aircrfaft reciprocating engine mock up

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AIRCRFAFT RECIPROCATING ENGINE MOCK UP

MUHAMAD NADHIR KHALIS BIN MOHD NASIR

53156112019

NUR AZIZI BIN LAILA MURAT

531561102145

EN IMRAN BIN MOHD SALLEH

SUPERVISOR

DIPLOMA OF ENGINEERING TECHNOLOGY IN

AEROPLANE MAINTENANCE

SEMESTER 5

UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF AVIATION TECHNOLOGY

JANUARY 2012



AIRCRAFT RECIPROCATING ENGINE MOCK UP FOR TEACHING AID ON THE

OPERATION OF RECIPROCATING ENGINE

MUHAMAD NADHIR KHALIS BIN MOHD NASIR

53156112019

NUR AZIZI BIN LAILA MURAT

53156112045

SEMESTER 5



TABLE OF CONTENTS

Page No.

Title

Declaration i

Approval ii

Acknowledgement iii

List of Tables vii

List of Figures viii

Abstract x

CHAPTER 1: INTRODUCTION

1.1 Introduction to Project 1

1.2 Problem Statement 1

1.3 Project Objective 2

1.4 Limitation of Project 2



CHAPTER 2: LITERATURE REVIEW

2.1Introduction 3

2.2 Types of reciprocating engine 4

2.3 Operating Principles 7

2.4 Piston Engine Configuration 10

2.5 Piston Engine Component 11

2.6 Cylinder Numbering 15

2.7 Firing Order 15

2.8 Engine Horsepower 15

2.9 Engine Efficiency 16

2.10 Reciprocating Engine Manufacturer 17

CHAPTER 3: METHODOLOGY

3.1 Collecting Data 18

3.2 Preparing Equipment and Materials 18

3.3 Built the Mock-up 18

3.4 Tools 22

3.5 Safety Precaution 26

3.6 Procedure 28

3.7 Complete Paper Work 28

3.8 Cost 29

3.9 Weekly Progress 30



CHAPTER 4: RESULT & DISCUSSION

4.1 Result 31

4.2 Discussion 32

CHAPTER 5: CONCLUSION & SUGGESTION

5.1 Conclusion 35

5.2 Suggestion 35

References 36



LIST OF TABLES

Page No.

Table 1: Project Cost 29

Table 4: Work Progress 30



LIST OF FIGURES

Page No.

Figure 1: Radial Engine 4

Figure 2: In Line Engine 5

Figure 3: V Engine 5

Figure 4: Opposed Engine 6

Figure 5: Wankel Engine 6

Figure 6: Four Stroke Cycle 8

Figure 7: Two Stroke Cycle 9

Figure 8: Piston Engine Configuration 10

Figure 9: Crankcase 11

Figure 10: Crankshaft 11

Figure 11: Connecting Rod 12

Figure 12: Piston 12

Figure 13: Cylinder 13

Figure 14: Valve 13

Figure 15: Camshafts 14

Figure 16: Spark Plug 14

Figure 17: Grinding Process 19



Figure 18: Spraying Process 20

Figure 19: Cleaning Process 21

Figure 20: Measuring Tape 22

Figure 21: Spray Paint 22

Figure 22: Wrench Set 23

Figure 23: File 23

Figure 24: Grinder 24

Figure 25: Valve Spring Tool 24

Figure 26: Cleaning Solvent 25

Figure 27: Sandpaper 25

Figure 28: Workshop Attire 26

Figure 29: Safety Shoe 26

Figure 30: Safety Glove 27

Figure 31: Safety Glass 27

Figure 32: Methodology Chart 33

Figure 33: Finish Product 30

Figure 34: Finish Product 30

ABSTRACT



The general purpose of this project about aircraft reciprocating engine is to educate the student

and help the lecturer in teaching by using our mock-up as a learning aid. The aircraft

reciprocating engine can been helpful to all UniKL MIAT students. It is also important to help

the students with their understanding about the operation of piston engine. Now days, we found

that only three of aircraft reciprocating engine mock-up available and only one of them can be

operated.

Due to the lack of mock-up model inside the workshop, we have decided to make one to

use as a teaching aid. To make sure all the component of our aircraft reciprocating mock-up

model working well, we had gathered and study all the information of the piston engine from

various sources including textbook and internet to prepare ourselves in doing this project. Last

but not least, troubleshooting and testing will be done before completely finish this project to

avoid any mistake and all the process and details of this project has been compiled into this

thesis for evaluation

CHAPTER



engine operates. Furthermore, we also gain more knowledge, skills and experiences regarding

piston engine operation. In this project, we try to show the operation of a piston engine with a

cross sectional view, we choose to cut only half section of the piston engine so that the

mechanism and component such as valve, piston, and connecting rod can be seen when it is

operating. Half section or cross sectional view is the best method of depicting internal

arrangement of 3D object.

1.4 LIMITATION

To complete this project, there are always limitation and risks that will be encountered. After

study the theory and the mock up of other researchers, the problem was found while conducting

this experiment. They are:

1. What type of cutter that we are going to used cut a smooth and precise section of the piston

engine?

2. The arrangement of the component inside engine might be displaced, damaged, or not

functioning.

3. Some of the component inside the reciprocating engine is missing.

4. Majority of the workshops do not have the equipment used to cut the piston engine

component.

CHAPTER

2



LITERATURE REVIEW

2.1 INTRODUCTION

An early known example of rotary to reciprocating motion can be found in a number ofRomansaw mills (dating to the 3rd to 6th century AD) in which a crank and connecting rod

mechanism converted the rotary motion of the waterwheel into the linear movement of the saw

blades.[2]

The reciprocating engine developed in Europe during the 18th century, first as the atmospheric

engine then later as the steam engine. These were followed by the Stirling engine and internal

combustion engine in the 19th century. Today the most common form of reciprocating engine is

the internal combustion engine running on the combustion of petrol, diesel, Liquefied petroleum

gas (LPG) or compressed natural gas (CNG) and used to power motor vehicles.

One notable reciprocating engine from the WWII Era was the 28-cylinder, 3,500 hp (2,600 kW)

Pratt & Whitney R-4360 "Wasp Major" radial engine. It powered the last generation of large

piston-engined planes before jet engines and turboprops took over from 1944 onward. It had a

total engine capacity of 71.5 L (4,360 cu in), and a high power-to-weight ratio.

The largest reciprocating engine in production at present, but not the largest ever built, is the

Wärtsilä-Sulzer RTA96-C turbocharged two-stroke diesel engine of 2006 built by Japan’s Diesel

United, Ltd. It is used to power the largest modern container ships such as the Emma Mærsk . It

is five stories high (13.5 m or 44 ft), 27 m (89 ft) long, and weighs over 2,300 metric tons (2,500

short tons) in its largest 14 cylinders version producing more than 84.42 MW (114,800 bhp).

http://en.wikipedia.org/wiki/Roman_Empire


http://en.wikipedia.org/wiki/Reciprocating_engine#cite_note-Tullia_et_al._.282007.29_161-2



http://en.wikipedia.org/wiki/Atmospheric_engine




http://en.wikipedia.org/wiki/Steam_engine



http://en.wikipedia.org/wiki/Stirling_engine



http://en.wikipedia.org/wiki/Internal_combustion_engine




http://en.wikipedia.org/wiki/Petrol



http://en.wikipedia.org/wiki/Diesel_fuel



http://en.wikipedia.org/wiki/Liquefied_petroleum_gas




http://en.wikipedia.org/wiki/Compressed_natural_gas



http://en.wikipedia.org/wiki/Motor_vehicle



http://en.wikipedia.org/wiki/Horsepower



http://en.wikipedia.org/wiki/Pratt_%26_Whitney_R-4360


http://en.wikipedia.org/wiki/W%C3%A4rtsil%C3%A4-Sulzer_RTA96-C


http://en.wikipedia.org/wiki/Emma_M%C3%A6rsk
























Each cylinder has a capacity of 1,820 L (64 cu ft), making a total capacity of 25,480 L

(900 cu ft) for the largest versions.

aircrfaft reciprocating engine mock up

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