Machine and Engine Reciprocating Engine Design, Construction and Materials

21/02/2018
MACHINE and ENGINE

MACHINE :
Reciprocating Engine Design, Is a set of mechanism that joints and work
Construction and Materials which convert input energy into useful output energy.
together
ADOLFO CRUZ OSORIO MASTER IN ENGINE :

AUTOMOTIVE ENGINEERING
Is a machine which convert heat energy from combustion
& AERONAUTICAL process of fuel and air mixture into useful output
ENGINEERING. energy.
Note :
The
rotoroutput energy normally is mechanical energy of the
shaft.
miércoles, 21 de febrero de MIA&IA ACRUZO 2

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INTERNAL
The aircraft powerplant
ENGINE
COMBUSTION
• The airplane engine and

propeller, often referred to
as the aircraft powerplant, • Is an
work in combination combustio
engine
engine and propeller to
produce thrust. nwhich
• The powerplant propels power
the airplane and drives developed
process
the various systems that
support the operation of
an airplane. and inside
2018
in the
engine

2018
EXTERNAL
Reciprocating engines
COMBUSTION ENGINE
• Most small airplanes are designed with
reciprocating engines. The name is derived from
• Is an engine the back-and-forth, or reciprocating, movement of
the pistons. It is this motion that produces the
which mechanical energy needed to accomplish work.
combustion Two common means of classifying reciprocating
engines are:
process
and • By cylinder arrangement with respect to the
power developed crankshaft—radial, in-line, v-type or opposed.
in • By the method of cooling—liquid or air-cooled.
different
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Cylinder arrangements Cylinder arrangements
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Cylinder arrangements Cylinder arrangements

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Reciprocating engines Reciprocating engines
• RADIAL ENGINE
• Radial engines were widely
used during World War II,
and many are still in service
today. With these engines,
a row or rows of cylinders
are arranged in a circular
pattern around the
crankcase. The main
advantage of a radial
engine is the favorable
power-to-weight ratio
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TURBOCOMPOUND
RADIAL ENGINE

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TURBOCOMPOUND
RADIAL ENGINE
• IN-LINE ENGINE
• In-line engines have a
comparatively small frontal
area, but their power-to-
weight ratios are relatively
low. In addition, the
rearmost cylinders of an air-
cooled, in-line engine
receive very little cooling
air, so these engines are
normally limited to four or
six cylinders.
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• OPPOSED HORIZONTAL
• Vee-TYPE ENGINE ENGINE
• Vee-type engines
• Opposed-type engines are the
provide more
most popular reciprocating
horsepower than in-
line engines and still engines used on small airplanes.
retain a small frontal Opposed-type engines have high
area. power-to-weight ratios because
they have a comparatively small,
• Further improvements
in engine design led to lightweight crankcase. In
addition, the compact cylinder
the development of the
horizontally-opposed arrangement reduces the
engine. engine’s frontal area and allows
miércoles, 21 de febrero de MIA&IA ACRUZO 17 a streamlined installation that
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• The main parts of a

reciprocating engine are: • Reciprocating
– Cylinders engine use
– Crankcase
stroke
four cycle :
– Housing
The intake/exhaust valves – Intake

spark plugs, and pistons are – Compression
located in the cylinders. The
crankshaft and connecting rods – Power
are located in the crankcase. – Exhaust
The magnetos are normally
located on the engine
accessory housing.
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Reciprocating INTRODUCTION
Wright Engine

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Reciprocating Engine
0-360-A1
Design and Construction

2018 2018
TIGO-541 SERIES

2018 2018
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Aero Engine Aero Engine

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Aero Engine Aero Engine

2018 2018
Reciprocating Engine Reciprocating Engine

Design and Construction Design and Construction

2018 2018

• Basic Parts • Crankcase
• Crankcase • Foundation of the engine, containing the

• Cylinders bearings in which the crankshaft revolves.
• Pistons
• Connecting rods
• Valves
• Valve-operating
mechanism
• Crankshaft
• Head
• Spark plugs
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• Crankcase • Radial Engine Crankcase
• Tight enclosure for lubricating oil.
• Support for attachment of the cylinders and

the powerplant to the aircraft.
• Must be rigid, strong and light.
• Cast of forged aluminum alloy.
Bearings
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• Opposed Engine Crankcase
Bearings
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• Opposed
crankcase
• Sections are not
as distinct as in
the radial and
the crankcase
splits from front
to rear instead of
in radial sections

• Crankshafts • Crankshaft
• Transforms the reciprocating motion of the
piston and connecting rod into rotary motion • Backbone of engine.
for the propeller.
• Forged from very strong alloy (Chromium-
nickel-molybdenum steel).
• Single or multi-piece.

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• Crankshaft
• Four-throw used on four-cylinder engines.
• Six-throw used on six-cylinder engines.
• Three Main Parts
– Journal
– Crankpin
– Crankcheek

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• Crankshaft Balance
• Dynamic dampers are used to reduce vibration
during engine operation.
• Pendulum which
is fastened to the
crankshaft.

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• Connecting Rods
• Link which transmits forces between the piston
and the crankshaft.
Master and Articulated Fork and
Blade
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• Master and Articulated Rod Assembly • Fork And Blade Assembly
• Commonly used in radial engines.
• One piston in each row is connected to the • Used primarily in V-type engines.
master rod. Others are connected to the
master rod by articulated rods.

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• Plain Type Connecting Rod • Pistons
• Acts as a
• Used in in-line and moving
opposed engines. wall
within
the
combusti
on
chamber.

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• Piston Construction
• As the piston moves down it draws in fuel/air • Machined from aluminum
mixture. alloy forgings.
• As it moves up it compresses the charge. • Grooves machined for
• Ignition occurs, and expanding gases force the piston rings.
piston down.
• Cooling fins inside for
• This force is transmitted to crankshaft through greater heat transfer.
connecting rod.
• Piston pin (wrist pin)
• On the return upward stroke, the piston forces the joins the piston to the
exhaust gas out. connecting rod.
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• Piston Rings
• Compression Rings
Slipper • Oil Control Rings
• Oil Scraper Rings
• Piston Types
Trunk
• Trunk Type Rings
• Slipper Type Pin boss
– Not used
in
aircraft
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• Compression Rings • Oil Control Rings
• Prevent the escape of gas past the piston • Placed in grooves immediately below the
during engine operation. compression rings.
• Number used depends on engine design. • One or more rings per piston.
• Cross section of the ring is either rectangular • Regulate the thickness of the oil film on the
or wedge shaped cylinder wall.

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• Oil Scraper Ring
• Installed in the groove
at the bottom of the
piston skirt.
• Installed with the
scraping edge away
from the piston head
or in the reverse
position.
• Returns surplus oil to
the crankcase.

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• Cylinders
• The portion of the engine
in which the power is
developed.
• Provides a combustion
chamber where the
burning and expansion of
gases take place.
• Houses the piston and
the connecting rod.

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• Cylinders • Cylinder Heads
• Either produced
singly or cast in a • Provides a place for combustion of the fuel/air
block. mixture.
• Air-cooled engine • Gives the cylinder more heat conductivity for
uses the overhead cooling.
valve type.
• Contains the intake valve, exhaust valve and
• Two major parts: sparkplugs.
Head, Barrel.
• Contains fins for cooling.

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• Cylinder Barrels
• Made of a steel alloy forging with the inner

surface hardened to resist wear. (Nitrided)
• Worn Cylinder walls can be ground out and re-

nitrided or chrome plated.
• Chrome plated cylinders can be recognized by

orange paint mark on cylinder.

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• Cylinder Numbering (Opposed Engine) • Cylinder Numbering (Opposed Engine)
• Propeller • Numbering is by no means standard.

(Front)
• Continental starts from rear.
• Accessory
(Rear) • Lycoming starts from front.
• Left, right
(Pilot’s view)
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• Cylinder Numbering (Radial Engine)

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• Cylinder Numbering (Radial Engine) • Firing Order
• Numbered clockwise as viewed from the • The Sequence in which the power event occurs
accessory end. in the different cylinders.
• Single-row, cylinder No. 1 is the top cylinder. • Designed to provide for balance and to
eliminate vibration.
• Double-row, all odd-numbered cylinders are in
the rear, and all even numbered cylinders are
in the front.

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• Firing Order Single-Row-Radial • Firing Order Double-Row-Radial
• First all odd numbered cylinders fire in • Arranged with the firing impulse occurring in a
numerical succession. cylinder in one row and then in a cylinder in the
other row.
• Then the even-numbered cylinders fire in
numerical succession. • Two cylinders in the same row never fire in
succession.
1-3-5-7-9-2-4-6-8

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• Firing Order Opposed Engine • Firing Order Opposed Engine
• Lycoming and Continental number their

cylinders differently which gives us two sets of
firing orders.
1-4-2-3
• But the firing impulses are the same.

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Valves • Valves
• Fuel/air mixture enters the cylinders through

the intake valve.
• Burned gases are expelled through the exhaust

valve.
• Mushroom or tulip type depending on shape.

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• Valve Construction
• Intake valves, because of lower operating

temperatures, can be made of chrome-nickel
steel.
• Exhaust valves are made of exotic metals such

as inconel, silicon-chromium or cobalt-
chromium alloys.

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• Valve Construction • Valve Construction
Tip • Valve head has ground face which forms a seal

against the ground valve seat in the cylinder
head.
Stem • Valve face ground to an angle of either 30° or

Neck 45°.
Face • Valve face made more durable by the

application of stellite (an alloy of cobalt and
chromium).
Head
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• Valve Construction • Valve Construction
• Valve stem acts as a pilot for the valve head • The neck is the part that forms the junction
and rides in the valve guide. between the head and the stem.
• Surface-hardened to resist wear. • The tip is hardened to with stand the

hammering of the valve rocker arm.
• Some stems are hollow and partially filled with
metallic sodium.
2018 2018

• Valve Construction
• Machined groove near tip receives the split-
ring keys which form a lock ring to hold the
valve spring retaining washer.
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• Valve-Operating Mechanism
• Each valve must open at the proper time, stay

open for the required length of time, and close
at the proper time.
• Timing of the valves is controlled by the valve-

operating mechanism.

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• Valve-Operating Mechanism • Valve-Operating Mechanism (Opposed engine)
• Intake valves open just before the piston

reaches top dead center, and exhaust valves
remain open after top dead center.
• At this particular instant both valves are open

at the same time (end of the exhaust stroke and
beginning of the intake stroke).
• This valve overlap results in better volumetric

efficiency and lower operating temperatures.
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• Valve-Operating • Camshaft
Mechanism • Valve-operating mechanism is operated by a
(Radial engine) camshaft.
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• Camshaft
• The camshaft is
driven by a gear
that mates with
another gear
attached to the
crankshaft.
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• Tappet Assembly
• Converts rotational movement of the cam lobe

into reciprocating motion.
• Transmits this motion to the push rod, rocker

arm, and then to the valve tip.
• Opening the valve at the proper time.

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• Tappet Assembly • Hydraulic Valve Tappets
• Designed to automatically keep the valve

clearance at zero.
• Ball check valve traps oil in the pressure

chamber and.
• Acts as a cushion as the camshaft rotates.
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• Hydraulic Valve Tappets • Push Rod
• Transmits the force from the valve tappet to the

rocker arm.
PUSH ROD SOCKET
• Tubular form used because of its strength
• Permits lubricating oil to pass through the

hollow rod to the ball ends.
HIGH PRESSURE
OIL SOURCE

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• Rocker Arms • Valve Springs
• Transmits • Function is to
the lifting close the valve
force
and to hold the
from the
cam to valve securely
the valve. on the valve
seat.
2018 2018

• Valve Springs
• Two or more springs used to eliminate spring

vibration or surging during different engine
speeds.
• Held in place by split locks installed in the

recess of the valve spring upper retainer
washer.

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• Bearings • Bearings
• Any surface which supports, or is supported

by, another surface.
• Composed of material that is strong enough to

withstand the pressure imposed on it.
• Permit the other surface to move with a

minimum of friction and wear.
• Lubricated bearings.
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2018
Reciprocating Engine
Bearings
Design and Construction
• Bearings
• Three types of lubricated bearings used:
– Plain Bearings
– Ball Bearings
– Roller Bearings
• Bearings are required to take radial loads,

thrust loads, and a combination of the two.
2018 2018

• Plain Bearings • Ball Bearings
• Used for crankshaft, cam ring, camshaft, • Used in supercharger impeller shaft bearings
connecting rods, and accessory drive shaft. and rocker arm bearings.
• Subjected to radial • Special deep groove ball bearings are used in

loads. some aircraft engines to transmit propeller
thrust to the engines nose section.
• Made of nonferrous
metals.
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• Roller Bearings
• Straight roller bearings
used where the bearing is
subjected to radial loads
only.
• Tapered roller bearings

used where bearing is
subjected to both radial
and thrust loads.
2018 2018

• Propeller Reduction Gearing
• Turns the propeller at a slower speed than the

engine.
• Increases propeller efficiency.
• Three types:
– Spur Planetary
– Bevel Planetary
– Spur and Pinion
2018 2018

• Propeller Shafts
Spline
Taper Flange
Spur and Pinion
Spur Planetary
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FUTURE GENERAL
ASI SE HACE UN MOTOR
AVIATION PROPULSION

2018 2018
FUTURE GENERAL FUTURE GENERAL

AVIATION PROPULSION AVIATION PROPULSION
2018 2018

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FUTURE GENERAL
END
AVIATION PROPULSION
THANKS
FOR
YOURS
ATTENCION
2018 2018
27

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21/02/2018

MACHINE and ENGINE

ADOLFO CRUZ OSORIO MASTER IN ENGINE :

miércoles, 21 de febrero de MIA&IA ACRUZO 2

• The airplane engine and

miércoles, 21 de febrero de MIA&IA ACRUZO 4

miércoles, 21 de febrero de MIA&IA ACRUZO 5

Cylinder arrangements Cylinder arrangements

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Cylinder arrangements Cylinder arrangements

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Reciprocating engines Reciprocating engines

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Reciprocating engines Reciprocating engines

Reciprocating engines Reciprocating engines

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Reciprocating engines Reciprocating engines

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Reciprocating engines Reciprocating engines

• The main parts of a

The intake/exhaust valves – Intake

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UL260i ULPOWER UL260i ULPOWER

miércoles, 21 de febrero de MIA&IA ACRUZO 35 miércoles, 21 de febrero de MIA&IA ACRUZO 36

UL260i ULPOWER UL260i ULPOWER

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Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine

• Crankcase • Foundation of the engine, containing the

Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine

• Tight enclosure for lubricating oil.

• Support for attachment of the cylinders and

• Must be rigid, strong and light.

• Cast of forged aluminum alloy.

Reciprocating Engine Reciprocating Engine

Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine

Reciprocating Engine Reciprocating Engine

Reciprocating Engine Reciprocating Engine

Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine

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Reciprocating Engine Reciprocating Engine