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Engine Knocking (Detonation) Explained


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Knocking (also called knock, detonation, spark knock or pinging) in spark-ignition internal combustion engines occurs when combustion of the air/fuel mixture in the cylinder starts off correctly in response to ignition by the spark plug, but one or more pockets of air/fuel mixture explode outside the envelope of the normal combustion front. The fuel-air charge is meant to be ignited by the spark plug only, and at a precise time in the piston's stroke cycle. The peak of the combustion process no longer occurs at the optimum moment for the four-stroke cycle. The shock wave creates the characteristic metallic "pinging" sound, and cylinder pressure increases dramatically. Effects of engine knocking range from inconsequential to completely destructive. It should not be confused with pre-ignition as they are two separate events.

Normal Combustion
Under ideal conditions the common internal combustion engine burns the fuel/air mixture in the cylinder in an orderly and controlled fashion. The combustion is started by the spark plug some 10 to 40 crankshaft degrees prior to top dead centre (TDC), depending on many factors including engine speed and load. This ignition advance allows time for the combustion process to develop peak pressure at the ideal time for maximum recovery of work from the expanding gases.
The spark across the spark plug's electrodes forms a small kernel of flame approximately the size of the spark plug gap. As it grows in size its heat output increases allowing it to grow at an accelerating rate, expanding rapidly through the combustion chamber. This growth is due to the travel of the flame front through the combustible fuel air mix itself and due to turbulence rapidly stretching the burning zone into a complex of fingers of burning gas that have a much greater surface area than a simple spherical ball of flame would have. In normal combustion, this flame front moves throughout the fuel/air mixture at a rate characteristic for the fuel/air mixture. Pressure rises smoothly to a peak, as nearly all the available fuel is consumed, then pressure falls as the piston descends. Maximum cylinder pressure is achieved a few crankshaft degrees after the piston passes TDC, so that the increasing pressure can give the piston a hard push when its speed and mechanical advantage on the crank shaft gives the best recovery of force from the expanding gases.

Abnormal Combustion (Detonation)
When unburned fuel/air mixture beyond the boundary of the flame front is subjected to a combination of heat and pressure for a certain duration (beyond the delay period of the fuel used), detonation may occur. Detonation is characterized by an instantaneous, explosive ignition of at least one pocket of fuel/air mixture outside of the flame front. A local shockwave is created around each pocket and the cylinder pressure may rise sharply beyond its design limits. If detonation is allowed to persist under extreme conditions or over many engine cycles, engine parts can be damaged or destroyed. The simplest deleterious effects are typically particle wear caused by moderate knocking, which may further ensue through the engine's oil system and cause wear on other parts before being trapped by the oil filter. Severe knocking can lead to catastrophic failure in the form of physical holes punched through the piston or head (i.e., rupture of the combustion chamber), either of which depressurizes the affected cylinder and introduces large metal fragments, fuel, and combustion products into the oil system. Hypereutectic pistons are known to break easily from such shock waves.
Detonation can be prevented by any or all of the following techniques:

1: The use of a fuel with high octane rating, which increases the combustion temperature of the fuel and reduces the proclivity to detonate
2: Enriching the fuel/air ratio, which adds extra fuel to the mixture and increases the cooling effect when the fuel vaporizes in the cylinder
3: Reducing peak cylinder pressure by increasing the engine revolutions (e.g., shifting to a lower gear, there is also evidence that knock occurs easier at low rpm than high regardless of other factors)
4: Increasing mixture turbulence or swirl by increasing engine revolutions or by increasing "squish" turbulence from the combustion chamber design
5: Decreasing the manifold pressure by reducing the throttle opening
6: Reducing the load on the engine.

Because pressure and temperature are strongly linked, knock can also be attenuated by controlling peak combustion chamber temperatures by compression ratio reduction, exhaust gas recirculation, appropriate calibration of the engine's ignition timing schedule, and careful design of the engine's combustion chambers and cooling system as well as controlling the initial air intake temp. Knock is less common in cold climates. As an aftermarket solution, a water injection system can be employed to reduce combustion chamber peak temperatures and thus suppress detonation. Interestingly the addition of certain materials such as lead and thallium will suppress detonation extremely well when certain fuels are used. The addition of tetraethllead (TEL) a soluble salt added to gasoline was common until it was discontinued for reasons of toxic pollution. Lead dust added to the intake charge will also reduce knock with various hydrocarbon fuels. Manganese compounds are also used to reduce knock with petrol fuel. Steam (water vapour) will suppress knock even though no added cooling is supplied. Certain chemical changes must first occur for knock to happen, hence fuels with certain structures tend to knock easier than others. Branched chain paraffins tend to resist knock while straight chain paraffins knock easily. It has been theorized that lead, steam, and the like interfere with some of the various oxidative changes that occur during combustion and hence the reduction in knock. Turbulence as stated has a very important effect on knock. Engines with good turbulence tend to knock less than engines with poor turbulence. Turbulence occurs not only while the engine is inhaling but also when the mixture is compressed and burned. During compression/expansion "squish" turbulence is used to violently mix the air/fuel together as it is ignited and burned which reduces knock greatly by speeding up burning and cooling the unburnt mixture. One excellent example of this is all modern side valve or flathead engines. A considerable portion of the head space is made to come in close proximity of the piston crown, making for much turbulence near TDC in the early days of side valve heads this was not done and a much lower comp ratio had to be used for any given fuel. Also such engines were sensitive to ignition advance and had less power of course.
Knocking is more or less unavoidable in diesel engines, where fuel is injected into highly compressed air towards the end of the compression stroke. There is a short lag between the fuel being injected and combustion starting. By this time there is already a quantity of fuel in the combustion chamber which will ignite first in areas of greater oxygen density prior to the combustion of the complete charge. This sudden increase in pressure and temperature causes the distinctive diesel 'knock' or 'clatter', some of which must be allowed for in the engine design. Careful design of the injector pump, fuel injector, combustion chamber, piston crown and cylinder head can reduce knocking greatly, and modern engines using electronic common rail injection have very low levels of knock. Engines using indirect injection generally have lower levels of knock than direct injection engine, due to the greater dispersal of oxygen in the combustion chamber and lower injection pressures providing a more complete mixing of fuel and air. diesels actually don't suffer the exact same "knock" as gas engines since the cause is known to be only the very fast rate of pressure rise, not unstable combustion. Diesel fuels are actually very prone to knock in gas engines but in the diesel there is no time for knock to occur as the fuel is only oxidized during the expansion cycle. In the gas engine the fuel is slowly oxidizing all the while it is being compressed before the spark. This allows for changes to occur in the structure/makeup of the molecules before the very critical period of high temp/pressure.
An unconventional engine that makes use of detonation to improve efficiency and decrease pollutants is the Bourke engine.

Pre-Ignition
Pre-ignition in a spark-ignition engine is a technically different phenomenon from engine knocking, and describes the event wherein the air/fuel mixture in the cylinder ignites before the spark plug fires. Pre-ignition is initiated by an ignition source other than the spark, such as hot spots in the combustion chamber, a spark plug that runs too hot for the application, or carbonaceous deposits in the combustion chamber heated to incandescence by previous engine combustion events.
The phenomenon is also referred to as after-run, or run-on when it causes the engine to carry on running after the ignition is shut off, or sometimes dieseling. This effect is more readily achieved on carburetted gasoline engines, as the fuel supply to the carburettor is typically regulated by a passive mechanical float valve and fuel delivery can feasibly continue until fuel line pressure has been relieved, provided the fuel can be somehow drawn past the throttle plate. The occurrence is rare in modern engines with throttle-body or electronic fuel injection, as the injectors will not be permitted to continue delivering fuel after the engine is shut off, and any occurrence may indicate the presence of a leaking (failed) injector.
In the case of highly supercharged or high compression multi-cylinder engines particularly ones that use methanol (or other fuels prone to pre-ignition) pre-ignition can quickly melt or burn pistons since the power generated by other still functioning pistons will force the overheated ones along no matter how early the mix pre-ignites. Many engines have suffered such failure where improper fuel delivery is present. Often one injector may clog while the others carry on normally allowing mild detonation in one cylinder that leads to serious detonation, then pre-ignition.
Pre-ignition and engine knock both sharply increase combustion chamber temperatures. Consequently, either effect increases the likelihood of the other effect occurring, and both can produce similar effects from the operator's perspective, such as rough engine operation or loss of performance due to operational intervention by a powertrain-management computer. For reasons like these, a person not familiarized with the distinction might describe one by the name of the other. Given proper combustion chamber design, pre-ignition can generally be eliminated by proper spark plug selection, proper fuel/air mixture adjustment, and periodic cleaning of the combustion chambers.

Detonation Induced Pre-Ignition
Due to the way detonation breaks down the boundary layer of protective gas surrounding components in the cylinder such as the spark plug electrode these components can start to get very hot over sustained periods of detonation and glow. Eventually this can lead to the far more catastrophic Pre-Ignition as described above.
While it is not uncommon for an automobile engine to continue on for thousands of miles with mild detonation, Pre-Ignition can destroy an engine in just a few strokes of the piston.

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