By
NAME OF STUDENT
SRIKANT CHAMARTHI AKASH SHARMA
ROLL NO
09 ME 030 09 ME 009
Internship I / Internship- II Course At Escorts Pvt Ltd LINGAYAS UNIVERITY, FARIDABAD SESSION 2012-2013
A REPORT ON
09 ME 030 09 ME 09
MECHANICAL MECHANICAL
PROJECT REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS OF THE COURSE INTERNSHIP- I / INTERSHIP- II At ESCORTS PVT LTD
Guides
CERTIFICATE
This is to certify that the project report titled INTERNAL COMBUSTION ENGINE AND ITS TESTING PARAMETERS submitted by CHAMARHTI SRIKANT in partial fulfilment of the requirements of course code 483 (Internship -I) Course 484 (Internship- II) at ESCORTS PVT LTD as part of the degree of Bachelor Of Technology in MECHNICAL ENGINEERING of LINGAYAS UNIVERSITY, session 2012-2013 is a record of bonafide work carried out under my / our supervision and has not been submitted anywhere else for any other purpose.
ACKNOWLEDGEMENT
As I begin to reflect on the magnitude of this project report, I am reminded of the celebrated quarterback who sprints on to the field in the last quarter of the game, confers in the huddle, confidently strides out to the line of scrimmage and throws the perfect spiral pass fifty yards downfield into the end zone to score the winning touchdown. The fans cheer ,the coaches are thrilled and the quarterback joyously revels in the glory of winning the game . But it was a team effort , for a team makes each individual achieve more . I have never been known to have words fail me , but as I begin to put on paper the feelings I have towards the people who changed my heart , soul & thought , I am overwhelmed . There is a difficulty in assigning a hierarchy since it has been a true team effort from the beginning. I take this opportunity to acknowledge the invaluable support and guidance given by to Mr. RC.MEHTA, (Senior MANAGER , assembly line)) for putting his faith in me leading me through the projects. Sir, Thank you for being a light At the same time I would like to thank MR.NAGARJUN SINGH for all the support be it as good friend or as a colleague who helped me through the difficult times of the project and
ABSTRACT
I was working in the engine housing. Basically, I was supposed to check the engine performance, 25 engines per shift. I had to note down the testing readings per engine. I also had the opportunity to look into the assembly line but didnt have much concentration in the assembly line. The engine after the assembly is sent to the testing house from where it is sent to the final inspection. After the inspection is done, the engines are tagged as ok or not ok. The engines tagged as ok are sent to the main line assembly where they are assembled and to the further process. The engines tagged as not ok are sent for further correction and are checked according to their checklist manuals. The same procedure was repeated for all the engines. I studied the various combustion process and its measurement unit. I also studied the soot and its particulates which are mentioned in the further chapters. I also worked on the vertical rough boring machine for 15 days. My job was to clean the machine before sending it for the machining process.
TABLE OF CONTENTS
CERTIFICATE ACKNOWLEDGEMENT
iii iv
1
1.1 1.2 1.3
CHAPTER ONE
COMAPNY PROFILE THE FOUNDING PHILOSOPHY BACKGROUND 1 2 4
2
2.1 2.2 2.3 2.4 2.5 2.6 2.7
CHAPTER TWO
OVERVIEW-MANUFACTURING FARMTRAC LINE AXLE HOUSING IMAGE OF AXLE MANUFACTURING PROCESS OF REAR AXLE TRUMPET HOUSING CONSTRUCTION OF GTA 1040 5 6 6 7 10 13 13
3
3.1 3.2 3.3 3.4 3.5 3.6 3.7
ENGINE HOUSING
INTRODUCTION ENGINE SPECIFICATIONS CYLINDERICAL BLOCK IMAGE OF A CYLINDERICAL BLOCK FOUR SIDES OF CYLINDER BLOCK VERTICAL BORING MACHINE IMAGE OF VERTICAL BORING MACHINE 15 16 16 18 19 20 22
4
4.1 4.2 4.3 4.4 4.5 4.6 4.7
24 24 24 26 27 28 29
4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18
CI EIGINES COMBUSTION CHARACTERSITCS PARTICULATES SCIENTIFIC IDENTIFACTION OF PM PARTICULATE COMPOSITION SAMPLE OF SOOT PARTICLE FORMATION OF SOOT IGNITION DELAY FUEL IGNITON QYALITY FACTORS AFFECTING IGNITION DELAY TIME CETANE NUMBER MEASUREMENT
30 31 31 32 33 33 34 34 35 36 36
5
5.1 5.2
CHAPTER FIVE
INTRODUCTION POWER AND MECHANICAL EFFICIENCY 5.2.1 BRAKE POWER 5.2.2 INDICATED POWER 5.2.3 MEAN EFFECTIVE PRESSURE 5.2.4 FUEL-AIR RATIO 5.2.5 IMAGE OF TESTING PARAMETERS 5.2.6 EXHAUST MOKE ENGINE TESTING PROCESS 37 38 38 39 39 40 40 41
5.3
6
6.1 6.2
CHAPTER SIX
FUTURE SCOPE & CONCLUSION REFERCNCES 45 46
Chapter - 1
Throughout the evolution of Escorts, technology has always been its greatest ally for growth. In the over six decades of our inception, Escorts has been much more than just being one of India's largest engineering companies. It has been a harbinger of new technology, a prime mover on the industrial front, at every stage introducing products and technologies that helped take the country forward in key growth areas. Over a million tractors and over 16,000 construction and material handling equipment that have rolled out from the facilities of Escorts, complemented by a highly satisfied customer base, are testimony to the manufacturing excellence of Escorts. Following the globally accepted best manufacturing practices with relentless focus on research and development, Escorts is today in the league of premier corporate entities in India. Technological and business collaboration with world leaders over the years, globally competitive indigenous engineering capabilities, over 1600 sales and service outlets and footprints in over 40 countries have been instrumental in making Escorts the Indian multinational. At a time when the world is looking at India as an outsourcing destination, Escorts is rightly placed to be the dependable outsourcing partner of world's leading engineering corporations looking at outsourcing manufacture of engines, transmissions, gears, hydraulics, implements and attachments to tractors, and shock absorbers for heavy trailers. In today's Global Market Place, Escorts is fast on the path of an internal transformation, which will help it to be a key driver of manufacturing excellence in the global arena. For this we are going beyond just adhering to prevailing norms, we are setting our own standards and relentlessly pursuing them to achieve our desired benchmarks of excellence.
1.2
Over six decades back two young men set out on a journey together armed with little beyond intelligence, business acumen and determination and dreams aplenty. They believed that India could only achieve total freedom with a breakthrough in the field of agriculture and mechanization would have to rule the fields. Their youthful enthusiasm had kindled the hope that one day they would make a mark of their own. They were in fact writing the first chapter of what has come to be widely recognized as one of the greatest success stories in Indian industry. Escorts came into being with a vision. A vision that eschewed
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easy paths to profitability, and sought instead for ways to make a contribution. A vision that led two young brothers, Yudi and Hari Nanda, to branch out of their family's prospering transport business and institute ventures that were to become the foundations of Escorts Limited. On 17th October 1944, Escorts Agents Limited was born at Lahore (now in Pakistan) with Mr. Yudi Nanda as Managing Director and Mr. Hari Nanda as Chairman. It was a trendsetting marketing house driven by the same business philosophy, which had given their family enterprise an unrivalled reputation: customer concern. Not long afterwards, this driving ambition to go beyond the expected led Hari Nanda to the first of his many successful business insights - the discovery of the great business potential that lay in India's villages. This led to the launch, in 1948, of Escorts (Agriculture and Machines) Ltd., with Yudi Nanda as Director. Though separate business entities then, both companies had two great strengths in common: the dynamic Nanda brothers and the unifying force of the name they gave their companies; Escorts, literally 'escorting' their products and services to the customer while most other businessmen were just selling. Tragically, Mr. Yudi Nanda died in an accident in 1952 - but his spirit remained embedded in the foundations of the company. Mr. Nanda then took on the mantle to realize the dreams which he had always seen with his brother. Escorts (Agents) Ltd. and Escorts (Agriculture and Machines) Ltd. merged in 1953 to create a single entity -Escorts Agents Pvt Ltd. Having initially started with a franchise for Westinghouse domestic appliances, by this time the Company had already expanded its marketing and service operations, representing internationally known German and American organizations such as MAN, AEG, Haniel & Leug, Knorr Bremse, MIAG and BMA for sophisticated electrical and mechanical engineering equipment and Minneapolis Moline and Wisconsin for agricultural tractors, implements and engines. Escorts made a major thrust into the agricultural arena by taking on the marketing and service franchise for Massey Ferguson tractors in Northern India, which soon comprised 75% of MF's all-India sales - a signal tribute to Escorts' inherent strengths. Its first industrial venture came up in 1954, in partnership with Goetzewerke of Germany for the manufacture of piston rings and cylinder liners - followed by production of pistons in collaboration with MAHLE, also of Germany, in 1960.
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The company's incorporation in its present name, Escorts Limited, was effected on 18th January, 1960. Escorts' next major industrial activity was the assembly of tractors in 1961 in technical cooperation with URSUS of Poland. Subsequently this led to the manufacture of the country's first indigenous tractors under Escorts' own brand name, which were to play a pivotal role in the Green Revolution. This went on to lay the foundations that even today are the Company's core strengths -relevant, world-standard technology through strategic international alliances; a broad based marketing and service network yet unrivalled. Beyond the growth of the organization, these principles have ensured that Mr. H. P. Nanda's contribution to the cause of industry and the consumer will endure. He pioneered the revolutionary concept of interdependence between ancillary and large industries, institutionalizing vendor development and in the process building Faridabad and the entire belt of townships in the region. He introduced the discipline of service going before marketing, reassuring the customer that Escorts would stay with them that they were here for the long run.
1.3 Background
In 1960, our parent company, Escorts, set up the strategic Agri Machinery Group (AMG) to venture into tractors. In 1965, we rolled out our first batch of tractors under the brand name of Escort. In 1969 a separate company, Escorts Tractors Ltd., was established with equity participation of Ford Motor Co., Basildon, UK for the manufacture of Ford agricultural tractors in India. In the year 1996 Escorts Tractors Ltd. formally merged with the parent company, Escorts Ltd. Since inception, we have manufactured over 1 million tractors.
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Chapter-2
12
After the tractor is completely assembled, the tests are performed by checking the bhp and specific fuel consumption etc which are further explained in the further chapters. After the tests are performed and if tested ok, they are sent to the dispatch area from where they are sent to the showrooms.
13
In other types of suspension systems, the axles serve only to transmit driving torque to the wheels. The position and angle of the wheel hubs is a function of the suspension system. This is typical of the independent suspension found on new cars and on the front many light trucks.
The rear axle housings can be made so they can be dismantled (vertically). A housing that can be dismantled consists of two parts joined by bolts. The final drive is in the middle, wide part of the housing. In a rear axle with a housing that cannot be dismantled, the final drive has a separate housing that is fastened by bolts to the middle part of the housing. The wide middle part of the housing reduces the road clearance of the motor vehicle and makes it necessary to increase the height of the floor. In order to decrease the dimensions of this part of the housing (which is especially important for heavy-duty vehicles and for tractors), the reduction gear of the final drive is made smaller by introducing additional, so-called wheel, gearing.
Rear-wheel-drive tractors are very manoeuvrable and create little soil disturbance when turning. Large rear wheels provide the traction necessary to
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pull implements in firm to loose soil without undue soil compaction. Small front tires provide the operator with good visibility and are used to steer the tractor. It is important to match tractor size to pulling requirements and size of the implement. Consideration must be given to addition of wheel weights and/or liquid in the rear tires for increased traction. Weights on the front of the tractor are necessary for weight transfer (increased traction) and stability. Tractors are designed to pull either large loads at slow speeds or lighter loads at higher speeds. Field speeds up to 10 mph are possible, but rangeland applications usually vary from 2 to 5 mph. Many attachments are available including front-end loaders. Soil compaction from tractors can be a problem when soil moisture is high. The rear axle assembly is used on rear-wheel drive vehicles. This assembly is the final leg of the drive train. It is often called the final drive or rear end. The rear axle assembly is often mistakenly called the differential. The differential is only part of the rear axle assembly. The basic design of rear axle assemblies has been adopted by all manufacturers for many years. There are several variations, but all operate according to the same basic principles. The major difference between rear axle assemblies depends on whether the vehicle has solid-axle rear suspension or independent rear suspension. Solid-axle rear suspension incorporates rigid and nonflexing drive axles and axle tubes; both wheels move as one solid unit in response to bumps and potholes. Independent rear suspension incorporates jointed drive axles (no axle tubes) that allow for flexibility and independent axle movement.
15
16
S.NO
OPERATION
3 4
Drill and finish hole mill 8 nos bolt holes through and drill 2 nos manufacturing holes Form oil groove on stem end face Chamfering of back face of 8 nos bolt holes Milling of 38 involutes splines on stem end Washing of component
1. Drum dia 2. Big end flange dia 3. Length of drum dia 4. Flange width 5. Length of seal dia 6. Length of bearing dia 7. Thread size 8. Thread length 9. Length of splines 10. Length of seal dia 11. Stem dia 12. Fillet radius of stem taper dia 13. Surface finishing of stem taper dia 1. Bolt hole dia 2. Bolt hole coordinates 3. Manufacturing hole dia 4. Manufacturing hole co-ordinates 1. 2. 1. 2. Oil groove depth Oil groove profile Chamfer dia Chamfer angle
ETL- 01 VLM- 03
SMM-02 Hurth make spline milling machine WSM-01 thermas make washing machine
1. No of splines dia over measuring pins 2. PCD run out 3. Length od splines 1. Effective case depth on stem 2. Effective case depth towards flange dia 3. Effective case depth at rest dia of splines 4. Effective case depth at root of m-642 threads
3.55(jps)
5 (80jps)
17
IHM-03 IHM-04
1. Quenching media 2. Temp of quenching media 3. Pressure of quenching media 4. Radial gap b/w inductor and component 5. Quench lag time 6. Pre heating time 7. Power required 8. Spindle speed 9. Inductor transverse rate
Check file hardness at neck & stem Normalise the shaft if requires for rework Flange hardened stem and face Tamper the induction hardened shaft Straightening of shaft stem Grinding of seal dia& finish grinding of bearing dia & bearing seating face Finish grinding of seal dia
10
11
12
13
IHM-04 Induction hardening machine Flange hardening equipment TFF-04 TFF-05 Tampering furnace HDP-05 BEMCO make hydraulic press AGR-07 Angular head grinder
Surface hardness
Runout on 47 involute spline dia 1. Seal dia 3.45(139jps) 2. Bearing dia 3. Surface finish on bearing dia 4. Dist of bearing seating face from flange front Length of seal dia surface 2.91(165jps) finish of seal dia
14
18
15
16
17 18
Check crack on rear axle shaft Final inspection of shaft rear axle
SFM-02 suffina make super finishing machine Magna flux crack detector stage
1. Surface finish of stem end face 2. Length of stem end face wrt bearing seating face 1. Seal dia surface finish of seal dia
4.21(132jps)
2(132jps)
The rear axle assembly includes the differential assembly, the rear drive axles, and the rear axle housing. Rear axle assemblies are subjected to heavy loads from the engine and road. They are ruggedly constructed and seldom fail. The most common rear end failures are axle bearing failures. In a rear axle assembly, engine power enters the drive pinion gear from the drive shaft assembly and differential pinion yoke/flange. The drive pinion gear, which is in mesh with the ring gear, causes the ring gear to turn. The interaction of the ring and drive pinion gears turns the power flow at a 90 angle. The difference in the number of teeth on the ring and pinion gears causes a reduction gear ratio. This reduces turning speed, while increasing torque. Power from the ring gear flows through the differential case, spider gears, and side gears to the drive axles. The drive axles transfer power from the differential assembly to the rear wheels. The bearings and rear axle housing are key components of the rear axle assembly. They are designed to support and align the differential assembly and the drive axles. Notice that the bearings and axle housing are large, heavyduty parts. This is to ensure they will stand up under hard usage. Seals and gaskets are also very important to the operation of the rear axle assembly. Seals are used at the differential pinion yoke/flange and at the outer drive axles. Gaskets are used at housing interfaces, such as between the differential cover and the housing, to provide a tight seal from the outside.
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21
Chapter-3
ENGINE HOUSING
3.1 INTRODUCTION
We started our project which is detailed study on the combustion on FT60/70 engine and its testing. It is the most widely used engine in the farmtrac series because of its efficiency. Before starting with the project, we studied some basic areas of the engine like cylindrical block and its manufacturing and then its assembly. Engine assembly starts with the manufacturing of the cylinder block. The cylinder block has to go through 26 machines before going into the final inspection. After the inspection is done it is sent for the heat treatment and then it is sent to the assembly line where the engine parts are assembled. We didnt much focus on the assembly line and just went though the procedures and steps involved in it. We also worked as helper where we were supposed to count the nuts and bolts everyday and handing over it to the assembly line the daily shift basis. Assembly involves 14 steps before giving it as a shape of an engine. 28 workers work in the assembly line.
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3.2
1. PERFORMANCE
Engine power :- 50 hp @ 2000 rpm Maximum pto power :- 42.8 hp (power take off) Maximum torque :- 18.2 @ 1166 rpm
2. ENGINE
Type Aspiration No of cylinders Displacement Fuel tank capacity Starting system Cooling system Air cleaner :- 4 stroke (direct ignition of fuel); Water cooled :- Natural :- 3 :- 3147 cc :- 50 :- 12v electrical starter :- pressurised, water cooled :- dual dry air cleaner
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A block made of aluminium alloy is lighter than if it were made of cast iron. So if two engines are generating the same power, the alloy version would have a better weight-to-power ratio than the cast iron version. Cast iron liners are usually used in the cylinders of aluminium blocks, and sometimes in cast-iron blocks. Some sleeves are cast into the block. Grooves on the outside form a key that stops any movement in the cylinder. They also increase surface area to assist heat transfer from the sleeve to the block. Some blocks dont need liners. They can be made of wear resistant material that makes a hard-wearing surface for the pistons and piston rings. Or the cylinder bore may have some sort of surface treatment to make it hard-wearing. When the cylinders, block and crankcase are all cast together, it is called a monoblock construction. A horizontally-opposed block has a split crankcase. The two engine blocks are joined together by the flanges of the crankcase. In air-cooled engines, the cylinders are usually made as separate parts, and then bolted to the same crankcase. Each cylinder has cooling fins. Theyre often machined to give uniform thickness and allow free flow of air.
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3.4
1. Cylinder block has total 4 faces, which are: Sump face Right end Left end Joint face
2. Some useful points on the cylinder block are: Rough dia of the block is 4.335 inch. Dimension of the block after boring is 4.9 inch. Oil gallery final dia is 0.557 inch.
25
3. Some of the machines used are as follows: Vertical boring machine Vertical rough boring machine Duplex milling machine Hobbling machine
Left End
Right End
Sump Face
Fig 5 Source: - curtsy escorts pvt ltd
Joint Face
26
Operation: Cylinder block rest on sump rail and locate from manufacturing holes no.91 &92. Rough bore cylinder bores (Bore No. 1 to 3) and chamfer 30 at the end. Tools: 1. Boring Fixtures : HMT (OSD) Numbers required: 1 Tool No: - 6015F-EF-120 2. Boring Bar: HMT(OSD) Numbers required: 1 Tool No: 6015F-ET-624 Speed: 230 (rpm) Feed: 125mm/min 3. Chip Breaker: STD Numbers required:-4 Tool No: - 73085872(T10009680) 4. Cartridge: STD Numbers required:-4 Toll No:-PSNKR-12CA-12 (modified) 5. Insert: STD Number required: 4 Tool No: - SNNG120408-(GRADE)EN-TMR-CTC1235 (T10040010) 6. Chamfering Tool :- Bottom Numbers required:-1 Speed:-230rpm Feed Rate:-125mm/min Tool NO: - 6015F-ET-621 (T10088860)
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7. Insert:- STD Numbers required:-1 Tool No:-CMT-09T304UM-(GRADE)-SAL-H13A (T10038710) FIXTURES PARTS: 1. Round locating pin Numbers required:-1 Tool No: - 6015-EF-98/1 (T10045600) 2. Diamond locating pin Numbers required:-1 Tool No:-6015-EF-98/2 (T10044940) 3. Rack for locating pin Numbers required:-2 Toll No:-6015-EF-98/3 4. Pinion Numbers required:-2 Toll No:-6015-EF-98/4 5. Shaft for locating pin Numbers required:-1 Toll No:-6015-EF-98/5
28
29
Setting Gauges:1. Setting gauge for boring radial Numbers required:-1 Tool No:-6015-SG-445 2. Setting gauge for boring Axial Numbers required:-1 Tool No:-6015-SG-446 3. Setting Gauge For Bottom chamfer Numbers required:-1 Tool No:-6015-SG-447 4. Setting Master for bottom chamfer Numbers required:-1 Tool No:-6015-SG-448 5. Dial indicator Numbers required:-3 Toll No:-STD Least Count:-.0001.
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Chapter-4
31
The compression ignition engine completes one cycle of events in two crankshafts revolutions or four piston strokes. These four strokes are as follows: Induction stroke Compression stroke Power stroke Exhaust stroke
1. INDUCTION STROKE: - with the inlet valve open and the exhaust
valve closed, the piston moves away from the cylinder head, the outward movement of the piston will establish a depression in the cylinder, its magnitude depending on the ratio of the cross sectional areas of the cylinder and the inlet port and on the speed at which the piston is moving. The pressure difference established between the inside and the outside of the cylinder will induce air at atmospheric pressure to enter and fill up the cylinder.
3. POWER STROKE: -
with both the inlet and the exhaust valves closed and the piston almost at the end of the compression stroke. Diesel fuel oil is injected into the dense and heated air as a high pressure spray of fine particles. Provided that they are properly atomized and distributed throughout the air charge, the heat of the compression will then quickly vaporize and ignite the tiny droplets of fuel. Then the piston will reach its innermost position and extensive burning then releases heat energy which is rapidly converted into pressure energy. Expansion then follows, pushing the piston away from the cylinder head and the linear thrust
32
acting on the piston end of the connecting rod will then be changed to rotary movement of the crankshaft.
4. EXHAUST STROKE: -
completion and the piston has reaches the outmost position, the exhaust valve is opened. The piston then reverses its direction of motion and moves towards the cylinder head. The sudden opening of the exhaust vale towards the end of the power stroke will release the still burning products of combustion to the atmosphere. The pressure energy of the gases at this point will accelerate their expulsion from the cylinder, and only towards the end of the pistons return stroke will the piston actually catch up with the outgoing gases.
33
34
Fig 9
The combustion process proceeds by the following stages (as per the above graph):
combustion of the fuel which has mixed with the air to within the flammability limits (air at high-temperature and high- pressure) during the ignition delay period occurs rapidly in a few crank angles.
35
For very-large engines (stationary power generation) which operate at low Engine speeds the time available for mixing is long so a direct injection Quiescent chamber type is used (open or shallow bowl in piston). For small high-speed engines used in automobiles chamber swirl is not Sufficient, indirect injection is used where high swirl or turbulence is generated in the pre-chamber during compression and products/fuel blow down and mix with main chamber air. As engine size decreases and engine speed increases, increasing amounts Of swirl are used to achieve fuel-air mixing (deep bowl in piston).
36
4.10 PARTICULATES
A high concentration of particulate matter (PM) is manifested as visible smoke in the exhaust gases. Particulates are any substance other than water that can be collected by filtering the exhaust, classified as:- Solid carbon material or soot. Condensed hydrocarbons and their partial oxidation products.
38
Diesel particulates consist of solid carbon (soot) at exhaust gas temperatures below 500oC, HC compounds become absorbed on the surface. In a properly adjusted SI engines soot is not usually a problem. Particulate can arise if leaded fuel or overly rich fuel-air mixture are used. Burning crankcase oil will also produce smoke especially during engine warm up where the HC condense in the exhaust gas.
39
Composition
Fig 13
40
Chemical processes similar to that described for auto ignition phenomenon in premixed fuel-air, only more complex since heterogeneous reactions (Reactions occurring on the liquid fuel drop surface) also occur.
41
42
With the engine running at these conditions with the test fuel, the compression ratio is varied until combustion starts at TC ignition delay period of 13 degree. The above procedure is repeated using blends of isocetane and cetane. The blend that gives a 13 degree ignition delay with the same compression ratio is used to calculate the test fuel cetane number.
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Chapter -5
ENGINE TESTING PARAMETERS
5.1 INTRODUCTION
Engine performance is an indication of the degree of success of the engine performs its assigned task i.e. the conversion of the chemical energy contained in the fuel into the useful mechanical work. The performance of an engine is evaluated in the basis of the following:
Specific fuel consumption. Brake mean effective pressure. Specific power output. Specific weight. Exhaust smoke and other emissions.
The particular application of the engine decides the relative importance of these performance parameters The basic performance parameters are the following: Power and mechanical efficiency. Mean effective pressure and Torque. Specific output. Volumetric efficiency. Fuel-air ratio. Specific fuel consumption. Thermal efficiency and heat balance. Exhaust smoke and other emissions. Specific weight.
44
Where,
pm = Mean effective pressure, N/m2, L = Length of the stroke, m, A = Area of the piston, m2, N = Rotational speed of the engine, rpm (It is N/2 for Four Stroke engine). k = Number of cylinders.
Mechanical efficiency =
ip bp
45
ip x 60 LANK
where,
Pm = Mean effective pressure, N/m2, Ip = Indicated power, Watt, L = Length of the stroke, m, A = Area of the piston, m2, N = Rotational speed of the engine, rpm (It is N/2 for four stroke engine), k = Number of cylinders.
If the mean effective pressure is based on the bp then it is called brake mean effective pressure.
46
Mount engine on test bed and make necessary connections for fuel, water intake, exhaust etc.
WARMIING UP (7 min)
Start the engine and set tappet clearance for inlet valve. Inlet valve and Exhaust valve = 30/35 (0.4mm) AVL 0.6mm Run at no loads & 1400 rpm and check the following:1. Water inlet temperature (74-85). 2. Oil pressure idling. 3. Lubrication of push rod sockets. 4. Lubrication of rocker shaft. 5. Rotation of push rods. 6. Lubrication of rocker arm. = 30/35 (0.3mm) AVL 0.4mm
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(10min)
MODEL
RPM
FT-60/60E
1500 2000
FT-70
1500 2200
Run the engine at high idling speed at no load. Full throttle performance at rated speed & peak torque speed (4min).
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MODEL
2000 rpm OBSERVED LOAD (Kg) 21.3 22.8 21.8 25.3 23.4 - 29
1200 rpm ONSERVED LOAD (Kg) 24.5 26.6 23.8 26.3 26.5 29.0
GENERAL CHECKS
(5 min)
Oil pressure on idling & high temperature, leakages, cleaning of air filter, oil level in oil pan, water temperature and pressure, abnormal noise.
50
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Chapter-6
6.1 FUTURE SCOPE & CONCLUSION
While there has been intensive work on more or less promising alternatives on the internal combustion engines for some years, now more than 100 years old, it has revealed its enormous development potential. Despite of all these advantages the diesel engine has to fight against prejudices all the time. Although it is no longer considered as noisy and sluggish, there remains the reproach that compression ignition engines produce a higher amount of more harmful exhaust gas constituents than petrol engines.
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6.2 REFERENCES
1. Company profile www.escortsgroup.com . 2. Axle housing curtsy escorts pvt ltd. 3. Trumpet housing http://tractorz.blogspot.in/2012/07/normal-dutytrumpet-housings-gpa40.html . 4. John B Heywood internal combustion engine diesel engine working. 5. Combustion in ic engines http://me.queensu.ca/Courses/435/files/6.CombustioninICengineslecture. pdf . 6. Engine testing parameters curtsy escorts pvt ltd.
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