Deglazing is a process by which the surface of an engine cylinder is roughened to create friction between the moving parts and allow engine oil to grip the sides of the cylinder.
Friction is the force resisting the relative motion of solid surfaces, fluid layers, and material elements sliding against each other. There are several types of friction:
In a gasoline or diesel engine, the pistons ride up and down within the engine maintaining a tight seal via the piston rings. Over time, the constant rubbing of the rings against the cylinder wall can polish it to a very smooth finish. This creates problems in two ways. First, the lubricating oil in the engine will not adhere properly to the smooth surface, and in the absence of an oil film the resulting friction is increased. Secondly, while breaking in newly installed piston rings, a minute amount of wear must occur between rings and cylinder wall in order to seat the rings properly, and ensure a gas-tight seal. If the cylinder walls are too smooth, this wear will not occur, with the rings "skating" over the polished surface. [1]
Gasoline, gas or petrol is a colorless petroleum-derived flammable liquid that is used primarily as a fuel in spark-ignited internal combustion engines. It consists mostly of organic compounds obtained by the fractional distillation of petroleum, enhanced with a variety of additives. On average, a 42-U.S.-gallon (160-liter) barrel of crude oil yields about 19 U.S. gallons of gasoline after processing in an oil refinery, though this varies based on the crude oil assay.
The Diesel engine, named after Rudolf Diesel, is an internal combustion engine in which ignition of the fuel, which is injected into the combustion chamber, is caused by the elevated temperature of the air in the cylinder due to the mechanical compression. Diesel engines work by compressing only the air. This increases the air temperature inside the cylinder to such a high degree that atomised Diesel fuel injected into the combustion chamber ignites spontaneously. With the fuel being injected into the air just before combustion, the dispersion of the fuel is uneven; this is called a heterogenous air-fuel mixture. The process of mixing air and fuel happens almost entirely during combustion, the oxygen diffuses into the flame, which means that the Diesel engine operates with a diffusion flame. The torque a Diesel engine produces is controlled by manipulating the air ratio; this means, that instead of throttling the intake air, the Diesel engine relies on altering the amount of fuel that is injected, and the air ratio is usually high.
A piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders, among other similar mechanisms. It is the moving component that is contained by a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. In a pump, the function is reversed and force is transferred from the crankshaft to the piston for the purpose of compressing or ejecting the fluid in the cylinder. In some engines, the piston also acts as a valve by covering and uncovering ports in the cylinder.
In order to correct the situation, a mechanic can take the engine apart, and deglaze the cylinders, usually using an abrasive. This creates a roughly 45 degree angle crosshatching of tiny grooves in the cylinder wall, and restores the engine's performance. [1] Crosshatching that deviates too far from 45 degrees can either cause an unwanted accumulation of oil or be unable to hold on to the oil entirely. [2]
A mechanic is an artisan, technician or skilled tradesperson who uses tools to build or repair machinery.
An abrasive is a material, often a mineral, that is used to shape or finish a workpiece through rubbing which leads to part of the workpiece being worn away by friction. While finishing a material often means polishing it to gain a smooth, reflective surface, the process can also involve roughening as in satin, matte or beaded finishes. In short, the ceramics which are used to cut, grind and polish other softer materials are known as abrasives.
A crankshaft—related to crank—is a mechanical part able to perform a conversion between reciprocating motion and rotational motion. In a reciprocating engine, it translates reciprocating motion of the piston into rotational motion; whereas in a reciprocating compressor, it converts the rotational motion into reciprocating motion. In order to do the conversion between two motions, the crankshaft has "crank throws" or "crankpins", additional bearing surfaces whose axis is offset from that of the crank, to which the "big ends" of the connecting rods from each cylinder attach.
A camshaft is a shaft to which a cam is fastened or of which a cam forms an integral part.
A four-strokeengine is an internal combustion (IC) engine in which the piston completes four separate strokes while turning the crankshaft. A stroke refers to the full travel of the piston along the cylinder, in either direction. The four separate strokes are termed:
A connecting rod is a rigid member which connects a piston to a crank or crankshaft in a reciprocating engine. Together with the crank, it forms a simple mechanism that converts reciprocating motion into rotating motion.
A cylinder is the central working part of a reciprocating engine or pump, the space in which a piston travels. Multiple cylinders are commonly arranged side by side in a bank, or engine block, which is typically cast from aluminum or cast iron before receiving precision machine work. Cylinders may be sleeved or sleeveless. A sleeveless engine may also be referred to as a "parent-bore engine".
Engine braking occurs when the retarding forces within an engine are used to slow down a motor vehicle, as opposed to using additional external braking mechanisms such as friction brakes or magnetic brakes.
A crankcase is the housing for the crankshaft in a reciprocating internal combustion engine. The enclosure forms the largest cavity in the engine and is located below the cylinder(s), which in a multicylinder engine is usually integrated into one or several cylinder blocks. Crankcases have often been discrete parts, but more often they are integral with the cylinder bank(s), forming an engine block. Nevertheless, the area around the crankshaft is still usually called the crankcase. Crankcases and other basic engine structural components are typically made of cast iron or cast aluminium via sand casting. Today the foundry processes are usually highly automated, with a few skilled workers to manage the casting of thousands of parts.
Engine balance refers to those factors in the design, production, engine tuning, maintenance and the operation of an engine that benefit from being balanced. Major considerations are:
A piston ring is a split ring that fits into a groove on the outer diameter of a piston in a reciprocating engine such as an internal combustion engine or steam engine.
The Bourke engine was an attempt by Russell Bourke, in the 1920s, to improve the two-stroke engine. Despite finishing his design and building several working engines, the onset of World War II, lack of test results, and the poor health of his wife compounded to prevent his engine from ever coming successfully to market. The main claimed virtues of the design are that it has only two moving parts, is lightweight, has two power pulses per revolution, and does not need oil mixed into the fuel.
A hydraulic cylinder is a mechanical actuator that is used to give a unidirectional force through a unidirectional stroke. It has many applications, notably in construction equipment, manufacturing machinery, and civil engineering.
Idle speed is the rotational speed an engine runs at when the engine is idling, that is, when the engine is uncoupled from the drivetrain and the throttle pedal is not depressed. In combustion engines, idle speed is generally measured in revolutions per minute (rpm) of the crankshaft. At idle speed, the engine generates enough power to run reasonably smoothly and operate its ancillaries, but usually not enough to perform useful work, such as moving an automobile.
Cylinder head porting refers to the process of modifying the intake and exhaust ports of an internal combustion engine to improve the quality and quantity of the air flow. Cylinder heads, as manufactured, are usually suboptimal due to design and manufacturing constraints. Porting the heads provides the finely detailed attention required to bring the engine to the highest level of efficiency. More than any other single factor, the porting process is responsible for the high power output of modern engines.
A hydraulic motor is a mechanical actuator that converts hydraulic pressure and flow into torque and angular displacement (rotation). The hydraulic motor is the rotary counterpart of the hydraulic cylinder as a linear actuator. Most broadly, the category of devices called hydraulic motors has sometimes included those that run on hydropower—namely, water engines and water motors—but in today's terminology the name usually refers more specifically to motors that use hydraulic fluid as part of closed hydraulic circuits in modern hydraulic machinery.
In most types of reciprocating engines, a valve guide is provided for each poppet valve in the cylinder head. Along with the valve spring, it serves to positively locate the valve so that it may make proper contact with the valve seat. A valve guide is a cylindrical piece of metal, pressed or integrally cast into the cylinder head, with the valve reciprocating inside it. Guides also serve to conduct heat from the combustion process out from the exhaust valve and into the cylinder head where it may be taken up by the cooling system. Bronze is commonly used, as is steel; a balance between stiffness and wear on the valve is essential to achieve a useful service life.
The oil pump in an internal combustion engine circulates engine oil under pressure to the rotating bearings, the sliding pistons and the camshaft of the engine. This lubricates the bearings, allows the use of higher-capacity fluid bearings and also assists in cooling the engine.
Honing is an abrasive machining process that produces a precision surface on a metal workpiece by scrubbing an abrasive stone against it along a controlled path. Honing is primarily used to improve the geometric form of a surface, but may also improve the surface texture.
Break-in or breaking in, also known as run-in or running in, is the procedure of conditioning a new piece of equipment by giving it an initial period of running, usually under light load, but sometimes under heavy load or normal load. It is generally a process of moving parts wearing against each other to produce the last small bit of size and shape adjustment that will settle them into a stable relationship for the rest of their working life.
Diesel engines can suffer damage as a result of misapplication or misuse, such as internal glazing and carbon build-up. Ideally, diesel engines should be run at least 60% to 75% of their maximum rated load. Short periods of low load running are permissible providing the set is brought up to full load, or close to full load on a regular basis. Another potential problem is cylinder cavitation and erosion.
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