Chapter - 6

1 Engine cooling system

 2 Engine cooling system
 Engine cooling is the process of dissipating excess heat generated during an engine's
operation to maintain its optimal operating temperature. Proper cooling prevents
overheating, reduces wear on engine components, and ensures efficient performance and
durability.
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How Cooling Works
 The cooling system in an engine absorbs heat from the engine block and other high-
temperature areas and releases it into the environment. This maintains a stable temperature
range that prevents damage to engine components while optimizing efficiency.
 4 Necessity Of Engine Cooling
 In an I.C. engine, the temperature of the gases inside the engine cylinder may vary from
35°C or less to as high as 2750°C during the cycle. If an engine is allowed to run without
external cooling, the cylinder walls, cylinder and pistons will tend to assume the average
temperature of the gases to which they are exposed, which may be of the order of 1000 to
1500°C.
 Obviously at such high temperature ; the metals will loose their characteristics and piston
will expand considerably and sieze the liner..
 If the cylinder wall temperature is allowed to rise above a certain limit, about 65°C, the
lubricating oil will begin to evaporate rapidly and both cylinder and piston may be
damaged.
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Thus cooling system is provided on an engine for the following reasons :

 1. The even expansion of piston in the cylinder may result in seizure of the piston.

 2. High temperatures reduce strength of piston and cylinder liner.

 3. Overheated cylinder may lead to pre-ignition of the charge, in case of spark ignition
engines.
 4. Physical and chemical changes may occur in lubricating oil which may cause sticking of
piston rings and excessive wear of cylinder.
 5. If the cylinder head temperature is high the volumetric efficiency and hence the power
output of the engine is reduced.
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Thus engine cooling is required to keep the temperature of the engine low in order to avoid :

 (i) Loss of volumetric efficiency and hence power ;

 (ii) Engine seizure ;

 (iii) Danger of engine failure.

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The Purpose of Cooling System

Prevent Overheating

Excess Heat generated in engine

Peak temperatures exceed melting point of metal

Regulate the most efficient Temperature

Regulate Temperature

Allow engine to warm up in cool weather

Maintain engine in optimum range.

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Introduction
 Consequence of engine running too hot:
 Pre-ignition
 Detonation/Knock
– All result in very high pressure rise and possible damage to engine
 Heat Fatigue of components
Burnt Pistons
Burnt Valves
 Failure of lubrication system
Oil breakdown
Oil film at cylinder destroyed at 200C
Scoring of piston & sleeves
 Warping & fracture of components
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Introduction
 Consequence of engine running too cold:

Unnecessary Wear

Poor Fuel Economy

Incomplete Combustion

Lower coolant Temperature

More energy transferred out of cylinder

Energy from is wasted & not available for work (Power)

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Introduction
Promotes corrosive conditions in engine

Water of combustion reacts with sulfur oxides in exhaust

Forms acids

Allows water & sludge to accumulate in crankcase

Over time, fuel diluting the oil will accumulate

Normally lighter volatile fuel will evaporate as temp. rises

 11 Parameters Affecting Heat Transfer
 Engine heat transfer depends upon many parameters, unless the effect of these parameters is known, the
design of a proper cooling system will be difficult.
 Fuel-Air Ratio
A change in fuel-air ratio will change the temperature of the cylinder gases and affect the flame
speed.
 Spark Advance
More or less spark advance from the optimum value will result in increased heat rejection to the
cooling system
 Pre-ignition and knocking
 Engine output
Engines which are designed for high M.E.P or high piston speeds, heat rejection will be less
 Cylinder wall temperature
 12 Power required to cool the engine
 The power required to run the cooling system should come from the engine.
 For air cooled engine
 Assumptions
Engine operated at constant fuel-air ratio
Change in fin or coolant temperature are assumed to be small enough so that ΔT, (Tcyl gas-T cyl wall) is
constant
The density and temperature of cooling media are assumed to be unaffected by its flow through the
engine or radiator fins.

 The variation of cooling power required in terms of the indicated power of the engine is
Ae (i p ) 2.25
Pc 
( A f T f ) 3.75  a2
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Where Ae - the effective area

 ip - indicated power
 Af - the fin area
 ΔTf-the temperature difference b/n the air and the fin
 ρa - the density of air
 A great reduction in required cooling power can be effected :
 by increasing the fin area and the temperature difference as much as possible
 By reducing the air velocity, the power required for the cooling Pe can be reduced.
 14 Characteristics of an efficient cooling system

 The two main characteristics desired of an efficient cooling system

It should capable of removing about 30 % of the heat generated in the combustion
chamber while maintaining the optimum temperature of the engine under all operating
conditions of the engine

It should remove heat at a faster rate when engine is hot. However during starting of the
engine the cooling should be minimum, so that the working parts of the engine reach
their operating temperatures in a short time.
 15 Types of cooling System

 There are two types of system in general

Liquid or indirect cooling system
Air or direct cooling system
 Liquid cooling system
 Mainly water is used and made to circulate through the jackets provided around the
cylinder, cylinder head, valve ports and seats where it extracts most of the heat.
 The heat transferred from the cylinder wall and other parts by convection and
conduction.
 The heat from liquid in turn is transferred to air. Hence it is called the indirect cooling
system
 16 Methods of water-cooling System

 Water cooling can be carried out by any one of the following five methods

Direct or non return system

Thermosyphon system

Forced circulation cooling system

Evaporation cooling system

Pressure cooling system

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Direct or Non return System
 This system is useful for large installations where plenty of water is available.
 The water from a storage tank is directly supplied through an inlet valve to the engine
cooling water jacket
 The hot water is not cooled for reuse but simply discharged.
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 Thermosyphon System
A Thermosyphon system is a passive heat exchange mechanism that relies on natural convection to circulate a
fluid without the need for mechanical pumps. It is commonly used in solar water heaters, cooling systems for
engines, and other thermal management applications.
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 Cont..
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 Cont..
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Forced circulation Cooling System

 This system is added in a large number of Automobiles.
 Here the flow of water from radiators to water jackets is by convection assisted by a pump
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 Water or coolant is circulated with through jackets around the parts of the engine to be cooled is kept in
motion by a centrifugal pump which is driven by the engine
 The water is passed through the radiator where it is cooled by the forward motion of the vehicle
 A thermostat is used to control the water temperature required for cooling
 This system consists of 4 components
 Radiator water pump
 Fan thermostat
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 cont
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 Cont..
 25 Evaporative cooling system
 Cont..
 26 Evaporative cooling system
 Cont..
27 Basic Schematic Layout

Cab heat
exchanger

Heater Control Thermo-

stat

Fan Radiator
Engine Block &
Cylinder head
Water Jacket Water
Pump
28
Parts of Engine Cooling System
29 Cooling System Construction

Radiator
Cap

Top Hose Radiator

Thermostat Fan

Water
Engine Block Pump
& Water
Jacket
 30 Cold Engine
 When an engine is cold, the thermostat is closed. Coolant flow is through the bypass hose
and the water jackets. This allows the engine to warm up evenly.
 31 Warm Engine
 The thermostat opens when the engine warms up. This allows coolant to circulate through
the radiator and the water jackets

.
 32 Water jackets

 Defined as the open space within in the cylinder block and cylinder head where coolant
flows
 Water jackets are designed to allow coolant flow to the right spots flow to the right spots so
that maximum cooling can be obtained
 33 Water Pump
 The water pump is a critical component of an engine's cooling system. Its primary role is
to circulate coolant throughout the engine and radiator to regulate temperature and prevent
overheating. Here's how it works:
 Purpose of the Water Pump
 The water pump ensures a continuous flow of coolant between the engine block, cylinder
head, radiator, and heater core, keeping the engine at an optimal operating temperature.
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 How It Works
a. Driving the Pump:
 The water pump is typically powered by a serpentine belt, timing belt, or timing chain connected
to the engine's crankshaft.
 As the engine runs, the crankshaft turns the pulley, driving the pump's impeller.
b. Coolant Flow:
 The impeller blades spin inside the pump housing, creating centrifugal force.
 This force pushes coolant outward through the pump and into the engine block and cylinder head.
 After absorbing heat from the engine, the coolant flows to the radiator, where it releases heat to the
air.
c. Continuous Circulation:
 The coolant returns to the water pump after cooling in the radiator, repeating the cycle.
 35 Thermostat

A thermostat is a regulating device component which senses the temperature of a physical

system and performs actions so that the system's temperature is maintained near a desired
setpoint.

 One of the most important parts of the cooling system

Purpose of thermostat

 Is to keep the engine coolant at most efficient temperature

 The thermostat is used to bring the coolant temperature up to operating as quickly as possible

 It is designed to sense the temperature of the coolant

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 Continue..

When the coolant is still cold, the thermostat shuts off the
longer circuit closing the supply to the radiator.
The coolant circulates within the shorter circuit bypassing the
radiator and causing the engine to warm up to its operation
temperature faster .
37 Thermostat
 38 Radiator
 What is a function of radiator?
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Purpose of radiator

Is to allow fresh air to reduce the temperature of the coolant

 As the coolant passes through the tubes air is forced around the tube

 This causes a transfer of heat from the hot coolant to the cooler air. This is called Heat
exchanged

 In this case, heat is exchanged from the liquid coolant to air. This is called a liquid-to air
heat exchanger
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 How It Works
a. Coolant Enters the Radiator:
 Heated coolant from the engine flows into the radiator's inlet tank via a hose.
 The radiator core disperses the coolant into thin tubes to maximize surface area.
b. Heat Dissipation:
 Airflow: As the vehicle moves, air flows through the radiator's fins, carrying heat away.
 Cooling Fan: When airflow is insufficient (e.g., at low speeds), the fan pulls or pushes air
through the radiator.
c. Coolant Exits the Radiator:
 After cooling, the coolant collects in the outlet tank and returns to the engine through
another hose to repeat the cycle.
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Radiator Parts
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43

 Radiator
 44 Radiator pressure cap
 A pressure cap in an engine cooling system plays a critical role in maintaining the system's
performance and preventing overheating.
 Pressure caps are designed to
Increase the pressure on the cooing system
Reduce cavitation's
Protecting the radiator hose
Prevent or reduce surging
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 How It Works
a. Under Normal Operation:
 When the engine heats up, the coolant expands, increasing pressure within the system.
 The pressure cap has a predetermined pressure rating (e.g., 15 psi). It keeps the system sealed until this limit
is reached.
b. When Pressure Exceeds the Limit:
 If the pressure exceeds the cap's rating, the spring-loaded valve opens, allowing excess coolant to escape into
the overflow tank.
 This prevents damage to hoses and other components from excessive pressure.
c. As the Engine Cools:
 When the engine cools down, the coolant contracts, creating a vacuum in the system.
 The vacuum valve in the pressure cap opens, allowing coolant from the overflow tank to return to the radiator,
maintaining a full cooling system.
46 Pressure Cap
47 Pressure Cap
 48 Pressure Cap
 Components
49 Expansion tank
50 Expansion tank
51 Fan
52 Electric Fan Relay
53 Coolant Temperature Indicator
54 Coolant Temperature Indicator
55 Types of Coolant
56 Coolant
57 Thank you

Class End