AGK: Piston 1

  1. Physics Revision
  • Internal Combustion = Convert chemical energy to heat energy by burning fuel with air internally
  • Boyle's law: P 𝜶 1/V
  • Charle's law: V𝜶T
  • Combined gas law: PV/T = constant
  • Eqn. of continuity (Mass flow) (Alien vs Predator) AV⍴ = Mass flow = constant
  • Bernoulli's: Ps + Pdyn = constant
  • Mechanism for Heat Transfer: Conduction, Convection (via circulation of a fluid), Radiation (via EM waves)
  • Newton's laws
  • F (Thrust) = m*a (Newton's 2nd)
  • Momentum = m*v
  • Work (Joules) = F*d
  • Power (Watt) = Rate of doing work = W/t
  • Torque = F*dist (and depends on angle applied)
  • Efficiency = a measure of output c/f input
  1. Piston Engine

4 stroke cycle (Otto Cycle) - ICPE

  • Induction > Compression > Power > Exhaust
  • Top dead centre (TDC), Bottom Dead Centre (BDC)
  • Stroke = TDC - BDC (180deg crank rotation)
  • Power stroke only one that generates power!
  • 2 revs of crank needed for 4 stroke
  • Typical Firing seq: 1 -3-4-2

Types

  • Rotary: Fixed crankshaft with cylinders rotating around it
  • Radial: Fixed cylinders with central rotating crankshaft
  • In Line: cylinders in line,⬇️frontal area, cooling problem ∴usually only 4 or 6
  • Inverted In Line: Clearance over eng. for good viz. Risk of hydraulicing.
  • Horizontally opposed most common - cylin & piston horizontal either side of central crankshaft
    Good viz, smaller than in-line (can fit into nacelle = less drag), No hydraulicing, more even cooling
  • V: ⬆️cylinders without ⬆️engine length

Components

  • Piston: Crown > Compression Ring (cast iron. Carbon in it = self-lube) > Oil control ring (even spread oil in cylin. > Skirt ( joined to con-rod small end by Gudgeon pin)
  • Connecting Rod
    • Small end joined to piston via Gudgeon pin
    • Big End (2 halves) joined to crankshaft big end bearing/journal
  • Crankshaft: Steel (case = iron), main journal (oil ways), BE journals. Throw = BE to crankshaft. Throw = 1/2 stroke
  • Cylinder head + cylin. Barrel. Head has more cooling fins cos of combustion
    • Cam shaft: EXAM: Rotates at 1/2 speed of crankshaft. Driven by crankshaft. Controls poppet valves open/close
  • Ports: Inlet bigger than exhaust
  • Valves (Poppet): Inlet bigger than exhaust
  • Valve Gear: Cam lobe > hydr. tappet > push rod >rocker arm > clearance > valve (via stem)

    Springs rtns valve to open. Springs wound different direction to stop valve rotating

  • Sodium filled exhaust valves for cooling

Calcs

  • Swept volume = how much charge can be displaced
  • Clearance volume = vol. between TDC and top of cylinder (where piston can’t go)
  • CompressionRatio=SweptVolume+ClearanceVolumeClearanceVolume

Piston Eng. Power

  • Work = Force * Dist.
  • Power (HP) = Work / Time (rate of Work)
  • 1hp = 330lbs coal pulled 100ft in 1 min = 33000 lb ft/min
  • Friction (Prony) brake - measure hp (tries stop eng from turning)
  • \( Brake\;HP\;(actual\;HP) = \frac{Force\;*\;Moment\;arm\;*\;2pi\;*RPM}{33000} \)
  • \( Brake\;HP\;(actual\;HP) = Torque\;*\;RPM \)
  • \( Indicated\;HP = \frac{PLANE}{33000} \)
    • P = Indicated Mean Effective Pressure (mean press. put on piston in power stroke)
    • L = Length of stroke
    • A = Area of piston crown
    • N = Number of POWER strokes per min
    • E = Number of cylinders
      .
    • P * A = Force
    • L = Distance
    • N * E = rate
  • BHP = IHP (theoretical HP) - FHP (friction HP)

Factors Affecting Power Output - DME

  • Density - affected by Press, Temp, humidity
  • Mixture Ratio - becomes richer as density ⬇️correct manually
  • Exhaust Back Press. - as press. ⬇️ with alt., scavenging ⬆️ cos less work to get exhaust out

Efficiency - TMV

  • Thermal - only 30% of fuel = work
    \( Thermal\;Eff. = \frac{Work\;Out\;(BHP)}{Work\;(Energy)\;in\;fuel} \) **
  • Mechanical - ratio of BHP to IHP
  • % of power in the eng. to turn prop
  • typically 80-85%
  • Volumetric - ratio of vol. of charge drawn c/f swept vol (induction)
  • Indication of how well eng. is breathing
  • typically 85%

⬆️ Volumetric Efficiency - Practical cycle

  • Ineffective crank angle - Close to TDC & BDC v. lil linear movement of piston even though angular rotation speed of crankshaft unchanged
  • Practical 4-stroke cycle - counter Ineffective crank angle
    • Inlet Lead and Lag
    • Ignition Advanced
    • Exhaust Lead & Lag
    • Valve Overlap
      .
  • SFC ( Lb (or Kg) / BHP/ Hour )
    • The mass of fuel used per unit HP produced per unit time

4 Piston Eng. Lube & Cooling

  • Oil: ⬇️friction, cooling, seal & cushion, protect from corrosion, cleaning

Types

  • Straight Mineral (no additiv)
    • 'Running in' oil - first 50hrs
    • Tends to oxidise at hi temp, causes sludge = block filters
  • Detergent (flushing)

    *Hi cleaning - not generally approved for aero engs.

  • Synthetic
    • Superior cos of additives etc but expensive so not common

Grades

  • Graded by viscosity (resistance to flow) - affected by temp
  • Saybolt Universal Viscometer (US) = 2 * Society of Automotive Engineers (SAE) UK

    i.e. 100 Saybolt = 50 SAE


  • Slow flow = Hi Visco. (i.e. best for summer)
  • Free flow = Low Visco. (i.e. best for winter)
  • Multigrade oil: behaves like thin oil in winter, thick in summer

Methods of lube

  • Pressure lubrication i.e. pressurised oil feeds
  • Splash lubrication i.e. crankshaft ‘splashing' in oil sump
  • Combination of pressure and splash

Wet Sump System

  • Oil stored on the underside of the crankcase
  • same components as Dry Sump except NO oil tank or scavenge line
  • Splash lubrication - when crank moves in sump

Dry Sump

  • Oil tank - oil rtns from scavenge line > de-aerator > hot-well > pump
  • Spur Gear Pump: 2 intermeshed gears, 1 driven by eng.
  • Pres. Relief Valve: Spring-loaded, if press. too hi, opens, sends oil back to pump
  • Oil Cooler: air cooling via matrix of fins. Air controlled via shutters. Thermostatic valve allows matrix bypass if temp too cold
    • Dry sump: located between scavenge pump and oil tank
    • Wet sump: located pressure line b4 engine.
  • Magnetic Plug (Chip detector): pickup ferrous debris (Dry=rtn line, Wet = sump)
  • Coarse filters (+bypass): Before pressure and scavenge pumps
  • Pressure (fine) filter(+bypass): filter fine particles that can damage bearings

Wet c/f Dry Sump

  • Dry
    • Adv: Oil supply even when inverted
    • Oil check immediate after shutdown to avoid drain back into eng. (give too low read)
      .
  • Wet
    • Disadv: Splash lube = excess oil, esp. at hi RPM, splash lube oil not filtered or cooled, oil starvation if inverted
    • Oil check 20min after shutdown to allow drain back to sump

EXAM

  • EXAM: What might cause oil pressure to be very low
  • A: Debris in pressure relief valve causing it to stay open
  • Cold morning = high pressure on initial start cos oil is v. viscous. This ⬇️when Temp @ operating

Cooling

  • Air
    • Cooling fins radiate heat. More fin = more surface area
    • Inter-cylinder baffles for even cooling
    • Cowl flap regulate air flow
  • Liquid
    • Extract heat from eng by running water & glycol mix thro galleries built into crank case & cylinder block. Hot fluid passed thro heat xchanger b4 returning to eng.
      • Adv: Equalised cooling, consitent temp regulation, heat ex. for better cabin heat & Demister
      • Disadv: Heavy, complex, more maintenance, leaks = overheat

5 Piston Fuel Sys.

  • Carburettion = mixing fuel and air
  • 15:1 is optimal
  • monitor exhaust gas temp, highest = 15:1
  • 9:1 Full rich, best for TO cos unburnt fuel cools cylinders so hi RPM
  • 12:1 Best Power (Fast crz)
  • 16:1 Best SFC crz
  • Detonation= spontaneous combustion post ignition. Triggered by shockwave from ignition. Excess hi press. at TDC, knocking. Power ⬇️ markedly, cylin. temp ⬆️ = damage
  • Caused by: Incorrect octane fuel, weak mix ratio, hi eng temp, if temp or press of mix raised b4 it's burnt i.e. low RPM, hi manifold press.
  • Preignition: Ignition of fuel b4 sparkplug. Caused by carbon deposits + Hi temps. Same symptoms as detonation
  • Pre-ignition worsen with ⬆️ RPM whereas detonation ⬇️ as RPM ⬆️
  • Pre-ignition unique characteristic – "Running on" = eng. continues to run for a short period after ignition turned off
  • Octane Rating - resistance to detonation
  • Normal Heptane - easy detonates = zero
  • IsoOctane - hard to detonate = 100
  • Octane #s >100 called performance #s
  • Additives
  • Tetra Ethyl Lead = ⬇️combustion temp & ⬆️ flame rate but Lead Oxide corrosive
  • Then added Ethylene Di-bromide convert Lead Ox. to Lead Bromide but lead poisoning,⬇️ mental capacity
  • Most popular additiv now aromatic hydrocarbons and alcohol
  • AVGAS80 - RED
  • AVGAS100 - GREEN
  • AVGAS100LL (Low Lead) most common - BLUE