intake Valve- opens at the proper time to let in air and fuel.
■ B. Valve Cover- Protects the valves and the valve springs. Keeps dirt
out and lubricating oil in.
■ C. Intake Port- the passageway in a cylinder head for the fuel and air
to pass through.
■ D. Head- a platform containing most of the parts of the combustion
chamber.
■ E. Coolant- circulating water and antifreeze to keep the temperature
regulated.
■ F. Engine Block- cast in one piece. The basis for most of the parts of
the engine.
■ G. Oil Pan- where the oil is collected and recirculated.
■ H. Oil Sump- the collected oil primarily for lubricating the crankshaft
and rod bearing.

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Basic Components of Four-Stroke Engines

■ I. Camshaft- a round shaft with lobes, that rotates to open and close
the fuel and exhaust valves.
■ J. Exhaust Valve- open at the proper time to release the exhaust
■ K. Spark Plug- a device, inserted into the combustion chamber for
firing an electrical spark to ignite air-fuel mixture
■ L. Exhaust Port- the passageway in a cylinder head, for the exhaust
to pass through
■ M. Piston- the part of the engine that moves up and down in the
cylinder converting the gasoline into motion
■ N. Connecting Rod- links the piston to the crankshaft.
■ O. Rod Bearing- used to reduce friction to the rod and crankshaft
■ P. Crankshaft- converts the up and down motion of the piston into a
turning, or rotating motion

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Four-Stroke Engine

■ Intake- process of filling the cylinder with the

proper air-fuel mixture through the intake valve.
■ Compression- the process of compressing the
air-fuel mixture in the cylinder to make it more
combustible
■ Combustion- the process of igniting the
compressed air-fuel mixture to create motion and
the over all power of the engine.
■ Exhaust- the process of releasing the exhaust
out of the cylinder through the exhaust valve.

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Two-Stroke Cycle Engines

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Comparison of Two-Stroke
vs. Four-Stroke Cycle Engines

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TERMINOLOGY AND ABBREVIATIONS

The following terms and abbreviations are commonly used in engine
technology
■ Internal Combustion (IC)
■ Spark Ignition (SI) An engine in which the combustion process in
each cycle is started by use of a spark plug.
■ Compression Ignition (CI) An engine in which the combustion
process starts when the air-fuel mixture self-ignites due to high
temperature in the combustion chamber caused by high
compression.
■ Top-Dead-Center (TDC) Position of the piston when it stops at the
furthest point away from the crankshaft.
■ Bottom-Dead-Center (BDC) Position of the piston when it stops at the
point closest to the crankshaft.
■ Direct Injection (DI) Fuel injection into the main combustion
chamber of an engine.

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TERMINOLOGY AND ABBREVIATIONS

■ Indirect Injection (IDI) Fuel injection into the secondary chamber of
an engine with a divided combustion chamber.
 Bore Diameter of the cylinder or diameter of the piston face, which is
the same minus a very small clearance.
 Stroke Movement distance of the piston from one extreme position
to the other: TDC to BDC or BDC to TDC.
 Clearance Volume Minimum volume in the combustion chamber
with piston at TDC.
 Displacement or Displacement Volume Volume displaced by the
piston as it travels through one stroke.
 Smart Engine Engine with computer controls that regulate operating
characteristics such as air-fuel ratio, ignition timing, valve timing,
exhaust control, intake tuning, etc.
 Air-Fuel Ratio (AF) Ratio of mass of air to mass of fuel input into
engine.
 Fuel-Air Ratio (FA) Ratio of mass of fuel to mass of air input into
engine.
 Ignition Delay (ID) Time interval between ignition initiation and the
actual start of Combustion

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INTERNAL COMBUSTION
ENGINES (ICE)
3. ENGINE CLASSIFICATIONS

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ENGINE CLASSIFICATIONS
Internal combustion engines can be classified in a number of different ways:

1. Types of Ignition
(a) Spark Ignition (SI). An SI engine starts the combustion process in each cycle by
use of a spark plug. The spark plug gives a high-voltage electrical discharge
between two electrodes which ignites the air-fuel mixture in the combustion
chamber surrounding the plug.
(b) Compression Ignition (CI). The combustion process in a CI engine starts when the
air-fuel mixture self-ignites due to high temperature in the combustion chamber
caused by high compression.
2. Engine Cycle

(a) Two-Stroke Cycle. A two-stroke cycle has two piston movements over one
revolution for each cycle.
(b) Four-Stroke Cycle. A four-stroke cycle experiences four piston movements over
two engine revolutions for each cycle.

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ENGINE CLASSIFICATIONS
3. Valve Location
(a) Valves in head (overhead valve), also called I Head engine.
(b) Valves in block (flat head), also called L Head engine. Some historic engines with
valves in block had the intake valve on one side of the cylinder and the exhaust
valve on the other side. These were called T Head engines.

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ENGINE CLASSIFICATIONS
4. Basic Design

(a) Reciprocating. Engine has one or more cylinders in which pistons reciprocate back
and forth. The combustion chamber is located in the closed end of each cylinder.
Power is delivered to a rotating output crankshaft by mechanical linkage with the
pistons.
(b) Rotary. Engine is made of a block (stator) built around a large non-concentric
rotor and crankshaft. The combustion chambers are built into the non-rotating
block.
5. Position and Number of Cylinders
(a) Single Cylinder. (d) Opposed Cylinder Engine. (g) Radial Engine.
(b) In-Line. (e) W Engine.
(c) V Engine. (f) Opposed Piston Engine.

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ENGINE CLASSIFICATIONS

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ENGINE CLASSIFICATIONS
6. Air Intake Process

(a) Naturally Aspirated. No intake air pressure boost system.

(b) Supercharged. Intake air pressure increased with the compressor driven
off of the engine crankshaft.
(c) Turbocharged. Intake air pressure increased with the turbine-compressor
driven by the engine exhaust gases.
(d) Crankcase Compressed. Two-stroke cycle engine which uses the crankcase as the
intake air compressor. Limited development work has also been done on design
and construction of four-stroke cycle engines with crankcase compression.

7. Method of Fuel Input for SI Engines

(a) Carbureted.
(b) Multipoint Port Fuel Injection. One or more injectors at each cylinder intake.
(c) Throttle Body Fuel Injection. Injectors upstream in intake manifold.

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ENGINE CLASSIFICATIONS
8. Fuel Used
(a) Gasoline.
(b) Diesel Oil or Fuel Oil.
(c) Gas, Natural Gas, Methane.
(d) LPG.
(e) Alcohol-Ethyl, Methyl.
(f) Dual Fuel. There are a number of engines that use a combination of two or more
fuels. Some, usually large, CI engines use a combination of methane and diesel fuel.
These are attractive in developing third-world countries because of the high cost of
diesel fuel. Combined gasoline-alcohol fuels are becoming more common as an
alternative to straight gasoline automobile engine fuel.
(g) Gasohol. Common fuel consisting of 90% gasoline and 10% alcohol.

9. Application
(a) Automobile, Truck, Bus.
(b) Locomotive.
(c) Stationary.
(d) Marine.
(e) Aircraft.
(f) Small Portable, Chain Saw, Model Airplane.
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ENGINE CLASSIFICATIONS
1O. Type of Cooling
(a) Air Cooled.
(b) Liquid Cooled, Water Cooled.

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INTERNAL COMBUSTION
ENGINES (ICE)
4. ENGINE PARTS

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ENGINE COMPONENTS
Name of Engine Parts

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Engine Upper End

■ Parts of the upper end of the engine
– Cylinder head(s) and valve train
■ Valve train
– Includes parts that open and close the valves
– Cam: located either in block or cylinder head
– Rocker arms: mounted on top of cylinder
head
– Pushrod engines: cam bearings are pressed
into bores in the block
– Overhead cam: cam journals ride in bores in
the cylinder head
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Cylinder Head

■ Cylinder head: bolts to the top of the engine

block, sealing off the cylinders
■ Valve parts
– Two valves per cylinder in combustion
chambers
■ Intake valve is the larger
– Several other valve parts
■ Intake manifold: bolted to side of a head or
between cylinder heads
■ Exhaust manifold: bolted to cylinder head

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Cylinder Head

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Cylinder Head

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Cylinder Block

“Backbone” of the engine.

Supports / aligns most
other components.
Part of basic tractor frame.
Contains:
Cylinders
Coolant passages
Oil passages
Bearings
One-piece, gray cast iron

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Cylinders
• Cylindrical holes in
which the pistons
reciprocate.
• May be:
– Enblock
– Liners
• Wet liners
• Dry liners
• Cylinder bore –
diameter of cylinder

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Intake Manifold

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Exhaust Manifold

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Valve Train
• Controls flow into and out of
the combustion chamber.
– Time and Duration
• Tractor engines use
“Overhead Valve (OHV)”
configuration.
• Components
– Camshaft
– Valve tappets
– Push rods
– Rocker arm
– Valves
– Valve springs
– Valve rotators
– Valve seats

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Camshaft
Open the intake and exhaust valves at correct time and for correct duration.
Driven by gear (or chain) from the crankshaft.
2:1 crankshaft to camshaft gear ratio.
Lift
Nose

Base circle

Cam Profile

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Engine Front
■ Camshaft: driven by timing gears or sprockets
– Used with a timing chain or belt
■ Timing cover: seals against oil leakage
– Keeps elements out of engines with a timing
belt
■ Vibration damper: minimizes vibrations in the
crankshaft and prevents damage
– Outer and inner ring are separated by thin
rubber strip
■ Also called harmonic balancer

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Timing Cover

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Cylinder Block Assembly (Lower

End)
■ Cylinder block
– Cast from iron or aluminum
– Crankshaft and bearings are in the crankcase
– Main bearing bores accommodate the
crankshaft
– Main bearing caps allow for installation and
removal of the crankshaft
– Cylinder head gasket fits between the head
and the deck

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Cylinder Block Casting

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Lower End Parts

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Short Block and Long Block

■ Long block: complete block assembly with entire

valve train
■ Short block: cylinder block assembly without
heads installed
■ Crankshaft: converts reciprocating motion to
rotating motion
■ Connecting rod: shaped like an I-beam
– Large bore connects rod journal
– Rod cap is attached to bottom of the rod

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Crankshaft

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Short Block and Long Block

(cont'd.)

■ Piston skirt: fits to cylinder bore

– Typical piston has three ring grooves above
■ Two on top for compression rings
■ Bottom for oil control
■ Piston pin: installed on connecting rod small end
– Pin bores provide a pivot point for the piston pin
■ Piston rings: seal between piston ring grooves and cylinder
wall
– Keeps combustion pressure from entering crankcase

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Piston and Rings

• Piston
– Forms the “moveable
bottom’ of the
combustion chamber.
• Iron alloy or aluminum
• Rings
– Compression
– Oil-control
• Cast iron
• Piston pin

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Piston and Rings

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Short Block and Long Block

(cont'd.)
■ Oil seals: installed on the front and rear of
crankshaft
■ Oil pan: stamped sheet metal or plastic that
encloses the crankcase
■ Flywheel: used with manual transmission
– Weight carries crankshaft beyond BDC
– Ring gear provides a gear drive for the starter
– Provides a surface for the clutch to work upon
■ Torque converter and flexplate: replace flywheel in
automatic transmissions
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Flywheel & Flexplate

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Connecting Rod
• Connects the piston to
the crankshaft
• Converts reciprocating
piston motion to
rotary motion at the
crankshaft.
• Nomenclature
• Drop-forged steel

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Crankshaft

Works with connecting rod to change reciprocating to rotary motion.

Transmits mechanical energy from the engine.
Made of heat-treated steel alloys.

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Summary
■ One four-stroke cycle completes the intake,
compression, power, and exhaust strokes
– Camshaft turns once and crankshaft turns
twice during one four-stroke cycle
■ Piston motion is changed to rotary motion by the
connecting rod and crankshaft
■ Flywheel gives momentum to the crankshaft and
smoothes impulses between power strokes
■ Camshaft and valve train control the engine’s
intake and exhaust flow

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