MID TERM REPORTON

ONE SEMESTER INDUSTRIAL TRAININGAT

NAME OF INDUSTRY

Submitted to

I. K. G. PUNJAB TECHNICAL UNIVERSITY, JALANDHAR

In partial fulfillment of the requirements for the award of the Degree of

Bachelor of Technology in

Mechanical Engineering

By

NAME OF STUDENT :Wilson aziz

Univ. Roll No. 1512668

Under the guidance of

Academic Tutor:Er.kuldeepak thakur Industrial Tutor

) Er. Harish chander(Q.E)

Department of Mechanical Engineering

RayatBahra Institute of Engineering & Nanotechnology

Hoshiarpur

CONTENTS

Acknowledgement i
About the training ii

Contents iii

Abstracts iv

Introduction v

Acknowledgement
I would like to express my special thanks of gratitude to my INDUSTRIAL

INSTRUCTOR (HARISH CHANDER) who gave me the golden opportunity to do

this wonderful project on the topic (ENGINEERING QUALICY CONTROL ON

ENGINES), which also helped me in doing a lot of Research and i came to know

about so many new things I am really thankful to them.

Secondly i would also like to thank my parents and friends who helped me a lot in

finalizing this project within the limited time frame.

ABOUT TRAINING

Training is teaching, or developing in oneself or others, any skills and knowledge

that relate to specific useful competencies. Training has specific goals of improving

one's capability, capacity, productivity and performance. It forms the core

ofapprenticeships and provides the backbone of content at institutes of technology

also known as technical colleges or polytechnics. In addition to the basic training

required for a trade, occupation or profession, observers of the labor-market recognize

as of 2008 the need to continue training beyond initial qualifications: to maintain,

upgrade and update skills throughout working life. People within many professions

and occupations may refer to this sort of training as professional development.we

have attented our industrial training at ITL Hoshiarpur .during the training we have

gained lots of experience and learned about various technologies those are we haven’t

know about before so I found this training very use full in my future . I am giving my

best regards to my teacher and also my cotrainees

Abstracts

As I learned to many things those are related to my core(M.E). every mechanical engr.

Have knowledge of various tools like vernier caliper and micrometer I think while

starting any kind of production its very necessary to control the quality of product in

order to survive in the market .so every industry have their own R&D as well as QC

department . this project report is solely is based on quality of engines and their

production line .i found every engine should folloing various stages in order to being
manufacture so this project report file is based on component and assembly of engines

and their quality control

INTRODUCTION

An engine or motor is a machine designed to convert one form of energy into

mechanical energy. Heat engines burn a fuel to create heat which is then used to do
work. Internal combustion engines are heat engines that burn fuel in a combustion

chamber to extract work from the pressure of expanding gases.Electric motors

convert electrical energy into mechanical motion; pneumatic motors use compressed

air; and clockwork motors in wind-up toys use elastic energy. In biological systems,

molecular motors, like myosins in muscles, use chemical energy to create forces and

eventually motion.

Types of Engine:

Internal combustion (E.C.) Engine

External Combustion (I.C.) Engine

Types of Internal Combustion Engines:

Reciprocating and Rotary Engines.In automobiles, reciprocating engines are used.

They are the most widely used type of engine. Reciprocating engines are classified

into two types: spark ignition (SI) engines and compression ignition (CI) engines.

working principle of diesel engine:

The diesel engine (also known as a compression-ignition or CI engine)is an internal

combustion engine in which ignition of the fuel, which is injected into the combustion

chamber, is caused by the elevated temperature of the air in the cylinder due to the

mechanical compression. Diesel engines work by compressing only the air. This

increases the air temperature inside the cylinder to such a high degree that atomised
diesel fuel injected into the combustion chamber ignites spontaneously. This contrasts

with spark-ignition engines such as a petrol engine or gas engine which use a spark

plug to ignite an air-fuel mixture. In diesel engines, glow plugs (combustion chamber

pre-warmers) may be used to aid starting in cold weather, or when the engine uses a

lower compression-ratio, or both. The original diesel engine operates on the constant

pressure cycle of gradual combustion and produces no audible knock

COMPONENTS OF IC ENGINE

Crankcase

A crankcase is the housing for the crankshaft in a reciprocating internal combustion

engine. The enclosure forms the largest cavity in the engine and is located below the

cylinder, which in a multicylinder engine is usually integrated into one or several

cylinder blocks.crankcase is a metal cast case used to cover the crankshaft of an

 engine.

The crankshaft

of the engine

is mounted

onto the

grooves of

the crankcase.

It is an

assembly.Crankcases and other basic engine structural components are typically made

of cast iron or cast aluminium via sand casting.

Fuel pump

The main object of a fuel pump in a diesel engine is to deliver a fuel to the injector

which spray the finely divided particles of the fuel suitable for rapid combustion. It

consist of a plunger which moves up and down in the barrel by the cam and spring

arrangement provided for pushing and lowering the plunger respectively.when the

plunger is at the bottom of its stroke the fuel enters the barrel through the inlet port

.As the plunger rises,it forces this fuel up into the injector ,until the upper part cut

away comes opposite the sill port

Liner

A cylinder liner is a cylindrical part to be fitted into an engine block to form a

cylinder. It is one of the most important functional

parts to make up the interior of an engine.It can be

replaced when worn out.As the material required

for liner is comparatively small,it can be

made of alloy cast iron having long life and

sufficient resistance to rapid wear and tear to the fast moving reciprocating parts.

Crankshaft

A crankshaft related to crank is a mechanical part able to perform a conversion

between reciprocating motion and rotational motion. In a reciprocating engine, it

translates reciprocating motion of the piston into rotational motion with the help of

connectimg rod.. This shaft contains one or more eccentric portion called cranks. That

part of the crank, to which bigger end of the connecting rod is fitted, is called crank

pin.special steel alloys are used for the manufacturing of crankshaft.

Piston

A piston is a component of reciprocating engines, reciprocating pumps, gas

compressors and pneumatic cylinders, among other similar mechanisms. It is the

moving component that is contained by a cylinder and is made gas-tight by piston

rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder

to the crankshaft. The piston are generally made of aluminium alloys which are light

in weight. aluminium may be alloyed with one or more other elements like copper,

magnesium,manganese,silicon and nickel. They have good heat conducting property

and also greater strength at higher temperature.

Piston rings

These are circular rings and made of special steel alloys which retain elastic

properties even at high temperature. A piston ring is a split ring that fits into a groove

on the outer diameter of a piston in a reciprocating engine such as an internal

combustion engine or steam engine.the pistpn rings are housed in the circumferential

grooves provided on the outer surface of the piston. Generally, there are two types of

rings mounted for the piston. The function of the upper rings to provide air tight seal

to prevent leakage of the burnt gases into the lower portion.the function of second

ring is to scribe the oil.similarly,the function of the lower rings is to provide effective

seal to prevent leakage of the oil into the engine cylinder.

Connecting rod

A connecting rod is a rigid member which connects a piston to a crank or crankshaft

in a reciprocating engine. Together with the crank, it forms a simple mechanism that

converts reciprocating motion into rotating motion. A connecting rod may also

convert rotating motion into reciprocating motion.the upper end of the connecting rod

is fitted to the piston and the lower end to the crank.The special steel alloy or

aluminium alloys are used for the manufacturing of connecting rods, as it is subjected

to alternatively compressive and tensile stresses as well as bending stresses.

Flywheel

It is a big wheel mounted on

the crankshaft,whose function is to maintain its speed constant .it is done by storing

excess energy during thr power stroke. Which is returned during other stroke.it is a

energy storing device which is used to store the energy when supply of energy is more

then the requirement and release energy when supply of energy is less then the

requirement.Flywheels are often used to provide continuous power output in systems

where the energy source is not continuous.Flywheels are made cast iron.The

efficiency of a flywheel is determined by the maximum amount of energy it can store

per unit weight.

Cylinder head

In an internal combustion engine, the cylinder head sits above the cylinders on top of
the cylinder block. It closes in the top of the cylinder, forming the combustion

chamber. This joint is sealed by a head gasket.The cylinder head contains inletvand

exit valves for admitting fresh charge and exhausting the burnt gases.it contains inlet

and exhaust manifold and valve mechanism. It also contain nozzle for injectingthe

fuel into the cylinder. The cylinder block and cylinder head are made from the same

material. It is generally made of cast iron. A asbestos gasket is provided between the

engine cylinder and cylinder head to make an air-tight joint.

Camshaft

The camshaft is a mechanical component of an internal combustion engine. It opens

and closes the inlet and exhaust valves of the engine at the right time, with the exact

stroke and in a precisely defined sequence. The camshaft is driven by the crankshaft

by way of gearwheelsIn internal combustion engines with pistons, the camshaft is

used to operate valves. It consists of a cylindrical rod running the length of the

cylinder bank with a number of oblong lobes protruding from it, one for each valve.

The cam lobes force the valves open by pressing on the valve, or on some

intermediate mechanism, as they rotate.used in high volume production, chilled iron

camshafts have good wear resistance since the chilling process hardens them. Other

elements are added to the iron before casting to make the material more suitable for

its application.

Tappet

A tappet is a projection that imparts a linear motion to some other component within a

mechanism.To reduce wear from the rotating camshaft, the tappets were usually

circular and allowed or even encouraged to rotate.To reduce wear from the rotating

camshaft, the tappets were usually circular and allowed to rotate.

Pushrod

A rod operated by cams that opens and closes the valves in an internal combustion

engine. pushrod engine is a reciprocating piston engine whose poppet valves are sited

in the cylinder head. An OHV engine's valvetrain operates its valves via a camshaft

within the cylinder block, cam followers pushrods and rocker arms.
Rocker arm

A rocker arm is an oscillating lever that conveys radial movement from the cam lobe

into linear movement at the poppet valve to open it. One end is raised and lowered by

a rotating lobe of the camshaft directly or via a tappet while the other end acts on the

valve stem. When the camshaft lobe raises the outside of the arm, the inside presses

down on the valve stem, opening the valve. When the outside of the arm is permitted

to return due to the camshafts rotation, the inside rises, allowing the valve spring to

close the valve.Tractor engines use stronger and stiffer rocker arms made of cast iron

or forged carbon steel.

Valves

Every cylinder in an internal-combustion engine contains one intake valve and one

exhaust valve. Both valves open and close internal passages in the cylinder head. The

intake valve is the larger of the two valves. It controls the flow of fuel into the

combustion chamber.the intake valves are made of an alloy that contains 8.5 percent

chromium. Exhaust valves may be made from a martensitic steel with chrome and

silicon alloys or a two-piece valve with a stainless steel head and martensitic steel

stem.
Oil pan

The oil pan is attached to the bottom of the engine with bolts and is the reservoir for

oil that gets pumped throughout the engine to lubricate clean and cool moving parts. A

pump forces the oil from the pan through a filter to remove dirt and other debris

before it circulates through the engine. The pan is usually made of steel or

aluminum.The oil dipstick extends into the oil pan and measures the oil level in the

reservoir. A drain plug on the bottom can be removed to drain oil.Gaskets or seals

installed where the pan attaches to the engine.

Suction strainer

A pump suction strainer or inlet strainer is a type of filtering device that attaches to a
oil pump's inlet port and prevents particulate from damaging the pump or passing

through the system to the final outlet.

Oil pump

The oil pump in an internal combustion engine circulates engine oil under pressure to

the rotating bearings, the sliding pistons and the camshaft of the engine. This

lubricates the bearings, allows the use of higher-capacity fluid bearings and also

assists in cooling the engine. generally we use gear pump in tractor engine. A gear

pump uses the meshing of gears to pump fluid by displacement. They are one of the

most common types of pumps for hydraulic fluid power applications. The gear pump

was invented around 1600 by Johannes Kepler .Gear pumps are positive displacement

meaning they pump a constant amount of fluid for each revolution.

Piston pin

The connecting rod is connected to the

piston through the piston pin. It is made of
case hardened alloy steel with precision
finish.

COOLING SYSTEM
A system, which controls the engine temperature, is known as a cooling system.

NECESSITY OF COOLING SYSTEM

The cooling system is provided in the IC engine for the following reasons:

• The temperature of the burning gases in the engine cylinder reaches up to 1500 to

2000°C, which

is above the melting point of the material of the cylinder body and head of the engine.

(Platinum, a

metal which has one of the highest melting points, melts at 1750 °C, iron at 1530°C

and

aluminium at 657°C.) Therefore, if the heat is not dissipated, it would result in the

failure of the

cylinder material.

• Due to very high temperatures, the film of the lubricating oil will get oxidized, thus

producing
carbon deposits on the surface. This will result in piston seizure.

• Due to overheating, large temperature differences may lead to a distortion of the

engine

components due to the thermal stresses set up. This makes it necessary for, the

temperature

variation to be kept to a minimum.

• Higher temperatures also lower the volumetric efficiency of the engine.

REQUIREMENTS OF EFFICIENT COOLING SYSTEM

The two main requirements of an efficient cooling system are:

1. It must be capable of removing only about 30% of the heat generated in the

combustion chamber. Too

much removal of heat lowers the thermal efficiency of the engine.

2. It should remove heat at a fast rate when the engine is hot. During the starting of

the engine, the

cooling should be very slow so that the different working parts reach their operating

temperatures in a short

time.

TYPES OF COOLING SYSTEM

There are two types of cooling systems:

(i) Air cooling system and

(ii) Water-cooling system.

AIR COOLING SYSTEM

In this type of cooling system, the heat, which is conducted to the outer parts of the

engine, is radiated and conducted away by the stream of air, which is obtained from

the atmosphere. In order to have efficientcooling by means of air, providing fins

around the cylinder and cylinder head increases the contact area. The fins are metallic

ridges, which are formed during the casting of the cylinder and cylinder head

The amount of heat carried off by the air-cooling depends upon the following factors:
(i) The total area of the fin surfaces,

(ii) The velocity and amount of the cooling air and

(iii) The temperature of the fins and of the cooling air.

Air-cooling is mostly tractors of less horsepower, motorcycles, scooters, small cars

and small aircraft engines where the forward motion of the machine gives good

velocity to cool the engine. Air-cooling isalso provided in some small industrial

engines. In this system, individual cylinders are generally employed to provide ample

cooling area by providing fins. A blower is used to provide air.

Advantages of Air Cooled Engines

Air cooled engines have the following advantages:

1. Its design of air-cooled engine is simple.

2. It is lighter in weight than water-cooled engines due to the absence of water jackets,

radiator, circulating pump and the weight of the cooling water.

3. It is cheaper to manufacture.

4. It needs less care and maintenance.

5. This system of cooling is particularly advantageous where there are extreme

climatic conditions in the arctic or where there is scarcity of water as in deserts.

6. No risk of damage from frost, such as cracking of cylinder jackets or radiator water

tubes.

WATER COOLING SYSTEM

It serves two purposes in the working of an engine:

a) It takes away the excessive heat generated in the engine and saves it from over

heating. b) It keeps the engine at working temperature for efficient and economical

working. This cooling system has four types of systems:

(i) Direct or non-return system,

(ii) Thermo-Syphone system,

(iii) Hopper system and

(iv) Pump/forced circulation system.

Though the present tractor has a forced circulation system, it is still worthwhile to get

acquainted with the other three systems.

Non-Return Water Cooling System

This is suitable for large installations and where plenty of water is available. The

water from a storage tank is directly supplied to the engine cylinder. The hot water is

not cooled for reuse but simply discharges. The low H.P. engine, coupled with the

irrigation pump is an example.

Thermo-Syphone Water Cooling System

This system works on the principle that hot water being lighter rises up and

the cold water being heavier goes down. In this system the radiator is placed at a

higher level than the engine for the easy flow of water towards the engine. Heat is

conducted to the water jackets from where it is taken away due to convection by the

circulating water. As the water jacket becomes hot, it rises to the top of the radiator.

Cold water from the radiator takes the place of the rising hot water and in this way a
circulation of water is set up the system. This helps in keeping the engine at working

temperature.

Disadvantages of Thermo-Syphone System

1 Rate of circulation is too slow.

2. Circulation commences only when there is a marked difference in temperature.

3. Circulation stops as the level of water falls below the top of the delivery pipe of the

radiator. For these reasons this system has become obsolete and is no more in use.

Hopper Water Cooling System

This also works on the same principle as the thermo-syphone system. In this there is a

hopper on a jacket

containing water, which surrounds the engine cylinder. In this system, as soon as

water starts boiling, it is replaced by cold water. An engine fitted with this system

cannot run for several hours without it being refilled with water.

Force Circulation Water Cooling System

This system is similar in construction to the thermo-syphone system except that it

makes use of a centrifugal pump to circulate the water throughout the water jackets

and radiator The water flows from the lower portion of the radiator to the water jacket

of the engine through the centrifugal pump. After the circulation water comes back to

the radiator, it loses its heat by the process of radiation. This system is employed in

cars, trucks, tractors, etc.