the romance of engines - takashi suzuki cap1-3-red

8/7/2019 The Romance of Engines - Takashi Suzuki Cap1-3-Red

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Chapter IWhy Was the Englne Needed?

The needsfor human happiness and water for Versailles resultin tite needfor an invention.)C

Water Keeper Christiaan Huygens' IdeaAccording 10 the historical rccords(lI), me first long-distance automobiletrip, Ihat s, Ihe grand touriog, was mude by Madum Berthu Beoz, wife ofGcrman enginccr and inventor Kurl Benz, and her two ehildren. The secooolong-distanee driving trip was mude by Armand Peugcot, who foundcd IhePcugeot MOlor Company. Peugeot traveled me Paris-Bresl-Paris route.If a traveler were riding on an express lrain from Bres! to Pars. he wouldsee on the left side of Ihe lrack, appro1t im alely 20 minules 10 Ihe Montparnasse train station in pans. Ihe famous Palaee of Versailles. The Palace ofVersailles was converted by King Louis XN from a royal hunting lodgc 10the premier palaee of Ihe We stem world_The palaee and lIS auxiliary buildngs 100k 21 ycars to complele, from 166710 1688. The 425-meter-loogmuio building was lurge enough 10 entertain 10,000 guesls and was DOledfor lIs lavish fumiture aOO innovativc architccture (sec Ph oto 1-1).The palacc grounds wcre exlensive. A mlle-long canal was dug al !he fronlof the building. permitting boaters 10 leisuTely sip a glass of aperitifbefore aglorious dinner. The formal gardeos of Versailles were Ihe pride of LouisXIV aod eomplemenled Ihe sp lendor of Ihe palace wilh a beau!y Ihat wasadmired by all me royalty of Europe. Broad aveoues were lined with symmetrical plantings of trees. Hedges were planted in elabornle e mbroldercdpallems, and founlains spewed jels of water into pools (see Photo 1-2).Flowers and bushes were arranged in pallems of vibrant eolors_

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2 T h ~ HOm(Jnu 01 EngintS

I'hOIO , - , Vusai/les P% u (166710 1688}: From he unru af /he mD i"buildi"g /O Ih tl sOlllh ..,ing.

PlwlO /-1 Vtrsaiflu Polou: Vitwing mi/t-/DlIB conallor hotIDrro gutsufromLnIOfltl Founrai" (ht garden olont luu mortl 1M" ItI" 1u.rllriousfounloinsJ.

Allhough lhe gardens were designe


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Chapler / ,

rcsponsibilily of Chrisliaan Huygens, wh o was a me mber of King LouisXIV 's eoun, serJing as 11 water keeper atlhis lime. Waler 10 keep!he gardensluxurianl was drawn from Ihe nearby Seine Rive r. More Ih an 3000 eub iemclers of waler wcrc needed lo provide Ihe palaee and ils grounds wi lh ilsdaily supply o water. Both Ihe efTort, man or animaJ power, and lime necessary lo lranspon Ihe water from Ihe river lo Ihe paJ ace werc enonnous. Huy_gens. who was in eharge of the paJace wnterworks. was constanlly thinkingof how lo simplify obtaining the water necessary for the gardens and!he palaee. Finally, in 1673, he dev ised a prololype of an inlernal -combus tionengine.(1-2)The concept of this primitive engine is iIIu strated in Fig. 1-1. The linc A-Brepresents the cylinder. Gunpowder is placed:1I poinl e and then igniled.Th e explosive gases force piston D 10 Ihe top of!he eylinde r, and one-waylealher release valves (E-F) allow Ihe was te gases to ex haust 10 the ~ t m ophere . A near vacuum then exists in Ihe eylinder. Almospheric pressurerorces Ihe piston baek lowaro Ihe bouom of Ihe cylinder, fai s ing substanceG, which could be water.

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Fig. /-/ Conuplual Jra ...ing ofillumal-combus/icm t llSillt origirmleJby Huygens ( /671).

Huygens documented Ihis firsl inlernal-eombuslion eogine in 3 letter to hisbrother. Several versions of Ihe engine were buill and tried.(t.]) Obviousl)'.Ihe m3n who originated this innovative concept was nOI an ordinary court ier.


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, Romance o[EnginesIn ract. Christiaan Huygens was one of he roremosl natural phitosophers ofhis era (Fig. 1-2). In 1673, he year he engine was bu ilt , Huygens was Ihefirst foreign member 10 be accepted mo!he Paris Acadcmy. He was a Dulchphysicisl who originated Ihe principIe of Iight known as Huygens' Principie.He di scovered Ihal Satum was surrounded by Oauened ringo He patcn tedlhe fina pendulum clock, which keeps accu rnlc time.In 1685, 12 years afte r li s design , he water pump was built by using 14waler wheels, each with a 12-metc:r diameler, lo transport 3000 cubic metersof water daily from Ihe Scine River 10 he ga rdens of Versailles, baTelycnough 10 meet jls needs.(1-4) The enormous qunntity of water rcqui reddaily by he palace can be realized ir the reader knows Iha! (he en lire Hinoplnnl of Hin o Motors. Lid. uses only 4000 clIbic melcrs ofwnlcr da ily in ilstolal manllfncluring process.

Eng ln e

Salum

(

Automobi le?

_ Tl1e innergrounds 01lile Palace01 Versailles .

Red wine7.,. _

Fig. 12 Wa u r J:.uper and h iu:leganl ide" (162910 /695). (} 5)

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Chuplu 1 ,I f Garly inlernal-cornbustion engines are to be reviewed, Ihen one moregenius mu st be mentioned herc. This genius was the ltalilln Leonardo daVinci, who skelched a gunpowde r engine in 1509. The sketch i5 very similarto Huygens' concept. However, the da Vi nci engine was never buH!. Thegunpowdcr enginc was one of da Vi nci's many inventions and ideas Ihalwerc noted only in drawings. Since Huygens had never seen da Vinci 'ssketch , Huygens' idea was his own.{l3)Beginnlng of the Steam EngineDenis Papin was a French inventor, medical student, and industria l anist.He served as an assistant in developing Ihe Huygens engine, and he developed ideas concerning a sleam engine instead of a gunpowder enginearou nd 1670. However, il is be lieved that he neve! fu lly deveJoped his ideasinto practical machines. This devclopmcnt was left for fuwrc generalions.Eng lishrnan Thomas Savery dcvised the firsl practica! apparalus for harncssing steam power. Hi s machine and Papin's idea also!ed 10 the invenl ionby Thomas Ncwcomen in 1712 oflhe firsl successful stcam engine. JamesWatl modified and improved Ihe Newcomen steam engine, which rcsulledin Watl's new steam engine being rccognized a . ~ a practical engine powerplant.Joseph Cugnots was Ihe finl inventor 10 use Ihe sleam engine in a ve hiclefor Iran sporlalion, around 1763-1771. Later, in 1890, C lernen l Ade rauempled lo insla l l lhe sleam engine into an airplane. 80lh Ih e vehicle(Photo 1-3) aOO Ihe airplane (Pholo 1-4) are on display al the ConservaloirNalional de Arts el Malien in pan s. However, nei!her vehicle WIIS practicalror transportation. The invenlion of Ihe really useful engine for transportation was left for rmure generalions of dreamers. The inlemal-combuslionengine suitable for vehiele use was nol avai lable unlillhe invention of:1Oengine by Nicolaus Augusl OUo. As noted in this chapter, the reason fordcveloping nn engine ;5 10 meel Ihe needs of Ihe people and 10 have Ihesemachines relieve Ihem of Ihe lremendous burdens prcviously borne by thehuman back. This need lo improve lhe condi lion of humanity, of course, islhe primary reason for a ll inventions and progress. Even Ihough an idea maybe conceived by the single pen;on responsible, for example, for providingwate r to trees, planls, and fountains, Ihe dedicalion of many skilled andimaginative people are required to nurture and gmw Ihat idea. New technology is Ihe realization of crilical thinking and originality Ihrough Ihe applicalion of skilland I:.nowledge. This principie is iHuSlmtcd on Ihe lin; t pages oflhe hislory of the engine.

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6

PholO /-3 CugnolS ' ~ o m t "sine CUT ( no) (Co/Utrw:uoir Nalional de Ami!:I Matius TI Paris).

PhOIO 1-4 Cltrntnt Adu's J l tam airplnt (1890)(Conurvalo ir Na/iolUll de Arrs t i MDliuJ in Paris).


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Chapter 2A Great Work ofthe EarIy Perlod:

Newcomen's Steam EnglneSuccess comesJrom the ca reJuf compilation ofinformalion. The

key lo success is one young man 's lenacity.

Fundamental Reformation of the Heat EngineWhen a visitor wa lks into Ihe Seien ce Museum in London, one of Ih e fi rslexhibils Ihat he sees is the Newcomen e ngine (Photo 2-1). The eng ineappenrs 10 ri se fm m the fl oor like a diving board sland at poolside. The significance of this e ngine is thal it was the fi rst practical use of the pi stoncylinder assembl y in a work-producing con figuration. Thomas Newcomen,a blacksmith and invcn tor, was bom in Dartmouth, England.(2-l) His workwas based on Ihe ea rlie r d iseoveries of Christiaan Hllygens a nd De nisPapio, both discussed in Chaptcr 1. He combined their conceplS by usingthe spray je t developed by Dr. Desag llliers, and he. with he[p fro m g lassand lead pipe worker John Calley, modified and redesigned he engine buil!er]ier by Thomas Savery in 1698.(2-2)Fig. 2-1 il1uslra!es Ihe Newcomen cngine. A piston (Photo 2-2) and n cylindeT are placed aboye an o ld distillalion boiler. rh e steam from Ih e boile rexpands. is dirccled imo lhe cylinde r, and pushes Ihe pislon 10 Ihe 10p af Ihecy linde r. When Ihe piston rcaches ils peak, the interior jet sproy sprayswa ler into the cylinder, condensing Ihe steam inlO waler. Concurrently withIhe water spray, the valve separating the cyl inder fm m the boiler is closed.Al this point, a near-vacuum is created in the cy linder. rhe atm osphericpressure pushes Ih e piston down , cllusi ng Ihe drawing pllmp 10 operaleIhrough Ihe beam. This engine. in effect. demonstnnes the concepllhal had


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, Th e Rontilllct o[E"sints

Photo 21 HUBe Ntwcomen ""B" nI!': frhibil t d erlgine wa,r mo.nufOCl"rt d in J79f byFrancis Thompson. /4 54-mm bofe, 2U)()mm strokt, 25 PS, 18 l/rotes/mi'lul"

(l.cn.don Sci"nce Mu.u:um. 8oTe, SITOkt!, o"d PS i"dico/e c)'linder d;(Jm t leT, pisto/ls/rote, Wld horstpo....t r, resptct>'dy).

bec o poslul ated by Huygens with his earlier engine. In this version, how-ever, gunpowder had bcen replaced by sleam as the powering force.Young Man Potta's Tenacious SpiritIn Newcomen's en gine, aCluaing Ihe valve, shuuing off Ihe Sleam, andspraying Ih e water had 10 be done fo r each pumping stroke. Since Ih esepans of Ihe cycle had lO be perfarmed manually, an aucndant was hired 10carry out this fun c tion. Dne of (he first men hired 10 monitor he condensa-tion cycle was Humphrey Potla. This young man is credited with havingautomated so rne of mese laborious procedures lO simplify operation of theengine. After extensive trial and error. he had the waler flowing inlo Ihe cyl-inder on Ihe 10p of me piston. This water flow also cooled the lealher sea l onIhe pi ston. Potta also atlached a dasp and a strap to a lever, which opcnedand c\osed the val ve.The Newcomen engine was the fi rst steam engine that could successfu llypump me ground water from flooded mine shafts. 1e removal of Ihis obsta-ele allowed the sinking of deeper shafts 10 mine coal seams Ihat prcviouslywould have becn unworkable. The Newcomen engine spread rapidly among


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Pislan

Ilon boiler usadlor making " ' : ' ' ' " '

ChaplU 2

Waterpipe

l

Boam

Tha laboring MI. PanaFig. 2-1 NelllCQnretl t tlgine ( 1712); The t tlgine lilas compleltd lhanb

10 Ihe Polla pro{'(lsal.

9

the British mining districts, greatly expanding the production of coa!. Thisengine removed one of!he great bottlenecks restraining me economic growth

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10 Tht Romance 01Engints

Phoro 2-2 Pis/orl Qua ol/he Ntwcomtn tngint (Mun ich. German muuum).

of England. As a result, the industrial revolution exploded in England. Thus.PaUa 's tenacious spirit se rved as Ihe trigger for the indu strial change inEngland and subsequently Ihe world.

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Chapter 3The Watt Stearn Englne Grew from a

Model Steam EnglneA new engine is created as a result o//ailure analysis.

An Indispensable Problem-Solving TechniqueIn 1763, a model of the Newcomen sleam engine thal had been used as aleaehing 1001al Ihe Univer.lily of Glasgow slopped working. Sinee JamesWan was the inslrumenl maker al me UniversilY, he was askcd 10 repair tbeengine. Wau's work wim this engine is me reason mal his engine appears 10be so similar 10 Ihe Newcomen engine. \Vall , ralher than Newcomen, is rccog nized as the inventor of Ihe modem Sleam engine bccause his steamengine was the forerunner of Ihe engines Ihal utilize the pressure of steamilself, unlike an atmospheric cnginc, as detailed later.\Van began a syslemalic eaminalion lo determine why the Newcomenengine model failed to operatc satisfactorily, cven though it was made 00almosl the same scale as thal of a full-size engine. In modem lerminology,his approaeh lo lacale the problem can be ca lled a failure analysis. In erreet,fai!ure analysis mea ns that if he maehine has broken down or has beendamaged, hen the investigator muSI systematiea l1y determine the cause oflhe problem. Then he musI study Ihe proble m in a logical manner lo providca so lulion. Even Ihough these problem-so lving techniques may nOI havebeen ca lled failure analysis over he years, it has becn ane of the mostimportanl aspt!Cts of improving and developing me enginc.

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Chaptt r 3 "Watl's Idea for Bis New Engine Carne from the NewcomenEngineWhen WaU began repairing Ihe Newcomen model engine al the Universityof Glasgow, he feh Ihat Ihe engine produced an insufficient volume of steamin view of lhe amount of heal put into the engine. Today, we know Ihat th ecylinder wall of the Newcomen engine model may have been 100 Ihick,requiring excessive steam to rai se the lemperature of the cylinder and thenan excessive amount of water 10 cool the cylinder. Watt heated and cooledthe engine for several cycles, finally detennining Ihe exUCI volume of steamrequired 10 operate Ihe machine. During lhis process, Watt uncovered a contradictory point in the Newcomen engine in thal a large amount of waterwas requred to coollhe healed cylinder, and in !he neXI cycle, Ihe cylinderhad 10 be healed agan by a large amount of steam. To reduee his need for somuch water and Sleam, WaU added to the eogine a separale chamber forcondensing steam, thal is, a condense r. Further, he Ihoughl that even beuerresults mighl be oblained by suppl eme nting almospheric pressure with theprcssure of the steam ilse lf afler!he steam was relumed to Ihe condenser. Asa result, he applied the sleam's pressure to the cy linder. However, Ihe pressure was reponedJy only one atmosphere above ambient pressure.In Ihis manner, WaU instalJed Ihe condenser and eompleled a steam enginein which the pistan i5 being driven direelly by sleam pressure.(2-l) Thesleam engine was said 10 have beeo completed in 1776, 13 years aflerWaU's failure analysis began. Photo 3-3 shows Watt 's early sleam engine.NOle Ihal almosl a1l the leeth in me gear used 10 tnmsfer!he power from theengine were broken.The gear teeth used in today's engines are based on a curved line called theinvolute, and their strenglh has been sufficiently calculated. However. inWaU's era around Ihe 1770s,!he industrial gear was still in ils formativeslages. Since the jnvolute curve-bascd gear had nol appeared yel, g e a ~ wcrebased on Ihe curved line known as an cpicydoid. The fil"lil pernon who calculaled lhe slrenglh of gear leeth was Walt. His assistanl, Mauhew Bou1l0n,wrole Watt a lelter aclvising mal gear profiles must be machined more prccisely 10 protecl gear leelh from damagepl) Machining processes and theiraccuracy are inseparable problems thal are nol limiled to cngines, but areIhe basis of all mechanical producIs (see Chapter 38). Machining or manufacluring process and Ihe aceurncy for Ihe desired product are !he mast basicand imponanl pans of all mechanical products. This conccpl originaledwilh Wau's engine.


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16 The Romance 01 Engints

PholO J.J TIre use OfWllt/'S Sfeam enginr: spuad lilu: wildfire rhroughoUl modemEuropean na/ions. This engine is he one IrUJde by Wall in 1788 wilh 476-mm bore./200-mm s/rake. and 13.75 PS. Thefocllhallhe powtr-lrarumitting gear lu th are

011 broken corwinus me Ihul Walr wa.s rhefirsl puson /O ptrform rhi! slr


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CJwprer 3 17

Ihal a highcr slcam pressurc would be required 10 achicvc a highcr cfficiency. In spile of Wau's opposition, Richard Trevithick completed hishigh-pressure slearn engine in 1804.

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Chapter 4How Was an Intemal-CombustlonEnglne Establlshed?

The discovery ofrhe cenlury WQS lhe resu{' 01a faulty idea. Theearliest theory was buried dile lo on IInpaid lax bill.

)C

BarrierAgainst the Birtb of the Internal-CombustionEngineProgress in uny technology. particularly in natural science, is mude when ahypothesis is established lha! has been bascd on expe rimen ts tht reprn::lucea phenomenon and confirm he consislcnc y of sorne rule (design standard).(4-1) In th is case, the hypo thesis can be a mere conjecture and does nOIhave 10 be a valid the ory from ils very beginning. Because a hypolhesisserves as merely a single step on Ihe road IOwaro salving a problem, il canbe revised freel)' ir a contradiction arises, jusI as a hiker can change dircelions ir a rallen tree blocks his palh.The German experime nler Nicolaus AugusI 0110 in vented me fi rsl successfuI rour-strokc intcmal-combustion enginc. This firsl cnginc was the rorerunner for Ihe muhipurpose e ngines used loday. He was work.ing on theengine with the goa l of improving Ihe low efficiency of me new lenoir IWOslroke. noncompression engine. Howeve r, the conjcclure thal was Ihe bas isfor his inq uiry, Ih al is, his basis for improving Ih e low efficiency of thelenoir eng ine , was far removed from the faclors Ihat evcnlually producedthe high effieieney of lbe Quo engine.After Watt had commercialized Ihe sleam engine, allempls lOdesign a highperfonnance inlemal-combuslion engine were never ronde because no one


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20 The Romance oiErlgines

had thought 10 compress lile air/gasoline mixture prior 10 ils gnilico . JeanJoseph Etienne !..enoir, a French inventor, is generally crediled with designing he world's firs! intemaJ-combustion cogine in 1860, 155 yean; after heNewcomcn sleam engine had beco assemb led. His engine WIlS still nOI acompression machine because il ignited ils fuel al acmospheric pressure. Inhose cases with minimal hea! Iransfer, when he aiT/fuel mixture is com-pressed in me cylinder befare gnilico. Iheo the temperalure in the cylinderwiJ\ rise in proponian lo the power orlhe volume Talio (compression ratio) .As a result, he thennal efficiency ocreases Tapidly with the ocrease in hecompression mtio (Appendix A4). This ocrease in thennal efficiency is Ihercason engine manufacturers attempt to maximiz.e the compression ratio ofgasoline and diese1 engines e\'en today.The idea of compressing the air/fuel mixture before ignition had beeo presented by sorne people shortly afler the inventon of the lenor engine.OltO'S id ea was very differcnl in thal he relt the poor thermal efficiency wasallributable lo an abrupl ellplosion. Otto relt Ihat if the combustion processeould be slowed, Ihen Ihe effieiency would rise, His idea lo slow down Iherale of combustion was to stralify he air!fuel area (a region of several differenl mill!Ure ralios) and 10 initiate the combustion more slowly at gnition.Nelll, he promoled eombustion in a rieh mlllure (a mixture with a higherproportion of fuel) and then followOO with a lean mlllure (a millture wilh alower proportion of fuel).AI!hough nOI drectly related to!he four-stroke cyele engne, it is intcreslinglo nole that Duo separated !he intake stroke (in an attempl al stratifiealion)Ihrough his invention of Ihe slide valve system for intake and ellhauSI andalso of his mprovemenl ofthe flamed gnilion. whieh he had inherited from!he lenoir engine. This improvemenl eventually led 10 !he four-stroke eycleeompression engine. Historieal reeords indieate Iha! his design had a eompression ralio of about 2.5. For eomparison, today's gasoline engine has acompression ralio of approximalely 8 while a diesel engine has 11 ratio ofapprollimately 18.

Who Concelved the Principie or tbe Four-Stroke CycleEngine?If Duo mere1y improved Ihe Iwo-slroke eye!e lenor engine, then whoorigina lly coneeived !he idea of the four-slroke eycle engine? In my opinion. thal would be a Freneh citizen named Alphonse Beau de Rochas. In1862, righl after lenoir completed his twostroke eycle engine. Rochasdeveloped his idea sufficienlly to build his four- stroke eycle engine 14


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Chllpler4 21

years before the Ono engine. Thus, because of Ihis chronological record,the credit for Ihe four-slroke engine should go lo Rachas. If Ihis is Ihe case,Ihen why is Rachas generally nOI acknowledged for his engine? Afler Onohad buill his engine in 1876 and allempled 10 palent his idea, a palenl altorney named C. Wigand researched possibJe palenl infringemenl for 0110 .Wigand carne across unpublished docume nls and :Rapers Ihal showedRachas had invented the four-slroke cycle engine .(4. ) However, Rachas'French palen! had been invalidaled because he had railed lo pay talles onIhe palenl. During Ihis lime in French hislory, Ihe penally for delinquenllaxes was 10 invalidale Ihe palenl Ihal had been granted lo Ihe inventor. 1amdeeply impressed Ihal Rachas did nol prolesl when OUo was awarded agold prize for his engine al Ihe Paris Exposilion Ihe year aner Otto's invention. However, Rachas was officially commendcd as Ihe inventor of Ihefour-stroke cycJe engine Iwo ycars before his dealh and was awarded anODO prize. This attitude of Ihe Frenc h governmenl also made a deep. .lmpreSSlon on me.Because sorne French people were hurnilialed by Ihis luro of hislOry. aFrench lextbook laler wrole Ihat Ihe OUo e ngine had a Beau de RachascycJe inslead of a four-slroke cycJe. However, Ihis SUlemenl slill seems ali!tle odd 10 me.Appendlx A4 Compresslon Ratio and Therrnal EfficlencyAn 0110 cycJe is a process in which air is compressed adiabatically (withoulIhe Ir30sfer of heat lo or from Ihe air) by the piston in Ihe cy linder, heal isadded lO the nir during the constanl-volume heating process (in a real engineheat is obtained by buming ruel), and the air is subjecled 10 adiabatic ellpansion from the maximum pressure poim . This OUo cycJe is currentlyregarded as the ideal cycle for the spark-ignition engine.When pressure, lemperalure, and voJume are represemed with P1 ...P4,T 1T3' and VI '" V4, Ihe following equations can be cSlablished becausc ofhe relationship belween the heat added, Q /r and the heal rejected, QL (seeFig. M-l) .

where

Q. = mCv(T3 -Ji) = mc.,7jEx-1(1; - 1)QL = m C l r . ~ -7j) = mc.,7j(I-:;)

m = Weight of gasCy = Specific hcat al constant volumc

the romance of engines - takashi suzuki cap1-3-red

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