Unit 4
Cooling system of IC engine
Functions of the Cooling system
Control temperature of hot combustion.
Keep engine at its most efficient temperature
2500 degree temps. Could seriously damage engine
parts.
Provide Heat for passenger Compartment.
Cool Trans fluid & Oil
EFFECTS OF OVERHEATING OF THE ENGINE
COMPONENTS
Evaporation of lubricating oil.
Setting up of thermal stresses in the cylinder.
Sticking of piston rings in the ring grooves, due to
carbonization of the oil.
Burning of piston crown.
Burning and warping of exhaust valves.
Reduction in volumetric efficient i.e. reduced weight
of charge retained in the cylinder.
EFFECTS OF EXCESSIVE COOLING
Reduction in thermal efficiency.
Increased corrosion of engine parts.
Reduced mechanical efficiency.
Improper vaporization of fuel.
TYPES OF COOLING SYSTEM
There are two types of cooling systems:
(i) Air cooling system
(ii) Water-cooling system
AIR COOLING SYSTEM
In this type of cooling system, the heat, which is conducted to the
outer parts of the engine, is radiated and conducted away by the
stream of air, which is obtained from the atmosphere. In order to
have efficient cooling by means of air, providing fins around the
cylinder and cylinder head increases the contact area.
The fins are metallic ridges, which are formed during the casting
of the cylinder and cylinder head.
The amount of heat carried off by the air-cooling depends upon
the following factors:
o The total area of the fin surfaces,
o The velocity and amount of the cooling air and
o The temperature of the fins and of the cooling air
AIR COOLING SYSTEM
Advantages of Air Cooled Engines
1. The air-cooled engine is simple in design.
2. It is lighter in weight than water-cooled engines due to the
absence of water jackets, radiator, circulating pump and the
weight of the cooling water.
3. It is cheaper to manufacture.
4. It needs less maintenance.
5. This system of cooling is particularly advantageous where
there are extreme climatic conditions in the arctic or where
there is scarcity of water as in deserts.
6. No risk of damage from frost, such as cracking of cylinder
jackets or radiator water tubes.
WATER COOLING SYSTEM
In the present day, liquid cooling is widely used due to the
resistance to heat transfer from the cylinder wall to a liquid in
contact with it is low.
When the velocities of the liquid are fairly high, this resistance is
very low.
Due to this, the film heat transfer coefficients are high. Also heat
transfer is greater.
The most commonly used substances for cooling is water.
Other liquids are ethylene glycol or Preston or glycerin.
These have boiling points much higher than water, But they have
corrosive effects on engine parts.
In liquid cooled engines, water jackets are provided to circulate
coolant.
WATER COOLING SYSTEM
Merits and Demerits of Liquid cooling
system
Merits Demerits
Uniform cooling of Depends on supply of
cylinder, head and valves. coolant.
Specific fuel consumption Water pump takes power
improves. from engine.
If system fails, severe
Engine can be provided in
damage will occur to engine.
front or rear.
Costly
Less engine noise than air
Periodic Maintenance
cooled engine.
required.
Higher thermal efficiency.
Increases weight of vehicle.
Parts of Liquid(Water) Cooling System
(i) Water Pump
(ii) Fan
(iii) Radiator and Pressure Cap
(iv) Fan Belt
(v) Water Jacket
(vi) Thermostat Valve
(vii) Temperature Gauge
(viii) Hose Pipes
Water Pump
Centrifugal type pump.
Mounted at the front of
the cylinder block.
This type of pump consists
of the following parts:
(i) Body or casing,
(Ii) Impeller (rotor),
(Iii) Shaft
(Iv) Bearings, or bush,
(V) Water pump seal
(Vi) Pulley
Water Pump
Cooling Fan
The fan is mounted on radiator
frame. It serves two purposes in the
cooling system of an engine.
(a) It draws atmospheric air through
the radiator and thus increases the
efficiency of the radiator in cooling
hot water.
(b) It throws fresh air over the outer
surface of the engine, which takes
away the heat conducted by the
engine parts and thus increases the
efficiency of the entire cooling
system.
Radiator
The purpose of the radiator is to cool down the water
received from the engine. The radiator consists of three main
parts: (i) upper tank, (ii) lower tank and (iii) tubes.
Hot water from the upper tank, which comes from the engine,
flows downwards through the tubes. The heat contained in
the hot water is conducted to the copper fins provided
around the tubes.
An overflow pipe, connected to the upper1 tank, permits
excess water or steam to escape.
There are three types of radiators: (i) Gilled tube radiator,
(ii) tubular radiator and (iii) Honey Comb or Cellular
radiator
Radiator
Radiator
Different types of radiator cores
Thermostat Valve
It is check valve which opens and closes with the effect of temperature.
It is fitted in the water outlet of the engine to allow engine to warm-up.
During the warm-up period, the thermostat is closed and the water pump
circulates the water only throughout the cylinder block and cylinder head.
When the normal operating temperature is reached, the thermostat valve
opens and allows hot water to flow towards the radiator.
Standard thermostats are designed to start
opening at 70º to 75°C and they fully open at
82°C.
High temperature thermostats, with permanent
anti-freeze solutions (Prestine, Zerex, etc.), start
opening at 80° C to 90°C and fully open at
92°C.
Types of Thermostat
There are three types of thermostats:
(i) Bellow Type,
(ii) Bimetallic Type
(iii) Pellet Type.
Bimetallic type
thermostat
Bellow type thermostat Pellet type thermostat
Bellow type valve
Flexible bellows are filled with alcohol or ether. When the
bellows is heated, the liquid vaporizes, creating enough
pressure to expand the bellows. When the unit is cooled, the
gas condenses. The pressure reduces and the bellows
collapse to close the valve.
Bimetallic type Thermostat valve
This consists of a bimetallic strip. The unequal expansion of
two metallic strips causes the valve to open and allows the
water to flow in the radiator.
Pellet type Thermostat valve
A copper impregnated wax pellet expands when heated
and contracts when cooled. The pellet is connected to the
valve through a piston, such that on expansion of the pellet,
it opens the valve. A coil spring closes the valve when the
pellet contracts.
Pressure Cap
Important questions
1. List out effects of overheating of the engine components
2. Draw layout of liquid cooling system.
3. Explain working of water cooling system.
4. Difference between air cooling and water cooling system.
5. Advantages and disadvantages of water cooling system over
air cooling system.
6. List out types of thermostat valves.
7. Explain working of thermostat valve.