Design of I.C.

Engine Parts
By:
Er. Shankar Sehgal
Faculty of Mech. Engg., UIET,
Panjab University, Chandigarh
Website: http://shankarsehgal.weebly.com
I.C. Engine
 Design of Cylinder
• Types of stresses:
– Stresses due to Gas Pressure
• Longitudinal Stresses
• Circumferential Stresses
– Stresses due to Piston Side Thrust
 Design of Cylinder
• Bore and Length of Cylinder:
pmlAn
I .P. 
60
• Where,
– I .P.  B.P. ; I.P. = Indicated Power, B.P. = Brake Power
 mech
– pm is indicated mean effective pressure
– l is length of stroke = 1.5 D
– A is cross-sectional bore area of cylinder
– n is number of working strokes per minute
• Length of Cylinder = 1.15 l
 Design of Cylinder
• Thickness of Cylinder Wall:
pD
t C
• 2 c Based upon thin cylinder formula
• Where C is allowance for reboring
 Design of Cylinder Flange
• Cylinder flange thickness = 1.4 t
• Considering tensile failure of cylinder flange
bolts:
 2 
 D p
4 
F n
 
A  2
dc
4

• Use bolts of diameter greater than 16 mm only

 Design of Cylinder Head
• Cylinder head thickness:
C. p
th  D
c

• Considering tensile failure of cylinder head

bolts:  2 
 D p
4 
F n
 
A  2
dc
4
Design of Piston
Piston of I.C. Engine
 Design Considerations for Piston
• High strength to withstand the high gas
pressure and inertia forces.
• Low weight density
• Low coefficient of thermal expansion
• High heat conductivity
 Materials for Piston
• C.I.
• Cast Aluminium
• Cast Steel
• Forged Aluminium
• Forged Steel
 Design of Piton Head
• Considering tensile strength requirement:
– Using Grashoff’s Formula
3 p.D 2
tH 
16 t
 Design of Piton Head
• Considering heat dissipation requirement:
H
tH 
12.56k TC  TE 
• Where,
– H is heat flow rate
– k is coefficient of thermal conductivity
– TC is Temperature at centre of the piston
– TE is Temperature at edges of the piston
 Design of Piton Rings
• Compression Rings
– Three to seven in number
– Transfer heat from piston to cylinder liner
– Absorb side thrust on piston
– Cross-section is rectangular
– Diameter is slightly larger than cylinder bore
– Diagonal or step cut is provided
• Oil Control Rings
– Help in lubrication of liner
 Design of Piston Rings

3 pw D
t1  D t2 
t 10nrings
 Design of Piston Rings

• Width of top land

b1  t H
• Width of other ring lands
b2  t 2
 Design of Piston Barrel

3
t3  D  t1  4.9
100

1
t 4  t3
4
 Design of Piston Skirt
• Considering
bearing failure of
piston skirt:
1   2
p D 
10 4
pb   
Dlskirt
 Design of Piston Pin
• Considering bearing failure of piston pin:
 2
p D
pb  4
d 0l1

• Where,
l1  0.45 D
 Design of Piston Pin
• Considering bending failure of piston pin:
 M

y I
 P l2 P l1 
    
  2 2 2 4

 
 do    do 4  di 4 
   
 2   64 

Design of Connecting Rod
Connecting Rod
 l
Ratio
r
• l = length of connecting rod
• r = radius of crank
l
• Small l  4 _ to _ 5
rr
– small and compact engines
– large angular motion of connecting rod
– large side thrust of connecting rod
– rapid wear and tear of cylinder liner