Fuel properties
■    Fuels are any material that store potential energy in forms, which upon burning in oxygen liberates heat energy.
■    Calorific value of fuel is the total quantity of heat liberated when a unit mass or volume of fuel is completely burnt.
■    Higher or gross calorific value (HCV) in the total amount of heat produced when a unit mass/volume of fuel has been burnt completely and the products of combustion have been cooled to room temperature (15°C or 60°F).
■    Lower or net calorific value (LCV) is the heat produced when unit mass (volume) of the fuel is burnt completely and the products  are permitted to escape.
LCV = HCV – Latent heat of water formed
■    Natural or primary fuels are found in nature such as wood, peat, coal, natural gas, petroleum.
■    Artificial or secondary fuels are prepared from primary fuels charcoal, coal gas, coke, kerosene oil, diesel oil, petrol, etc.
■    Fuels are further classified as
1.     Solid Fuels
2.     Liquid Fuels
3.     Gaseous Fuels

Characteristics of solid fuels

1.     Ash is high.
2.     Low thermal efficiency
3.     Form clinker
4.     Low calorific value and require large excess air.
5.     Cost of handling high
6.     Cannot be used in IC engines.

Characteristics of liquid fuels

1.     High calorific value
2.     No dust ash and clinker
3.     Clean fuels
4.     Less furnace air
5.     Less furnace space
6.     Used in IC engines

Characteristics of Gaseous fuels

1.     Have high heat content
2.     No ash or smoke
3.     Very large storage tanks are required

An ideal fuel should have the following properties:

1.     High calorific value
2.     Moderate ignition temperature
3.     Low moisture content
4.     Low NOn combustible matter
5.     Moderate velocity of combustion
6.     Products of combustion not harmful
7.     Low cost
8.     Easy to transport
9.     Combustion should be controllable
10.  No spontaneous combustion
11.  Low storage cost
12.  Should burn in air with efficiency.


Thermodynamics is the branch of physics that deals with the relationships between heat and other forms of energy. In particular, it describes how thermal energy is converted to and from other forms of energy and how it affects matter.
The systems that we study in thermodynamics … consist of very large numbers of atoms or molecules interacting in complicated ways. But, if these systems meet the right criteria, which we call equilibrium, they can be described with a very small number of measurements or numbers. Often this is idealized as the mass of the system, the pressure of the system, and the volume of the system, or some other equivalent set of numbers. Three numbers describe 1026 or 1030 nominal independent variables."
Heat is energy can be converted from one form to another, or transferred from one object to another. For example, a stove burner converts electrical energy to heat and conducts that energy through the pot to the water. This increases the kinetic energy of the water molecules, causing them to move faster and faster. At a certain temperature (the boiling point), the atoms have gained enough energy to break free of the molecular bonds of the liquid and escape as vapor.

Heat

Thermodynamics, then, is concerned with several properties of matter; foremost among these is heat. Heat is energy transferred between substances or systems due to a temperature difference between them, according to Energy Education. As a form of energy, heat is conserved, i.e., it cannot be created or destroyed. It can, however, be transferred from one place to another. Heat can also be converted to and from other forms of energy. For example, a steam turbine can convert heat to kinetic energy to run a generator that converts kinetic energy to electrical energy. A light bulb can convert this electrical energy to electromagnetic radiation (light), which, when absorbed by a surface, is converted back into heat.

Temperature

The amount of heat transferred by a substance depends on the speed and number of atoms or molecules in motion, according to Energy Education. The faster the atoms or molecules move, the higher the temperature, and the more atoms or molecules that are in motion, the greater the quantity of heat they transfer.
Temperature is "a measure of the average kinetic energy of the particles in a sample of matter, expressed in terms of units or degrees designated on a standard scale," according to the American Heritage Dictionary. The most commonly used temperature scale is Celsius, which is based on the freezing and boiling points of water, assigning respective values of 0 degrees C and 100 degrees C. The Fahrenheit scale is also based on the freezing and boiling points of water which have assigned values of 32 F and 212 F, respectively.
Scientists worldwide, however, use the Kelvin (K with no degree sign) scale, named after William Thomson, 1st Baron Kelvin, because it works in calculations. This scale uses the same increment as the Celsius scale, i.e., a temperature change of 1 C is equal to 1 K. However, the Kelvin scale starts at absolute zero, the temperature at which there is a total absence of heat energy and all molecular motion stops. A temperature of 0 K is equal to minus 459.67 F or minus 273.15 C.

Specific heat

The amount of heat required to increase the temperature of a certain mass of a substance by a certain amount is called specific heat, or specific heat capacity, according to Wolfram Research. The conventional unit for this is calories per gram per kelvin. The calorie is defined as the amount of heat energy required to raise the temperature of 1 gram of water at 4 C by 1 degree.
The specific heat of a metal depends almost entirely on the number of atoms in the sample, not its mass.  For instance, a kilogram of aluminum can absorb about seven times more heat than a kilogram of lead. However, lead atoms can absorb only about 8 percent more heat than an equal number of aluminum atoms. A given mass of water, however, can absorb nearly five times as much heat as an equal mass of aluminum. The specific heat of a gas is more complex and depends on whether it is measured at constant pressure or constant volume.

Thermal conductivity

Thermal conductivity (k) is “the rate at which heat passes through a specified material, expressed as the amount of heat that flows per unit time through a unit area with a temperature gradient of one degree per unit distance,” according to the Oxford Dictionary. The unit for k is watts (W) per meter (m) per kelvin (K). Values of k for metals such as copper and silver are relatively high at 401 and 428 W/m·K, respectively. This property makes these materials useful for automobile radiators and cooling fins for computer chips because they can carry away heat quickly and exchange it with the environment. The highest value of k for any natural substance is diamond at 2,200 W/m·K.
Other materials are useful because they are extremely poor conductors of heat; this property is referred to as thermal resistance, or R-value, which describes the rate at which heat is transmitted through the material. These materials, such as rock wool, goose down and Styrofoam, are used for insulation in exterior building walls, winter coats and thermal coffee mugs. R-value is given in units of square feet times degrees Fahrenheit times hours per British thermal unit  (ft2·°F·h/Btu) for a 1-inch-thick slab.

Newton's Law of Cooling

In 1701, Sir Isaac Newton first stated his Law of Cooling in a short article titled "Scala graduum Caloris" ("A Scale of the Degrees of Heat") in the Philosophical Transactions of the Royal Society. Newton's statement of the law translates from the original Latin as, "the excess of the degrees of the heat ... were in geometrical progression when the times are in an arithmetical progression." Worcester Polytechnic Institute gives a more modern version of the law as "the rate of change of temperature is proportional to the difference between the temperature of the object and that of the surrounding environment."
This results in an exponential decay in the temperature difference. For example, if a warm object is placed in a cold bath, within a certain length of time, the difference in their temperatures will decrease by half. Then in that same length of time, the remaining difference will again decrease by half. This repeated halving of the temperature difference will continue at equal time intervals until it becomes too small to measure.

Heat transfer

Heat can be transferred from one body to another or between a body and the environment by three different means: conduction, convection and radiation. Conduction is the transfer of energy through a solid material. Conduction between bodies occurs when they are in direct contact, and molecules transfer their energy across the interface.
Convection is the transfer of heat to or from a fluid medium. Molecules in a gas or liquid in contact with a solid body transmit or absorb heat to or from that body and then move away, allowing other molecules to move into place and repeat the process. Efficiency can be improved by increasing the surface area to be heated or cooled, as with a radiator, and by forcing the fluid to move over the surface, as with a fan.
Radiation is the emission of electromagnetic (EM) energy, particularly infrared photons that carry heat energy. All matter emits and absorbs some EM radiation, the net amount of which determines whether this causes a loss or gain in heat.

The Carnot cycle

In 1824, Nicolas Léonard Sadi Carnot proposed a model for a heat engine based on what has come to be known as the Carnot cycle. The cycle exploits the relationships among pressure, volume and temperature of gasses and how an input of energy can change form and do work outside the system.
Compressing a gas increases its temperature so it becomes hotter than its environment. Heat can then be removed from the hot gas using a heat exchanger. Then, allowing it to expand causes it to cool. This is the basic principle behind heat pumps used for heating, air conditioning and refrigeration.
Conversely, heating a gas increases its pressure, causing it to expand. The expansive pressure can then be used to drive a piston, thus converting heat energy into kinetic energy. This is the basic principle behind heat engines.

Entropy

All thermodynamic systems generate waste heat. This waste results in an increase in entropy, which for a closed system is "a quantitative measure of the amount of thermal energy not available to do work," according to the American Heritage Dictionary. Entropy in any closed system always increases; it never decreases. Additionally, moving parts produce waste heat due to friction, and radiative heat inevitably leaks from the system.
This makes so-called perpetual motion machines impossible. Siabal Mitra, a professor of physics at Missouri State University, explains, "You cannot build an engine that is 100 percent efficient, which means you cannot build a perpetual motion machine. However, there are a lot of folks out there who still don't believe it, and there are people who are still trying to build perpetual motion machines."
Entropy is also defined as "a measure of the disorder or randomness in a closed system," which also inexorably increases. You can mix hot and cold water, but because a large cup of warm water is more disordered than two smaller cups containing hot and cold water, you can never separate it back into hot and cold without adding energy to the system. Put another way, you can’t unscramble an egg or remove cream from your coffee. While some processes appear to be completely reversible, in practice, none actually are. Entropy, therefore, provides us with an arrow of time: forward is the direction of increasing entropy.

The four laws of thermodynamics

The fundamental principles of thermodynamics were originally expressed in three laws. Later, it was determined that a more fundamental law had been neglected, apparently because it had seemed so obvious that it did not need to be stated explicitly. To form a complete set of rules, scientists decided this most fundamental law needed to be included. The problem, though, was that the first three laws had already been established and were well known by their assigned numbers. When faced with the prospect of renumbering the existing laws, which would cause considerable confusion, or placing the pre-eminent law at the end of the list, which would make no logical sense, a British physicist, Ralph H. Fowler, came up with an alternative that solved the dilemma: he called the new law the “Zeroth Law.” In brief, these laws are:
The Zeroth Law states that if two bodies are in thermal equilibrium with some third body, then they are also in equilibrium with each other. This establishes temperature as a fundamental and measurable property of matter.
The First Law states that the total increase in the energy of a system is equal to the increase in thermal energy plus the work done on the system. This states that heat is a form of energy and is therefore subject to the principle of conservation.
The Second Law states that heat energy cannot be transferred from a body at a lower temperature to a body at a higher temperature without the addition of energy. This is why it costs money to run an air conditioner.
The Third Law states that the entropy of a pure crystal at absolute zero is zero. As explained above, entropy is sometimes called "waste energy," i.e., energy that is unable to do work, and since there is no heat energy whatsoever at absolute zero, there can be no waste energy. Entropy is also a measure of the disorder in a system, and while a perfect crystal is by definition perfectly ordered, any positive value of temperature means there is motion within the crystal, which causes disorder. For these reasons, there can be no physical system with lower entropy, so entropy always has a positive value.

The science of thermodynamics has been developed over centuries, and its principles apply to nearly every device ever invented. Its importance in modern technology cannot be overstated.

Different types of loads  in engineering mechanics are compression, tension, torsion and bending.
Compression, tension, torsion and bending loads.

Compression:

Compression loading is an effect in which the component reduces it size. During compression load there is reduction in volume and increase in density of a component.

Tension:

Tension is the act of stretching rod, bar, spring, wire, cable etc. that is being pulled from the either ends.

Torsion:

Torsion is the act of twisting of an rod, wire, spring etc. about an axis due to applied couple (torque).

Bending:

Bending is act of changing component from straight form into a curved or angular form.

a basic diagram showing how superchargers work

What are Superchargers ?

In simple words, Superchargers are pressure boosting devices(compressors) which increase the pressure of the air before letting it get into cylinder of the internal combustion engine !
And the process of increasing the pressure OR forcing more air to get into engine is called as supercharging.

Why do we need superchargers ?

Let’s keep this simple by not diving into those big lengthy formulas, alright.
The power generated by engine is a function of the mean effective pressure aka. average pressure in the cylinder. Power is directly proportional to the average pressure.
Power  ∝  Mean effective pressure (MEP)
Pressure goes on increasing during compression stroke & goes on decreasing during exhaust stroke. So average pressure is calculated with the help of these data.
More the MEP, more the efficiency of engine !
So if more air is forced & compressed into the cylinder, there will be an increase in the mean pressure & hence will produce more power ! This is why we need them – to force the air into engine !

Working of Superchargers :-

a diagram showing working of superchargers
Diagram showing working of a supercharger
Superchargers are basically compressors/blowers which takes air at normal ambient pressure & compresses it and forcefully pushes it into engine ! Power to the compressor/blower is transmitted from engine via the belt drive.
The addition of extra amount of air-fuel mixture into the cylinder increases the mean effective pressure of the engine. An increment in MEP makes the engine produce more power. In this way, adding a compressor to the engine makes it more efficient.

Types of superchargers :-

types of supercharger
types of superchargers

●      Centrifugal superchargers –
These are commonly used in the vehicles & are powered by the engine via a belt-pulley system. The air-fuel mixture enters the impeller at the centre. The air is then passed through diffuser, which increases the pressure. Finally the air makes it way through the volute casing to the engine.
●      Root’s type supercharger –
Root’s type contain two rotors of epicycloid shape. The rotors are of equal size inter-meshed & are mounted and keyed on 2 different shafts. Any one shaft is powered by the engine via a V-belt or gear train(depending on the distance). Each rotor can have 2 or more than 2 lobes depending upon the requirement. The air enters through the inlet & gets trapped on its way to outlet. As a result, pressure at outlet would be greater than the inlet.
●      Vane type supercharger –
A number of vanes are mounted on the drum of the supercharger. These vanes are pushed outwards via pre-compressed springs. This arrangement helps the vane to stay in contact with the inner surface of the body.
Now due to eccentric rotation, the space between two vanes is more at the inlet & less at the oulet. In this way, the quantity of air which enters at the inlet decreases it’s volume on its way to oulet. A decrease in volume results in increment of pressure of air. Thus the mixture obtained at the outlet is at higher pressure than at the inlet.
working of vane type supercharger

Are there any other methods of supercharging ?

Yes. There are various other ways to force the air which doesn’t need extra power unlike compressors. The 2 most widely applied are –

Ram effect supercharging –

Here, the inlet manifold is designed in such a way that the air gets automatically pushed into the cylinder. The air continuously tries into the cylinder but the intake valves open/close several times a second ! Every time the valve closes, the air just rams into it. This generates a pressure wave which travels in the opposite direction until it hits the plenum & gets reflected back.
Now if the resonant frequency of the plenum & engine matches, this pressure wave carries more air into the cylinder doing the work of a supercharger.

Under piston supercharging –

This type of method is generally adopted in large marine engines. It utilizes the bottom side of the piston for compressing the air. With proper timing of valves, this system gives an adequate supply of compressed air, as there are 2 delivery strokes to each suction stroke of each stroke !

Advantages of supercharging :-

●      Higher power output. This was whole point of studying & installing superchargers.
●      Reduced smoke from exhaust gases. The extra air pushed into cylinder, helps the air to complete combust leading to lesser smoke generation.
●      Quicker acceleration of vehicle. Supercharger starts working as soon as the engine starts running. This way the engine gets a boost even at the beginning leading to quicker acceleration.
●      Cheaper than turbocharger.

Limitations :-

●      Draws power from engine. Though the overall mechanical efficiency is increased but it consumes power from the engine. The same job is done by a turbocharger without consuming extra power !
●      Increased heat generation. The engine should have proper heat dissipation systems as well as it should be able to withstand thermal stresses !
●      Induces stress. The engine must hold up against the high pressure & bigger explosions generated in the cylinder. If the engine is not designed considering these stresses, it may damage the piston head.




At its most basic level, forging is the process of forming and shaping metals through the use of hammering, pressing or rolling. The process begins with starting stock, usually a cast ingot (or a "cogged" billet which has already been forged from a cast ingot), which is heated to its plastic deformation temperature, then upset or "kneaded" between dies to the desired shape and size.
Forging is a metal forming process in which the metal is heated and a force is applied in such a way that a required shape can be obtain. It is basically a hot working process in which the work piece is heated up to plastic stage and the force is applied by manually or by press according to the requirement. This force is compressive in nature which is basic requirement of forging. Sometime forging operation is done without application of heat known as cold forging. Now days, Forging is used in every manufacturing industries.

 

What is Forging Process?

Operation:

Mainly forging consist two operations according to the force applied.

1.) Drawing Down:

Drawing down is a process of elongate the length and reduce the cross section area of work piece. Simply in this operation, the length of work piece increases and the cross section area decreases. In this process, a compressive force is applied at perpendicular direction of its length axis. If a tensile force is applied to change its length at parallel to its length axis, this process is known as wire drawing.
What is Forging Process, Operation, Types, Application, Advantages and Disadvantages?

2.) Upsetting:

Upsetting is just opposite operation to drawing down. In this operation, the length of work piece decreases and its cross section area increases. In this process, a compressive force is applied at parallel direction to its length axis.
 What is Forging Process, Operation, Types, Application, Advantages and Disadvantages?

Types of Forging:

Forging may be classified into following ways.

1.) According to the Temperature:


a.) Hot Forging:
If the work piece is heated above its recrystallization temperature and then force is applied, the process is known as hot forging. The recrystallization temperature of most of metals is half of its melting temperature.

b.) Warm Forging:
Warm forging done at the temperature about 40 percent of its melting point temperature.

c.) Cold Forging:
Cold forging is done at room temperature. This process gives highest mechanical properties among all forging processes.

2.) According to arrangement of Die:


a.) Open Die Forging:
This forging process uses flat dies or no die. This is mostly hot forging process in which the work piece heated and hammered to obtain desire shape. This process produce rough product.

b.) Close Die Forging:
Close die forging is a process in which a set of impression die is used to produce desire shape on work piece. Mostly these products do not need any finishing process. This process required higher force.

3.) According to the Forging equipment:


a.) Smith forging:
Smith forging is traditional method of metal forming. It is open die forging method in which the work piece is placed on a stationary anvil and a hammer strikes and deform the work piece. The force is applied either by manually or power hammers.

b.) Drop Forging:
Drop forging is done in closed impression dies. An automatic
hammer applied the force in series of blow by dropping action. In this type, a sudden applied force is used.

c.) Press Forging:
Press forging is similar to drop forging except it uses continuous squeezing type applied force by the hydraulic press.  This process increase the length and decrease its cross section of work piece.

d.) Machine Forging:
Machining forging is an upsetting process in which the cross section of work piece increases and length decreases.

Advantages and Disadvantages:

Advantages:

●     Forging gives comparatively tougher product compare to casting.
●     The fatigue strength and creep resistance of forge product is higher.
●     Forge product has higher mechanical properties.
●     Low cost operation.
●     This process does not required special skill operator.
●     Variety of shapes can be formed by this process.

Disadvantages:

●     Higher initial cost for big forging presses.
●     Secondary finishing process required in hot forging.
●     It cannot produce complex shapes.
●     Size is limited due to size of press.
●     Brittle metal cannot be forged.

Application of Forging:

●     Mainly forged products are used in every mechanical industry.
●     Turbine rotor, generator rotor etc. are forged product.
●     It gives higher fatigue strength so most of moving parts like crankshaft, camshaft gears etc. are made by forging operation.
●     Cold forging is used to produce chisel, bolts etc.
●     These are mostly used in hand tools and hardware manufacturing.
●     It is used in ship building in various structure works.

This is all about what is forging process, operation, types, application, advantages and disadvantages.
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