The document provides an introduction to the fundamentals of mechanical engineering and diesel engines. It discusses key concepts such as the different types of internal combustion engines including diesel engines. It describes how diesel engines work through the combustion process and four stroke cycle. It also outlines the different systems in diesel engines, including types of mechanical power transmission methods like gears, chains, and belts.
Electro Discharge Machining
Introduction
Process
Process Parameters
Dielectric
Advantages of EDM
APPLICATIONS
Power generator
Wire EDM
ELECTRIC DISCHARGE GRINDING (EDG)
This document discusses electric discharge machining (EDM), a non-conventional machining process that removes metal using electric sparks. EDM involves removing material through electric sparking between an electrode tool and a metal workpiece separated by a dielectric fluid. There are two main types of EDM: wire-cut EDM, which uses a continuously moving wire as the electrode, and ram/sinker EDM, which uses a solid electrode. EDM can machine very hard metals, achieve a high degree of accuracy and precision, and create complex shapes without mechanical forces.
The document discusses various unconventional machining processes. It begins with introducing that unconventional machining uses indirect energy like sparks, heat or chemicals rather than direct contact between a tool and workpiece. It then covers different unconventional processes like EDM, laser beam machining, electrochemical machining and their characteristics. The document categorizes unconventional machining processes and provides details on processes like chemical machining, electrochemical grinding and ultrasonic machining. It concludes with discussing advantages and disadvantages of non-conventional machining.
Brief description of Hydraulic power pack, basic parts of it and affecting parameters for the same, it is used in many industrial applications and in some heavy civil applications
The document discusses abrasive jet machining (AJM), which is a machining process where material is removed by a high-velocity stream of abrasive particles carried in a gas. It describes the process, components, parameters, capabilities, applications, advantages, and disadvantages of AJM. Key aspects covered include that AJM uses abrasive particles accelerated in a gas stream to cause micro-fracturing and erosion of the workpiece surface, and that it can machine hard and brittle materials with a cool cutting action and high surface finish.
This document provides an introduction to machine elements and power transmission devices taught in the second semester of a mechanical engineering course. It discusses various machine elements like shafts, keys, couplings, bearings, clutches, and brakes. It also covers power transmission devices such as belt drives, chain drives, and gear drives. The document describes the function, types, materials, and design of these common mechanical components.
This document outlines the syllabus for a course on Design of Machine Elements - I. It includes information on textbooks, reference books, modules, and topics to be covered. The course will cover the design process, analysis of forces on machine components, design for static strength, failure theories, stress concentration, and fundamentals of mechanical engineering design. It will consist of 3 hours of lectures and 2 hours of tutorials per week over 10 weeks. The first module will cover the introduction to design process, phases of design, engineering materials and properties, manufacturing processes, codes and standards, loading conditions, stresses, and design for static strength.
Computer Aided Engineering (CAE) uses computer software to simulate product performance in order to improve designs. The CAE process involves pre-processing to create models, solving using mathematical physics, and post-processing results. CAE allows designs to be evaluated using simulation rather than prototypes, saving time and money. Finite Element Analysis is a numerical technique used in CAE to approximate solutions to engineering problems. Common CAE applications include stress analysis, thermal/fluid analysis, and manufacturing simulation.
Electro Discharge Machining
Introduction
Process
Process Parameters
Dielectric
Advantages of EDM
APPLICATIONS
Power generator
Wire EDM
ELECTRIC DISCHARGE GRINDING (EDG)
This document discusses electric discharge machining (EDM), a non-conventional machining process that removes metal using electric sparks. EDM involves removing material through electric sparking between an electrode tool and a metal workpiece separated by a dielectric fluid. There are two main types of EDM: wire-cut EDM, which uses a continuously moving wire as the electrode, and ram/sinker EDM, which uses a solid electrode. EDM can machine very hard metals, achieve a high degree of accuracy and precision, and create complex shapes without mechanical forces.
The document discusses various unconventional machining processes. It begins with introducing that unconventional machining uses indirect energy like sparks, heat or chemicals rather than direct contact between a tool and workpiece. It then covers different unconventional processes like EDM, laser beam machining, electrochemical machining and their characteristics. The document categorizes unconventional machining processes and provides details on processes like chemical machining, electrochemical grinding and ultrasonic machining. It concludes with discussing advantages and disadvantages of non-conventional machining.
Brief description of Hydraulic power pack, basic parts of it and affecting parameters for the same, it is used in many industrial applications and in some heavy civil applications
The document discusses abrasive jet machining (AJM), which is a machining process where material is removed by a high-velocity stream of abrasive particles carried in a gas. It describes the process, components, parameters, capabilities, applications, advantages, and disadvantages of AJM. Key aspects covered include that AJM uses abrasive particles accelerated in a gas stream to cause micro-fracturing and erosion of the workpiece surface, and that it can machine hard and brittle materials with a cool cutting action and high surface finish.
This document provides an introduction to machine elements and power transmission devices taught in the second semester of a mechanical engineering course. It discusses various machine elements like shafts, keys, couplings, bearings, clutches, and brakes. It also covers power transmission devices such as belt drives, chain drives, and gear drives. The document describes the function, types, materials, and design of these common mechanical components.
This document outlines the syllabus for a course on Design of Machine Elements - I. It includes information on textbooks, reference books, modules, and topics to be covered. The course will cover the design process, analysis of forces on machine components, design for static strength, failure theories, stress concentration, and fundamentals of mechanical engineering design. It will consist of 3 hours of lectures and 2 hours of tutorials per week over 10 weeks. The first module will cover the introduction to design process, phases of design, engineering materials and properties, manufacturing processes, codes and standards, loading conditions, stresses, and design for static strength.
Computer Aided Engineering (CAE) uses computer software to simulate product performance in order to improve designs. The CAE process involves pre-processing to create models, solving using mathematical physics, and post-processing results. CAE allows designs to be evaluated using simulation rather than prototypes, saving time and money. Finite Element Analysis is a numerical technique used in CAE to approximate solutions to engineering problems. Common CAE applications include stress analysis, thermal/fluid analysis, and manufacturing simulation.
Electron beam machining (EBM) involves directing a high-velocity beam of electrons in a vacuum chamber to melt or vaporize material from a workpiece. The electron beam is generated in a gun and focused onto a small spot on the workpiece using magnetic coils. This localized heating allows for precise material removal with minimal heat effects. EBM can machine nearly any material and produces close tolerances, but requires expensive equipment and vacuum systems. Common applications include machining wire drawing dies and manufacturing semiconductor and optical components.
Electrical discharge machining (EDM) is an unconventional machining process that uses electrical sparks to erode unwanted material from a workpiece by discharging electricity between an electrode tool and the workpiece, separated by a dielectric fluid. EDM can machine hard materials and complex shapes by using individual sparks that briefly heat the material to plasma temperatures without direct contact. The process works by concentrating electrons and ions in the dielectric fluid gap between the tool and workpiece, causing sparks that thermally erode unwanted material. EDM enables precision machining of difficult shapes for aerospace and medical applications but has low material removal rates and leaves a rough surface finish.
This document discusses electrochemical machining (ECM), a non-traditional machining process that removes metal through an electrochemical process. ECM can machine extremely hard materials like titanium or carbide by acting as the cathode in an electrolytic cell, while the workpiece acts as the anode. Metal is removed from the workpiece as an electric current flows between the two electrodes in an electrolyte like salt water. ECM allows for intricate internal and external geometries to be machined and is capable of machining hard metals that other methods struggle with.
1) This document outlines the course objectives and syllabus for the Strength of Materials course taught by Dr. B. Janarthanan.
2) The course will cover concepts of stress, strain, deformation of solids, bending of beams, torsion of shafts, and stresses in thin shells.
3) The objectives are for students to understand stress and strain concepts, load transfer mechanisms, torsion and bending analyses, and thin shell design.
This document provides an introduction to non-traditional machining processes. It defines non-traditional machining as processes that remove material using mechanical, thermal, electrical or chemical energy without using sharp cutting tools. The need for developing such processes is discussed, such as difficulties in machining new hard materials and complex geometries. A comparison is provided between traditional and non-traditional machining. The document outlines the classification and selection of various non-traditional machining processes and provides examples of when they may be preferable to traditional processes. It introduces several specific non-traditional machining techniques that will be covered in more depth later in the document.
Electro Stream Drilling (ESD) is an electrochemical machining process that uses a high velocity stream of negatively charged acidic electrolyte to drill small diameter holes. It can drill holes between 0.127-0.89 mm using a voltage of 150-850 V. Unlike conventional electrochemical drilling, debris dissolved in the acidic electrolyte prevents clogging. ESD can drill deep and accurate holes through either dwell drilling or penetration drilling methods and offers advantages like high aspect ratio holes, low surface roughness, and no burrs or residual stresses. However, it has high initial costs and is limited to electrically conductive materials.
The document summarizes the wire drawing process. Wire drawing is used to reduce the cross-sectional area of wire by pulling it through progressively smaller dies. There are single step and continuous wire drawing machines. Proper lubrication is important for smooth finishes and long die life. Different types of dies and materials are used depending on the type of wire. Automation using programmable logic controllers allows maintaining constant speed and drawing force for high accuracy and reduced labor costs.
The document summarizes electron beam machining (EBM). EBM works by converting the kinetic energy of high-speed electrons into heat energy when they impinge on a workpiece. This heat energy vaporizes material. The process requires vacuum. An electron gun generates electrons that pass through magnetic lenses to focus the beam on the workpiece. Material removal occurs through melting and vaporization. EBM can machine small, complex holes and is used in aerospace and nuclear industries. It offers good finishes but has low material removal rates and high costs.
The document provides information on Electrical Discharge Machining (EDM). EDM is a manufacturing process where electrical discharges are used to erode material from a workpiece to achieve a desired shape. In EDM, a series of sparks erode material by rapidly recurring electrical discharges between two electrodes separated by a dielectric liquid and subject to an electric voltage. One electrode is the tool that shapes the workpiece. Material removal occurs through thermal melting and vaporization caused by the extreme heat of electrical sparks between the electrodes.
The document discusses Electrical Discharge Machining (EDM). EDM is a manufacturing process where a desired shape is obtained by removing material from a workpiece using electrical discharges between two electrodes separated by a dielectric liquid. As the distance between the electrodes is reduced, current flows due to dielectric breakdown causing material removal from both electrodes. EDM was invented in the 1940s and has since improved, increasing machining speeds and reducing costs. EDM can machine hard metals and intricate shapes without needing to soften the material. The main components of an EDM system are the power supply, dielectric medium, workpiece and tool electrodes, and servo control unit. Material is removed through the formation and collapse of plasma channels between the electrodes during
Roll forming Long parts with constant complex cross-sections; good surface finish; high
production rates; high tooling costs.
Stretch forming
Large parts with shallow contours; suitable for low-quantity production; high
labor costs; tooling and equipment costs depend on part size.
Drawing Shallow or deep parts with relatively simple shapes; high production rates;
high tooling and equipment costs.
Stamping Includes a variety of operations, such as punching, blanking, embossing,
bending, flanging, and coining; simple or complex shapes formed at high
production rates; tooling and equipment costs can be high, but labor costs
are low.
Rubber-pad
forming
Drawing and embossing of simple or complex shapes; sheet surface protected
by rubber membranes; flexibility of operation; low tooling costs.
Spinning Small or large axisymmetric parts; good surface finish; low tooling costs, but
labor costs can be high unless operations are automated.
Superplastic
forming
Complex shapes, fine detail, and close tolerances; forming times are long,
and hence production rates are low; parts not suitable for high-temperature
use.
Peen forming Shallow contours on large sheets; flexibility of operation; equipment costs
can be high; process is also used for straightening parts.
Explosive
forming
Very large sheets with relatively complex shapes, although usually axisymmetric;
low tooling costs, but high labor costs; suitable for low-quantity
production; long cycle times.
Magnetic-pulse
forming
Shallow forming, bulging, and embossing operations on relatively lowstrength
sheets; most suitable for tubular shapes; high production rates;
requires special tooling.
This document provides an overview of surface texture, including definitions of key terms like roughness, waviness, and lay. It discusses the importance of standard surface finish symbols and specifications in manufacturing. Specific objectives covered include identifying surface finish symbols, defining terms like roughness height and waviness width, and calculating different metrics of surface roughness including Ra, Rq, and Rt. Methods of measuring surface texture in both inches and metric units are also presented.
This document discusses explosive forming, a metal forming process that uses explosives. There are two main types - confined and unconfined. Unconfined uses a standoff distance between the explosive and workpiece, while confined places the explosive in direct contact with the workpiece. The process works by placing the metal workpiece on a die, then igniting the nearby explosive. The explosive's shockwave deforms the metal into the die's shape. Research showed deformation of an aluminum plate reached 39mm after 400 microseconds, with peak velocities of 280m/s near the center. Explosive forming can form large, complex parts but requires safety precautions due to using explosives.
CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSravikumarmrk
The document discusses various chemical and electro-chemical based machining processes. It describes the principles and processes of chemical machining, electro-chemical machining (ECM), electro-chemical grinding (ECG), and electro-chemical honing (ECH). ECM involves removing metal from a workpiece through controlled chemical dissolution using an electrolyte solution, with the workpiece as the anode. ECG combines 90% chemical dissolution with 10% conventional grinding, allowing for high-precision machining of hard materials. ECH similarly combines electro-chemical attack with honing to internally grind with less pressure and tool wear.
High energy rate forming (HERF) is a sheet metal forming process that forms products at very high velocities and pressures. It uses a short burst of high energy transmitted through a medium to the workpiece, forcing it into a die cavity. This allows materials to be formed beyond their normal limits with minimal springback. Some key advantages are higher production rates, lower die costs, and the ability to form difficult metals. Common HERF processes are explosive forming, electrohydraulic forming, and magnetic pulse forming.
Chemical machining (ChM) is a process that uses chemicals to remove material from a workpiece. It involves masking areas not to be etched, then immersing or spraying the workpiece with a corrosive chemical etchant. ChM provides advantages like weight reduction, stress-free material removal, and low tooling costs. The process involves part preparation through masking, etching with chemicals, mask removal, and finishing. Precise shapes can be produced using photoresist masks and photoetching. ChM finds applications for aerospace, electronics, and other precision parts.
This document discusses engineering design and different types of designs. It defines engineering design as a systematic process where engineers generate and evaluate solutions to meet client/user needs within constraints. The document outlines several types of designs - original, adaptive, redesign, selection, and industrial design. It provides examples and descriptions of each type. The document also defines key concepts in design including objectives, constraints, functions, form, and means. It frames design as a process of questioning to understand goals, limits, required functions, and determining how to achieve them.
The document discusses various types of welded joints, including lap joints, butt joints, and fillet welds. It describes the advantages of welded joints over riveted joints. Various welding processes are covered, including fusion welding processes like gas welding and electric arc welding. The document provides formulas to calculate the strength of different welded joint configurations, like transverse and parallel fillet welds, and discusses special cases like circular fillet welds subjected to torsion or bending moments. Design considerations for different welded joints are also presented.
This document provides an introduction to electrical discharge machining (EDM). EDM is an unconventional machining process where material is removed by electric sparks between an electrode tool and conductive workpiece, with no direct contact between them. Key aspects of EDM covered include the construction of EDM machines, the role of dielectric fluids, factors that affect the material removal rate such as capacitance and spark parameters, and electrode tool materials and wear characteristics. Graphite, copper, and copper-tungsten are commonly used as tool materials in EDM due to properties like machinability and erosion resistance.
Water jet machining uses a high-pressure stream of water to cut materials. It is a cold cutting process that produces no heat-affected zones. The water jet travels at supersonic speeds and erodes material when the local pressure exceeds the material's strength. Key components include a hydraulic pump to pressurize water, an intensifier to further pressurize it, and a nozzle to direct the jet. It can cut a variety of materials and offers advantages over other cutting methods like reduced burrs, flexibility of cutting complex shapes, and not producing heat or fumes. However, it is not suitable for high-volume production.
The document discusses various types of drive systems used for robotics, including electrical, hydraulic, and pneumatic drives. It provides details on common electric motors like stepper motors, servo motors, DC motors, and AC motors. It then focuses on electric drives like stepper motors, DC brush motors, DC brushless motors, AC synchronous motors, and AC asynchronous motors. Other drive types covered include hydraulic and pneumatic drives, as well as various gearing systems used to reduce speed and increase torque like planetary, spur, and harmonic drives.
Centrifugal pumps and compressors are power absorbing devices that use centrifugal force to increase the pressure of fluids and gases respectively. Centrifugal pumps have an impeller and casing that spin fluid at high velocities, converting kinetic energy to pressure energy. Centrifugal compressors accelerate gas velocities using an impeller and diffuser, converting the increased kinetic energy to pressure. Both are commonly used where high flow rates and moderate pressure increases are required. Belt and chain drives transmit power between parallel shafts using pulleys or sprockets connected by a belt or chain. They are used widely in industrial and domestic applications like conveyors, compressors, and bicycles.
Electron beam machining (EBM) involves directing a high-velocity beam of electrons in a vacuum chamber to melt or vaporize material from a workpiece. The electron beam is generated in a gun and focused onto a small spot on the workpiece using magnetic coils. This localized heating allows for precise material removal with minimal heat effects. EBM can machine nearly any material and produces close tolerances, but requires expensive equipment and vacuum systems. Common applications include machining wire drawing dies and manufacturing semiconductor and optical components.
Electrical discharge machining (EDM) is an unconventional machining process that uses electrical sparks to erode unwanted material from a workpiece by discharging electricity between an electrode tool and the workpiece, separated by a dielectric fluid. EDM can machine hard materials and complex shapes by using individual sparks that briefly heat the material to plasma temperatures without direct contact. The process works by concentrating electrons and ions in the dielectric fluid gap between the tool and workpiece, causing sparks that thermally erode unwanted material. EDM enables precision machining of difficult shapes for aerospace and medical applications but has low material removal rates and leaves a rough surface finish.
This document discusses electrochemical machining (ECM), a non-traditional machining process that removes metal through an electrochemical process. ECM can machine extremely hard materials like titanium or carbide by acting as the cathode in an electrolytic cell, while the workpiece acts as the anode. Metal is removed from the workpiece as an electric current flows between the two electrodes in an electrolyte like salt water. ECM allows for intricate internal and external geometries to be machined and is capable of machining hard metals that other methods struggle with.
1) This document outlines the course objectives and syllabus for the Strength of Materials course taught by Dr. B. Janarthanan.
2) The course will cover concepts of stress, strain, deformation of solids, bending of beams, torsion of shafts, and stresses in thin shells.
3) The objectives are for students to understand stress and strain concepts, load transfer mechanisms, torsion and bending analyses, and thin shell design.
This document provides an introduction to non-traditional machining processes. It defines non-traditional machining as processes that remove material using mechanical, thermal, electrical or chemical energy without using sharp cutting tools. The need for developing such processes is discussed, such as difficulties in machining new hard materials and complex geometries. A comparison is provided between traditional and non-traditional machining. The document outlines the classification and selection of various non-traditional machining processes and provides examples of when they may be preferable to traditional processes. It introduces several specific non-traditional machining techniques that will be covered in more depth later in the document.
Electro Stream Drilling (ESD) is an electrochemical machining process that uses a high velocity stream of negatively charged acidic electrolyte to drill small diameter holes. It can drill holes between 0.127-0.89 mm using a voltage of 150-850 V. Unlike conventional electrochemical drilling, debris dissolved in the acidic electrolyte prevents clogging. ESD can drill deep and accurate holes through either dwell drilling or penetration drilling methods and offers advantages like high aspect ratio holes, low surface roughness, and no burrs or residual stresses. However, it has high initial costs and is limited to electrically conductive materials.
The document summarizes the wire drawing process. Wire drawing is used to reduce the cross-sectional area of wire by pulling it through progressively smaller dies. There are single step and continuous wire drawing machines. Proper lubrication is important for smooth finishes and long die life. Different types of dies and materials are used depending on the type of wire. Automation using programmable logic controllers allows maintaining constant speed and drawing force for high accuracy and reduced labor costs.
The document summarizes electron beam machining (EBM). EBM works by converting the kinetic energy of high-speed electrons into heat energy when they impinge on a workpiece. This heat energy vaporizes material. The process requires vacuum. An electron gun generates electrons that pass through magnetic lenses to focus the beam on the workpiece. Material removal occurs through melting and vaporization. EBM can machine small, complex holes and is used in aerospace and nuclear industries. It offers good finishes but has low material removal rates and high costs.
The document provides information on Electrical Discharge Machining (EDM). EDM is a manufacturing process where electrical discharges are used to erode material from a workpiece to achieve a desired shape. In EDM, a series of sparks erode material by rapidly recurring electrical discharges between two electrodes separated by a dielectric liquid and subject to an electric voltage. One electrode is the tool that shapes the workpiece. Material removal occurs through thermal melting and vaporization caused by the extreme heat of electrical sparks between the electrodes.
The document discusses Electrical Discharge Machining (EDM). EDM is a manufacturing process where a desired shape is obtained by removing material from a workpiece using electrical discharges between two electrodes separated by a dielectric liquid. As the distance between the electrodes is reduced, current flows due to dielectric breakdown causing material removal from both electrodes. EDM was invented in the 1940s and has since improved, increasing machining speeds and reducing costs. EDM can machine hard metals and intricate shapes without needing to soften the material. The main components of an EDM system are the power supply, dielectric medium, workpiece and tool electrodes, and servo control unit. Material is removed through the formation and collapse of plasma channels between the electrodes during
Roll forming Long parts with constant complex cross-sections; good surface finish; high
production rates; high tooling costs.
Stretch forming
Large parts with shallow contours; suitable for low-quantity production; high
labor costs; tooling and equipment costs depend on part size.
Drawing Shallow or deep parts with relatively simple shapes; high production rates;
high tooling and equipment costs.
Stamping Includes a variety of operations, such as punching, blanking, embossing,
bending, flanging, and coining; simple or complex shapes formed at high
production rates; tooling and equipment costs can be high, but labor costs
are low.
Rubber-pad
forming
Drawing and embossing of simple or complex shapes; sheet surface protected
by rubber membranes; flexibility of operation; low tooling costs.
Spinning Small or large axisymmetric parts; good surface finish; low tooling costs, but
labor costs can be high unless operations are automated.
Superplastic
forming
Complex shapes, fine detail, and close tolerances; forming times are long,
and hence production rates are low; parts not suitable for high-temperature
use.
Peen forming Shallow contours on large sheets; flexibility of operation; equipment costs
can be high; process is also used for straightening parts.
Explosive
forming
Very large sheets with relatively complex shapes, although usually axisymmetric;
low tooling costs, but high labor costs; suitable for low-quantity
production; long cycle times.
Magnetic-pulse
forming
Shallow forming, bulging, and embossing operations on relatively lowstrength
sheets; most suitable for tubular shapes; high production rates;
requires special tooling.
This document provides an overview of surface texture, including definitions of key terms like roughness, waviness, and lay. It discusses the importance of standard surface finish symbols and specifications in manufacturing. Specific objectives covered include identifying surface finish symbols, defining terms like roughness height and waviness width, and calculating different metrics of surface roughness including Ra, Rq, and Rt. Methods of measuring surface texture in both inches and metric units are also presented.
This document discusses explosive forming, a metal forming process that uses explosives. There are two main types - confined and unconfined. Unconfined uses a standoff distance between the explosive and workpiece, while confined places the explosive in direct contact with the workpiece. The process works by placing the metal workpiece on a die, then igniting the nearby explosive. The explosive's shockwave deforms the metal into the die's shape. Research showed deformation of an aluminum plate reached 39mm after 400 microseconds, with peak velocities of 280m/s near the center. Explosive forming can form large, complex parts but requires safety precautions due to using explosives.
CHEMICAL AND ELECTRO-CHEMICAL ENERGY BASED PROCESSravikumarmrk
The document discusses various chemical and electro-chemical based machining processes. It describes the principles and processes of chemical machining, electro-chemical machining (ECM), electro-chemical grinding (ECG), and electro-chemical honing (ECH). ECM involves removing metal from a workpiece through controlled chemical dissolution using an electrolyte solution, with the workpiece as the anode. ECG combines 90% chemical dissolution with 10% conventional grinding, allowing for high-precision machining of hard materials. ECH similarly combines electro-chemical attack with honing to internally grind with less pressure and tool wear.
High energy rate forming (HERF) is a sheet metal forming process that forms products at very high velocities and pressures. It uses a short burst of high energy transmitted through a medium to the workpiece, forcing it into a die cavity. This allows materials to be formed beyond their normal limits with minimal springback. Some key advantages are higher production rates, lower die costs, and the ability to form difficult metals. Common HERF processes are explosive forming, electrohydraulic forming, and magnetic pulse forming.
Chemical machining (ChM) is a process that uses chemicals to remove material from a workpiece. It involves masking areas not to be etched, then immersing or spraying the workpiece with a corrosive chemical etchant. ChM provides advantages like weight reduction, stress-free material removal, and low tooling costs. The process involves part preparation through masking, etching with chemicals, mask removal, and finishing. Precise shapes can be produced using photoresist masks and photoetching. ChM finds applications for aerospace, electronics, and other precision parts.
This document discusses engineering design and different types of designs. It defines engineering design as a systematic process where engineers generate and evaluate solutions to meet client/user needs within constraints. The document outlines several types of designs - original, adaptive, redesign, selection, and industrial design. It provides examples and descriptions of each type. The document also defines key concepts in design including objectives, constraints, functions, form, and means. It frames design as a process of questioning to understand goals, limits, required functions, and determining how to achieve them.
The document discusses various types of welded joints, including lap joints, butt joints, and fillet welds. It describes the advantages of welded joints over riveted joints. Various welding processes are covered, including fusion welding processes like gas welding and electric arc welding. The document provides formulas to calculate the strength of different welded joint configurations, like transverse and parallel fillet welds, and discusses special cases like circular fillet welds subjected to torsion or bending moments. Design considerations for different welded joints are also presented.
This document provides an introduction to electrical discharge machining (EDM). EDM is an unconventional machining process where material is removed by electric sparks between an electrode tool and conductive workpiece, with no direct contact between them. Key aspects of EDM covered include the construction of EDM machines, the role of dielectric fluids, factors that affect the material removal rate such as capacitance and spark parameters, and electrode tool materials and wear characteristics. Graphite, copper, and copper-tungsten are commonly used as tool materials in EDM due to properties like machinability and erosion resistance.
Water jet machining uses a high-pressure stream of water to cut materials. It is a cold cutting process that produces no heat-affected zones. The water jet travels at supersonic speeds and erodes material when the local pressure exceeds the material's strength. Key components include a hydraulic pump to pressurize water, an intensifier to further pressurize it, and a nozzle to direct the jet. It can cut a variety of materials and offers advantages over other cutting methods like reduced burrs, flexibility of cutting complex shapes, and not producing heat or fumes. However, it is not suitable for high-volume production.
The document discusses various types of drive systems used for robotics, including electrical, hydraulic, and pneumatic drives. It provides details on common electric motors like stepper motors, servo motors, DC motors, and AC motors. It then focuses on electric drives like stepper motors, DC brush motors, DC brushless motors, AC synchronous motors, and AC asynchronous motors. Other drive types covered include hydraulic and pneumatic drives, as well as various gearing systems used to reduce speed and increase torque like planetary, spur, and harmonic drives.
Centrifugal pumps and compressors are power absorbing devices that use centrifugal force to increase the pressure of fluids and gases respectively. Centrifugal pumps have an impeller and casing that spin fluid at high velocities, converting kinetic energy to pressure energy. Centrifugal compressors accelerate gas velocities using an impeller and diffuser, converting the increased kinetic energy to pressure. Both are commonly used where high flow rates and moderate pressure increases are required. Belt and chain drives transmit power between parallel shafts using pulleys or sprockets connected by a belt or chain. They are used widely in industrial and domestic applications like conveyors, compressors, and bicycles.
The document discusses different types of prime movers and power transmission systems used in mining. It begins by defining a prime mover as a machine that converts energy from an energy source into motive power. Common prime movers in mining include internal combustion engines in vehicles and electrical motors. The document then covers the workings of internal combustion engines. It moves on to discuss pneumatic, hydraulic, and mechanical power transmission systems - covering their components, advantages, and disadvantages. Specific mechanical power transmission elements covered in detail include couplings, clutches, gears, belts/pulleys, and chains. The document provides illustrations and explanations of how each of these systems and elements function to transmit power for mining equipment and machinery.
This document describes a project to generate electricity from speed breakers. It lists the group members and describes four mechanisms - spring coil, roller, rack pinion, and crankshaft mechanisms. It provides details on the dimensions and construction of an experimental speed breaker. The mechanisms aim to convert the up and down motion of vehicles passing over the speed breaker into rotational motion that can power a generator. The document discusses the technical aspects and provides calculations of expected electricity output. It concludes that this approach has potential but also challenges in achieving sufficient power generation.
This document discusses power transmission through rotating machines. It defines different types of rotating machines including driving machines, transmission machines, and driven machines. It then focuses on the three major systems for transmitting rotary motion between adjacent shafts: belts, chains, and gears. The document provides detailed information on belt drives, including the four main types of belts and principles of V-belt operation. It also discusses synchronous belts, chain drives, and compares key aspects of belt drives and chain drives.
2 Robot Actuators and drive systems.pptAkashM918608
The document discusses various types of actuators and drive systems used in industrial robotics. It describes pneumatic, hydraulic, and electric drive systems. For electric drives, it covers stepper motors, DC motors, AC motors, and direct drive motors. It provides details on the operation, benefits, and usage of each type of actuator and examples of their application in robot segments, joints, and end-effectors. The document aims to educate about the options for moving and positioning robot components.
The document discusses various types of actuators and drive systems used in industrial robotics. It describes pneumatic, hydraulic, and electric drive systems, focusing on servo drives. For electric drives it covers stepper motors, DC motors, AC motors, and direct drive motors. It provides details on operation, benefits, disadvantages, and examples of each type of actuator and drive system. The goal is to help understand the options for moving and positioning robot components.
Robotics and automation _ power sources and sensorsJAIGANESH SEKAR
Hydraulic, pneumatic and electric drives – determination of HP of motor and gearing ratio – variable speed arrangements – path determination – micro machines in robotics – machine vision – ranging – laser – acoustic – magnetic, fiber optic and tactile sensors.
The document provides an overview of theory of machines and machine elements design. It discusses kinematics, which is the study of motion without considering forces. Kinematics of machines deals with the relative motion between machine parts through displacement, velocity and acceleration. A mechanism is defined as part of a machine that transmits motion and power from input to output. Key concepts discussed include links, kinematic pairs, degrees of freedom, and inversions of mechanisms. Common mechanisms like slider crank chains and their inversions are presented. The document also discusses straight line motion generators, intermittent motion mechanisms, and mechanical advantage in mechanisms.
Engine testing is done to develop and validate engine performance before mass production. It involves comprehensive testing of engine parameters like power, torque, emissions, fuel consumption, and validation against regulatory standards. A variety of instrumentation is used to monitor engine speeds, air and fuel flow rates, temperatures, pressures and emissions during testing. Dynamometers provide load on the engine and measure its output power and torque. Test results are used to improve engine design and efficiency.
Design and Fabrication of Multi Speed Centrifugal PumpRaushan Sah
This document summarizes a student project to design and fabricate a multi-speed centrifugal pump. The project uses a cone-shaped pulley connected to the pump by a round belt to allow variable pump speeds by moving the belt to different positions on the pulley. Calculations are shown to determine pump discharge rates at different belt/pulley configurations. The design is intended to provide a low-cost way to vary pump discharge rates for various industrial and agricultural applications. Future enhancements could include automation and improved components for longer operation.
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inclined car parking lift mechanism system by 070 batch (IOE Pulchowk)Dinesh Rawal
The document describes the design, fabrication and testing of an inclined car parking lift mechanism. It includes sections on the objectives, literature review, methodology, design calculations, components, working principle, results and analysis, costing, and conclusions. The key points are:
1. The project aims to design a vehicle lifting mechanism for easy movement on an inclined surface and analyze its operating cost.
2. A review of literature on lift systems from 1929 to present day showed they are powered by electric motors or hydraulic pumps to efficiently park vehicles.
3. The methodology involved concept development, data collection, design, fabrication, testing, and analysis of stress, velocity and operating costs with varying payloads.
4.
The document provides details about engine basics, including:
1. It outlines 12 lesson goals related to explaining engine operation, classifying engines, calculating compression ratio, describing displacement, listing engine parts, and comparing 2-stroke and 4-stroke engines.
2. The lesson content covers topics such as the evolution of vehicles, engine classification, operation of 4-stroke engines, firing order, engine measurements, construction overview, operation of 2-stroke engines, and comparisons between engine types.
3. The document provides definitions and explanations of key engine terms and components to help understand engine operation, including discussions of cylinders, pistons, crankshafts, camshafts, valves, and the four-stroke cycle
This document discusses energy conversion and engines. It defines an engine as a device that transforms one form of energy into another. Heat engines transform chemical energy from fuel into thermal and mechanical energy. The first internal combustion engines were developed in the early 1800s, with improvements over time leading to modern gasoline and diesel engines. Reciprocating internal combustion engines are widely used and have advantages like simplicity and efficiency, though they also cause vibration. The document describes the components, types, and nomenclature of reciprocating IC engines.
•Diesel power plant
•Advantages & disadvantages
•Site selection
• Diesel power plant working principle
•Terms related with ic engines
•Four stroke cycle diesel engines
•2-Stroke diesel engine
•Difference Between 2 Stroke and 4 Stroke Engines
Design and fabrication of motorized screw jackshashin vyas
This document describes the design of a motorized screw jack. It begins with an introduction to screw jacks and their history. Traditionally, screw jacks required high manual labor to lift vehicles. The objectives of this project were to design a device that can lift vehicles smoothly without impact using a motor as the power source. The proposed system is a remote-controlled cylinder jack that uses a DC motor powered by a battery. Design calculations are provided for the bevel gears, battery, screw dimensions and strength. The motorized screw jack is able to lift vehicles easily without manual effort. Advantages include easy lifting and maintenance, while disadvantages include higher costs and need for a power source. In conclusion, the motorized screw jack meets the
This document describes different mechanisms for generating electricity from speed breakers, including spring coil, roller, and rack pinion mechanisms. It provides details on the dimensions and materials used for constructing speed breakers. It also compares mechanisms based on their components like sprockets, chains, and dynamos. The document finds that mechanisms using rack and pinion arrangements to convert reciprocating motion to rotational motion show potential for generating electricity from passing vehicles in a low-cost manner. However, it notes challenges in achieving the proper balance of speed and torque.
This document provides an overview of mathematical modeling of mechanical systems including translational, rotational, and linkage systems. It begins with an outline describing translational systems, rotational systems, and mechanical linkages. It then discusses the basic elements of translational systems including springs, masses, and dampers. Several examples are provided of modeling simple translational spring-mass systems and deriving the equations of motion. The document also covers rotational systems and provides examples of modeling rotational spring-mass systems. Mechanical linkages such as gears are briefly discussed.
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#Abstract:
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#Prerequisites:
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Try at [killercoda.com](https://killercoda.com/cloudsecurity-scenario/)
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2. 2
INTRODUCTION
WHAT IS MECHANICAL ENGINEERING?
Understanding Of Core Concepts Mechanics,
Thermodynamics, Materials Science, Mechanical
Design and Structural Analysis.
Use of Computer-aided Product Engineering
Lifecycle Management, Design And Analyze
Manufacturing Plants, Industrial Equipment And
Machinery, Heating And Cooling Systems,
Transport Systems, Aircraft, Watercraft,
Robotics, Medical Devices And More.
3. 3
One of the broadest of all engineering
branches
Mechanical Engineering
• Involved with “Machines”:
– Design tools, engines,
machines
– Design and develop power-
producing machines,
including…
• internal combustion
engines
4. 4
– Design and develop
power-producing
machines, including
• Steam and Gas
turbines
TurboFans from Jet Aircraft
Turbinator Gas Turbine
Engine Race Car
Mechanical Engineering
5. 5
Mechanical Engineering
- Jet and Rocket engines.
Jet Engine powered Truck
NASA next-generation
rocket engine powered
spacecraft
6. 6
- Design and develop power-using
machines such as
• Heating, Ventilation, Air-
conditioning (HVAC) systems
Mechanical Engineering
19. 19
Work (W): Work is the result of force (F) moving an
object linear motion a distance (S).
W = F x S
Power (P): Power may be
defined as the rate of doing work, or
work over time (t).
P = W/t = F x S/t
Where Velocity V = S/t
Linear Motion
P = F x V
20. 20
Torque or moment (T): Is the
twisting force, or torque is the generated work (W) rotating
an object, tangent a circle of radius (r) about the center.
Rotational Motion
P = F x V
T = W = F x r
Power (P):
P = T x ω =F x r . ω
Where:
V = r . ω
Angular Velocity ω = 2 𝝅 RPM/60
22. Some Types of Simple Machines
(components)
Lever
Gear
Bearing
wheel and axle
pulley
Screw
Shaft
MACHINE THEORY
23. A compound machine is ...
a combination of two or
more simple machines.
MACHINE THEORY
24. 24
Power can be…
Power (ENERGY)
• Electrical.
• Mechanical.
• Chemical.
• Thermal.
• Fluid.
25. 25
Distance between drive and driven
shafts.
Operational speed.
Power to be transmitted.
MECHANICAL POWER TRANSIMISSION
26. 26
Means of power Transmission
Mechanically:
• Hi power & speed: by COUPLINGS,
CLUTCHES OR GEARS.
• Medium Power & Low speed: by
CHAIN & SPROCKETS.
• Low & Medium power & Hi speed : by
BELTS & PULLEYS.
MECHANICAL POWER TRANSIMISSION
27. 27
Rotating device is utilized to transmit the
power between two shafts on alignment
without reduction.
• From prime mover to machine.
• From one shaft to another.
Couplings
MECHANICAL POWER TRANSIMISSION
29. 29
REGID COUPLING
Flanged coupling
Muff coupling
• It is used for heavy power
transmission and low speed.
• It is used to connect two shafts
which are perfectly axial alignment.
• Any misalignment causes high
vibration, then failure.
Split Muff coupling
MECHANICAL POWER TRANSIMISSION
30. 30
• Permitting some parallel
misalignment up to 0.762 mm
and angular misalignment up
to ±30
• can drive in either direction,
absorb impulses, shocks and
vibrations.
FLIXABLE COUPLINGS
MECHANICAL POWER TRANSIMISSION
35. 35
MECHANICAL POWER TRANSIMISSION
GEARS
Straight Gear [spur gear].
Helical gear.
Bevel gear.
Worm gear.
Rack and Pinion.
• Are used to transmit power from one shaft to another shaft in
closed contact.
• The rotation direction of the driven opposite to the drive shaft
• Are used to control the output speed (reduction is common).
• Are used to control the output torque (increasing is common).
• Are classified according to location of the shaft, position of the
tooth and types of tooth shapes to:
39. 39
Chain = sequence of inner link and pin link articulated to form a
flexible device for power transmission
Main parameters:
- Pitch: distance between two consecutive pins
- Roller diameter: dimension of the outside diameter of the chain
rollers
- Inside width: distance between the two opposite inner sides of
the inner link plates
CHAIN & SPROCKET
MECHANICAL POWER TRANSIMISSION
41. 41
MECHANICAL POWER TRANSIMISSION
• Used to transfer the power,
and control the speed, so the
torque between the drive
sprocket and driven sprocket.
• This system is very similar to
that of the gear system, but
the relative motion of both
shafts is IN THE SAME
DIRECTION.
CHAIN & SPROCKET
42. 42
MECHANICAL POWER TRANSIMISSION
CHAIN & SPROCKET
speed Ratio (SR) (Reduction Ratio common)
Speed Ratio = D1 / D2 = N2 / N1= T1 / T2
As Driven sprocket Diameter increases, speed
decreases and torque increases .
Where:
D1 : Drive sprocket Diameter or No of teeth.
D2 : Driven sprocket Diameter or No of teeth.
N1 : Drive sprocket Speed.
N2 : Driven sprocket Speed.
T1 : Drive shaft Torque.
T2 : Driven Shaft Torque.
43. 43
• This system is very similar to that of the chain and sprocket
system : in this case, the RELATIVE MOTION of both shafts is IN
THE SAME DIRECTION.
• Belts are used to connect two rotating item.
• Usages are as source of motion (conveyors system) or as a high
efficiency power transmission.
• The demands on a belt drive transmission system are large.
BELTS & PULLEYS
MECHANICAL POWER TRANSIMISSION
45. 45
The "V" shape of the belt tracks in a mating
groove in the pulley (or sheave), with the
result that the belt cannot slip off.
The belt also tends to wedge into the groove
as the load increases — the greater the load,
the greater the wedging action — improving
torque transmission and making the vee belt
an effective solution.
For high-power requirements, two or more
vee belts can be joined side-by-side in an
arrangement called a multi-V, running on
matching multi-groove sheaves.
Good resistance to overloads
Timing between sheaves may not be
accurate
MECHANICAL POWER TRANSIMISSION
47. Diesel Engines Eng. Mohammad Embaby
- PROGRAM OBJECTIVE :
• INTRODUCTION
• UNDERSTAND DIFFERENT TYPES OF ENGINES.
• UNDERSTAND HOW DIESEL ENGINES WORK .
• UNDERSTAND CYCLE THEORY OF INTERNAL COMBUSTION ENGINES.
• UNDERSTAND THE DIFFERENT SYSTEMS OF DIESEL ENGINE.
47
48. 48
INTRODUCTION
The diesel engine is used as a source of power for thousands of
applications.
WHO INVENTED THE DIESEL ENGINE?
• In 1895 – RUDOLPH DIESEL successfully invented an
engine that burned coal dust injected by pressurized air.
• The diesel engine was born.
WHO DEVELOPED THE FIRST MASS PRODUCED INJECTION PUMP?
ROBERT BOSCH IN 1927
49. Eng. Mohammad Embaby
INTERNAL COMBUSTION ENGINES
CLASSIFICATION:
Internal combustion engines can be classified according to the
following:
FUEL TYPE: Into Diesel engine and Gasoline engine.
OPERATION CYCLE: Into four stroke engine and two stroke engine.
IGNETION: Into self ignition engine and spark ignition engine.
CYLINDE CONFIGURATIONS: Into line engine, Vee engine
horizontal engine.
COOLING SYSTEM: Water cooled engine and air cooled engine.
NUMBER OF CYLINDERS: 4, 5, 6, 8, 10, ………Cylinders.
ENGINE CAPACITY: 1000 cc/rev, 1300cc/rev, 1600cc/rev, …...and
so on.
Diesel Engines
49
51. Heat Engine
The Internal Combustion engine that produces
power by burning fuel inside a combustion
chamber within the engine.
A heat engine is a device which converts heat
energy into mechanical energy to do work.
Diesel Engines Eng. Mohammad Embaby
51
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
52. Three Elements produce heat energy
◦ To produce heat energy, it is mainly required
air, fuel and combustion. The heating of
air and spray fuel together produces
combustion and explosion, which create the
force required to run the engine.
Diesel Engines Eng. Mohammad Embaby
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
52
53. ◦ Air
Air contains oxygen. Oxygen is required to
burn fuel
◦ Fuel
Fuel produces heat and force. When atomized,
diesel fuels ignite easily and burn efficiently.
◦ Combustion
Combustion occurs when the air fuel mixture
heats up enough to ignite. It must burn
quickly in a controlled fashion to produce the
most heat energy
Diesel Engines Eng. Mohammad Embaby
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
53
54. Combustion Chamber
◦ The combustion chamber is the volume
inside the cylinder at the end of compression
is formed by the cylinder, piston, intake and
exhaust valves, and cylinder head .
Diesel Engines Eng. Mohammad Embaby
54
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
55. Factors that control Combustion
◦ Combustion is controlled by three factors
How much the air is compressed
The type of fuel that is used
The amount of fuel mixed with the air
55
Diesel Engines Eng. Mohammad Embaby
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
56. Compression
◦ Air can be compressed or squeezed into a
smaller volume. When air is compressed, it
heats up. The more you compress air, the
hotter it gets. If it is compressed enough, it
produces temperature above the fuel’s ignition
temperature.
Diesel Engines Eng. Mohammad Embaby
56
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
57. Type of Fuel
◦ The type of fuel used in the engine affects combustion
because different fuels burn at different temperatures,
and some burn more thoroughly.
Amount of Fuel
◦ The amount of fuel is also important because more fuel
produces more force. When injected into an enclosed
area containing sufficient air, a small amount of fuel
produces small amount of heat and force.
Diesel Engines Eng. Mohammad Embaby
57
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
58. Combustion Process: Diesel Engine
◦ In a diesel engine air is compressed inside the
combustion chamber until it is hot enough to self
ignition the fuel about 415Co. Then, fuel is injected
into the hot chamber and combustion & explosion
occurs.
Combustion Process: Gasoline Engine
◦ In a gasoline engine, a mixture of fuel and air is
compressed and a spark ignites the mixture within
the combustion chamber.
Diesel Engines Eng. Mohammad Embaby
58
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
59. Transmitting Heat Energy
◦ In both engine types, combustion produces
heat energy which causes the gases trapped
in the combustion chamber to expand
pushing the piston down.
◦ As the piston moves down, it moves other
mechanical components that do the work.
Diesel Engines Eng. Mohammad Embaby
59
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
60. Engines use two kinds of motion to convert the
heat of combustion into useable power.
◦ Reciprocating Motion
Reciprocating motion is up and down or back and forth
motion
◦ Rotary Motion
Rotary motion means circular motion around a fixed
point.
Rotary Motion
Crankshaft
Reciprocating Motion
piston & connecting rod
Diesel Engines Eng. Mohammad Embaby
60
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
61. ◦ Components that Transmit Motion
The piston, connecting rod and crankshaft
convert reciprocating motion into rotary motion.
As the piston moves up and down, the
connecting rod transmits the reciprocating
motion to the throws on the crankshaft. This
turns the crankshaft, producing rotary motion
which provides power to the equipment.
Diesel Engines Eng. Mohammad Embaby
61
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
62. Top Dead Center (TDC)
◦ Top Dead Center (TDC) describes the piston at its
highest point in the cylinder. The piston reaches TDC
on the compression and exhaust strokes.
Bottom Dead Center (BDC)
◦ Bottom Dead Center (BDC) describes the piston at its
lowest point in the cylinder. The piston reaches BDC
on the intake and power strokes.
Stroke
◦ Stroke is the distance the piston travels from TDC to
BDC.
Diesel Engines Eng. Mohammad Embaby
62
HOW INTERNAL COMBUSTION ENGINES WORK
BASIC CONCEPTS
64. DIESEL ENGINES CARACHTERSTICES
Diesel Engines are Heavier
◦ Diesel Engines are generally heavier than gasoline engines because the
diesel engine must withstand higher combustion pressures and
temperatures.
Compression Ratios
◦ Diesel Engines generally use higher compression ratios to heat the air
to combustion temperatures. Most diesel engines generally have a
13:1 to 22: 1 compression ratio. Gasoline engines generally use
compression ratios between 8:1 and 11:1.
Diesel Engines can perform more work
◦ Diesel Engines can generally perform more work at a lower rpm during
any given time. In general, diesel engines usually operate between 800
and 3000 rpm and provide more torque, and more power to do work.
Diesel Engines are more Fuel Efficient
◦ Diesel Engines are generally more fuel efficient for the amount of work
output than gasoline engines. It requires relatively small amounts of
fuel to produce the rated horsepower output in a diesel engine.
Diesel Engines Eng. Mohammad Embaby
64
65. 4-STROKE ENGINE
Four events of Combustion
◦ Combustion requires four events
Intake of air into the combustion chamber
Compression of the air
Injection and ignition of the fuel
Exhaust of spent combustion gases
Diesel Engines Eng. Mohammad Embaby
65
66. 4-Stroke Cycle
◦ Each event requires one stroke. The four strokes are
called:
1. Intake Stoke
2. Compression Stoke
3. Power Stoke
4. Exhaust Stoke
◦ The combustion chamber components work together in a
precise way during each step of the cycle. During the
four strokes, reciprocating motion is changed into rotary
motion.
Diesel Engines Eng. Mohammad Embaby
4-STROKE ENGINE
66
67. 1- Intake Stroke
During the intake stroke the piston
moves down from TDC and the intake
valve opens to allow the air inters to
cylinder from air filter.
The connecting rod turns the
crankshaft a final 180°.
When the piston reaches BDC the
intake valve closes and the exhaust
valve remains closed.
Diesel Engines Eng. Mohammad Embaby
4-STROKE ENGINE
67
68. 2- Compression Stroke
◦ During the compression stroke both
intake and exhaust valves close in
order to seal the combustion chamber.
◦ The piston moves up within the
cylinder liner to its highest point in the
combustion chamber, top dead center
(TDC).
◦ The connecting rod turns the
crankshaft another 180°.
◦ The piston motion compresses the air
in the cylinder.
◦ The amount the air is compressed is
called the compression ratio. Most
diesel engines have a compression ratio
between 13:1 and 20:1
Diesel Engines Eng. Mohammad Embaby
4 STROKE ENGINE
68
69. 3- Power Stroke
◦ Near the end of the compression
stroke diesel fuel is injected and
combustion occurs.
◦ The rapidly expanding gases force
the piston downward. This is the
power stroke.
◦ The intake and exhaust valves remain
closed to seal the combustion
chamber so that force is exerted on
the piston.
◦ The power stroke moves the piston
down, which causes the crankshaft to
turn 180°.
Diesel Engines Eng. Mohammad Embaby
4 STROKE ENGINE
69
70. 4- Exhaust Stroke
◦ During the exhaust stroke the piston
moves up and the exhaust valve opens to
remove combustion gases.
◦ The connecting rod turns the crankshaft a
final 180°.
◦ When the piston reaches TDC the exhaust
valve closes and the intake valve opens
again.
◦ The combustion cycle occurs over and over
as long as the engine is running.
◦ Each event corresponds to one stroke of
the piston.
Diesel Engines Eng. Mohammad Embaby
4-STROKE ENGINE
70
72. Firing Order
◦ The sequence in which each cylinder comes
to the power stroke is called the firing order
of the engine.
Crankshaft Rotation During 4 Strokes
◦ At the end of the exhaust stroke the
crankshaft has completed the cycle, per two
revolutions (360° rotations) we get one
power stroke.
Diesel Engines Eng. Mohammad Embaby
4-STROKE ENGINE
72
73. Eng. Mohammad Embaby
Every two events require one stroke. The two strokes are
called:
1. Compression Stroke.
2. Power Stroke.
Inlet Air & Exhaust Events
The combustion chamber components work together in a
precise way during each stroke of the cycle. During the
two strokes, reciprocating motion is converted into rotary
motion.
Diesel Engines
2-STROKE ENGINE
73
74. Eng. Mohammad Embaby
1. Compression Stroke:
• The piston moves up to TDC and compresses the
trapped air in the combustion chamber.
• The air pressure and temperature are raised too
much.
• Just before TDC the injector atomizes diesel in
the combustion chamber, self ignition and
explosion occurs .
Diesel Engines
2-STROKE ENGINE
74
75. Eng. Mohammad Embaby
2. Power Stroke:
• Due to explosion, very high pressure force
pushes the piston downward from TDC to
BDC.
• The exhaust valves and air ports are closed,
just Before the piston reaches to open the
cylinder air ports the exhaust valves are
opened.
• The exhaust leaves the cylinder, thus the
internal pressure is dropped.
Diesel Engines
2-STROKE ENGINE
75
76. • Air Intake & Exhaust Event
• The piston continues moving down from
TDC to BDC.
• The exhaust valve and air ports are
opened.
• The air is pushed by the blower into
cylinder through its lowest air ports and
scavenges the remaining exhaust out the
cylinder.
• The piston moves up, Just before the
piston closes the air ports, the exhaust
valves closed.
Eng. Mohammad Embaby
Diesel Engines
2-STROKE ENGINE
76
77. Eng. Mohammad Embaby
Crankshaft Rotation During 2-Stroke
At the end of cycle the crankshaft has completed one
revolution (360° rotation), i.e. we get one power stroke
per one revolution.
For the same size of cylinder bore and stroke, the
produced power from 2st engine equivalent to twice
that from 4st engine.
Diesel Engines
2-STROKE ENGINE
77
79. 79
Eng. Mohammad Embaby
• At the operation beginning the engine must be
started running by outer starter.
TYPES OF ENGINE STARTERS:
1- Electric Starter.
2- Air (pneumatic) Starter.
3- Hydraulic Starter.
4- Mechanical Spring Starter.
5- Manual Starter.
Diesel Engines
METHODS OF ENGINE STARTING
80. 80
1- Electric Starter:
• The system consists of electric motor (of 12V or 24 V – DC
and required amperes) and automatic magnetic coil, electric
battery 12V – DC (one or two), electric switch (Contact),
wiring and dynamo for battery recharging.
• The more current and the more wire, the higher the
magnetic field and the stronger the motor.
• The drive gear (Bendix) that is attached to the motor
meshes with the flywheel gear.
• The flywheel gear then moves the pistons in the cylinders,
setting the engine in motion.
Diesel Engines Eng. Mohammad Embaby
82. Eng. Mohammad Embaby
2- Air (pneumatic) Starter: The system consists of:
1. Pneumatic motor (vane type) attached with drive pinion gear
which will mesh with engine flywheel gear.
2. Air compressor (reciprocating type).
3. Air tank.
4. Air service unit (Drier, lubricator, manometer and Regulator).
5. 2/2 way Pilot operated air start valve.
6. 2/2 way Pilot pushbutton air valve.
Air starter
Diesel Engines
METHODS OF ENGINE STARTING
82
84. 3- Hydraulic Starter: The system consists of:
1. Hydraulic Pump.
2. Check Valve.
3. Accumulator.
4. 2/2 way valve.
5. Hydraulic motor.
6. Connecting hoses.
METHODS OF ENGINE STARTING
84
Diesel Engines Eng. Mohammad Embaby
(2)
(3)
(4)
(5)
(6)
(1)
85. 85
4- Mechanical Spring Starter: The system consists of:
1. Mechanical spring motor.
2. Spring charging handle.
3. Spring lock & release knop.
Eng. Mohammad Embaby
Diesel Engines
METHODS OF ENGINE STARTING
86. 86
5- Manual Starter:
1. handle is connected directly to
crankshaft, It is unsafe to use.
2. Recoil start usually on small
machines the starter consists
of a rope with a grip at the
end, coiled around an end of
the crankshaft.
Eng. Mohammad Embaby
Diesel Engines
90. Eng. Mohammad Embaby
2- BREATHING SYSTEM:
Air intake & Exhaust System
The system consists of:
1. Air suction filter
2. Air manifold.
3. Air valves.
4. Exhaust valves.
5. Exhaust manifold.
6. Spark arrestor.
7. Exhaust piping.
8. Exhaust muffler.
9. Turbocharger increases the air
intake, so the output power by
30%.
Diesel Engines
ENGINE SYSTEMS
(8)
(2)
(3)
(4)
(5) (7)
(9) 90
91. Eng. Mohammad Embaby
3- COOLING SYSTEM
• Remove Heat Generated from Fuel Combustion
Burn Temperatures Can Reach 3,500°F (1927°C)
Cooling systems are designed to keep an engine operating within
a desired temperature range.
Temperature of the coolant must remain high to allow the engine
to operate efficiently, however, temperature must stay low enough
to prevent the coolant from boiling.
A cooling system regulates temperature by transferring heat from
the engine to the coolant &eventually, into the air.
A major factor of heat transfer is the difference between the
temperature of coolant inside the radiator & the temperature of
surrounding air.
When the difference coolant temperature & the ambient
temperature increases, the rate of heat transfer increases.
Diesel Engines
ENGINE SYSTEMS
91
92. 92
• Increased engine wear
• Improper lubrication
• Increased fuel consumption
• Increased sludge formation
• Increased engine corrosion
• Moisture condenses if below 140 degrees in the
engine crankcase
SOME EFFECTS OF OVERCOOLING
• Cylinder head and block can crack or warp.
• Rings and valves may seize or stick due to gums and
varnishes forming from overheated oil and carbon formation.
• Bearings may be damaged causing excessive wear.
SOME EFFECTS OF ENGINE OVERHEATING
THE IDEAL OPERATING TEMPERATURE FOR MOST DIESEL
ENGINES is 165 – 185 DEGREES F (80-90 Co).
COOLING SYSTEM
93. Two types:
I.Water Cooling System
II.Air cooling system
I. Water Cooling System
• Water Is the Most Efficient Heat Transfer.
The system consists of:
1. Water pump.
2. Radiator.
3. Thermostat.
4. Piping and hoses.
5. Radiator cooling fan.
(2)
(5)
(4)
(3)
(1)
93
Diesel Engines Eng. Mohammad Embaby
COOLING SYSTEM
95. Eng. Mohammad Embaby
COOLING SYSTEM
II. Air cooling system
The system consists of:
1. Air Cooling fan.
2. Belt and pulleys.
3. Cylinders fins.
Diesel Engines
ENGINE SYSTEMS
95
96. 96
• LESS WEIGHT.
• LESS MAINTENANCE.
• LESS DOWN-TIME.
• NO CAVITATION EROSION.
• NO COOLANT CONCERNS.
• MORE EFFICIENT USE OF POWER.
• LESS VULNERABLE TO DAMAGE.
• LESS BULK.
• QUICKER WARM-UP.
SOME ADVANTAGES OF AIR-COOLED ENGINES:
• LENGTH OF THE ENGINE.
• LESS TEMPERATURE CONTROL.
• HIGHER OPERATINGTEMPERATURES.
• GREATER NOISE.
• MORE FREQUENT CLEANING.
DISADVANTAGES TO AIR-COOLED ENGINES:
Eng. Mohammad Embaby
Diesel Engines
98. Eng. Mohammad Embaby
LUBRECATION SYSTEM
The system consists of:
1. Oil pump (gear type).
2. Oil filter.
3. Oil sump.
4. Piping & hoses.
5. Suction oil strainer.
Diesel Engines
ENGINE SYSTEMS
(5)
(1)
(3)
(2)
(4)
Oil drain plug
98
99. 99
• Reduces shock, wear, and friction
• Seals compression.
• Provides some cleaning.
• Helps cool the engine.
• Quiets the engine operation
FUNCTIONS OF THE LUBRICATION system:
• OXIDATION INHIBITORS.
• CORROSION AND RUST INHIBITORS.
• DETERGENT DISPERSANTS.
THE THREE MOST COMMON OIL ADDITIVES:
Eng. Mohammad Embaby
Diesel Engines
101. 101
USES OF DIESEL ENGINES
Today, diesel engines are used to provide power in a variety of
applications in many industries.
THERE ARE SEVEN MAJOR USES OF DIESEL ENGINES
TRANSPORTATION.
MARINE.
OIL FIELD.
ELECTRICAL GENERATION PLANTS.
CONSTRUCTION.
AGRICULTURE/FARM.
FORESTRY.