Faculty of Engineering and Computing

Crankshaft, connecting rod and piston assembly

Advanced Manufacturing Processes and Materials

Prepared by Sachin Sawant S.I.D. 337736

!SC in "utomoti#e Engineering $EC%&'()

Contents

*. Introduction +. Component function 3. In ,er#ice condition, '. -perational .e/uirement, (. !aterial Characteri,tic, 6. Summary 7. .eference 0. "ppendi1

p. + p. 3 p. 6 p. 7 p. 0 p. *& p. ** p.*+

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Introduction

Internal combu,tion engine date, bac2 to *076 when -tto fir,t de#eloped the ,par2 ignition engine 3 * 0+ when Die,el in#ented the compre,,ion4ignition engine. Since then the,e engine, ha#e continued to de#elop a, our 2nowledge of engine proce,,e, ha, increa,ed5 a, new technologie, became a#ailable5 a, demand, of new type, of engine aro,e5 and a, en#ironmental con,traint, on engine u,ed changed. Internal combu,tion engine,5 and the indu,trie, that de#elop5 manufacture and ,upport their u,e5 now play a dominant role in the field, of power5 propul,ion 3 energy. %he la,t %wenty4fi#e year, or ,o ha#e witne,,ed an e1plo,i#e growth in engine re,earch 3 de#elopment a, the i,,ue, of air pollution5 fuel co,t 3 mar2et competiti#ene,, ha#e become increa,ingly important. %he purpo,e of a Combu,tion Engine i, to produce mechanical energy from chemical energy contained in the fuel. In internal combu,tion engine5 a, di,tinct from e1ternal combu,tion engine5 the energy i, relea,ed by burning or oxidation of fuel in,ide the engine. %he air4fuel mi1ture before combu,tion 3 the e1hau,t ga,e, po,t combu,tion are the actual wor2ing fluid, in the entire wor2ing proce,, of an IC engine. %he wor2 tran,fer, which pro#ide the de,ired power output occur directly between the wor2ing fluid and the mechanical power tran,mitting component, of the engine,. Due to combu,tion of compre,,ed air4fuel mi1ture within the cylinder5 a large pre,,ure gradient i, created which e1ert, mechanical force on the pi,ton tending it to mo#e in downward direction. Connecting rod5 which form, a medium in between the pi,ton and the cran2,haft5 ,tart, rotating the cran2,haft. 6ence con#erting the
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mechanical force into the tor,ion on the cran2,haft5 tran,ferring the chemical energy of the fuel to the mechanical energy at the cran2,haft.

Components function

During operation5 accurate mea,ure of air4fuel mi1ture i, ,uc2ed into the combu,tion chamber of the engine during the ,uction ,tro2e of the engine at ,uction pre,,ure of around &.74&.0 bar. %hi, mi1ture i, then compre,,ed in the compre,,ion ,tro2e at the ma1imum pre,,ure $depending upon the compre,,ion ratio of the engine). In the power ,tro2e5 the compre,,ed mi1ture i, ignited either by e1ternal ,ource $in SI engine) or by7,elf4ignition temperature8of the mi1ture $in CI engine)5 thu, applying force on the pi,ton head. During the downward mo#ement of pi,ton in the power ,tro2e5 the downward linear force on the pi,ton i, tran,formed to tor,ion by the mean, of 7,ingle4,lider mechani,m8of the combined ,y,tem of pi,ton4connecting rod4cran2,haft.

Piston:

%he force e1erted due to the combu,tion pu,he, the pi,ton along the cylinder wall. %hi, ,liding mo#ement along the cylinder tran,mit, the e1erted force to the connecting rod. In order to tran,mit the force efficiently5 the inertia of pi,ton i, 2ept minimal by u,ing aluminium pi,ton, in combination with hollow ,tructure. + ,et, of Pi,ton ring, are fitted on the pi,ton to fill up the gap between the pi,ton 3 cylinder. %he upper ,et of ring, i, to pro#ide
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air tight ,eal to pre#ent lea2age of the burnt ga,e, into the lower portion. %he lower ring, pro#ide effecti#e ,eal to pre#ent lea2age of oil in the engine cylinder.

Connecting Rod:

Connecting rod lin2, pi,ton with the cran2,haft5 who,e main function i, to tran,mit force from the pi,ton to the cran2,haft. !oreo#er it con#ert, the ,liding motion of the pi,ton into rotational motion of the cran2,haft5 in the wor2ing ,tro2e. %he upper $,maller) end of the rod i, connected to the pi,ton through gudgeon pin wherea, the lower $larger) end of the rod i, connected to the cran2,haft through cran2 pin. Special ,teel alloy, or aluminium alloy, are u,ed for the manufacture of the rod,. " ,pecial care ha, to be ta2en while de,igning 3 manufacturing connecting rod5 a, it i, ,ub9ected to alternate ten,ile 3 compre,,i#e ,tre,,e, alongwith bending ,tre,,e,. Crankshaft:

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It con,idered to be the bac2bone of IC engine who,e function i, to con#ert the reciprocating motion of the pi,ton to the rotational motion with the help of connecting rod. %he ,haft contain, number of eccentric portion, called a, 7cran28. %he bigger part of connecting rod i, connected to the cran2 by the mean, of cran2 pin. Cran2 pin, are the mo,t crucial part in the cran2,haft a, the force tran,mitted through the pi,ton i, directly applied on to it. 6ence careful de,igning and manufacturing ha, to be done for cran2,haft.

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In-service Conditions

Piston: During operation5 pi,ton undergoe, thermal 3 mechanical ,tre,,e, due to high4pre,,ure temperature condition,. In ab,ence of lubricating oil5 there are chance, of pi,ton 9amming in the cylinder bloc2 which cau,e, 7engine ,ei:ure8. "l,o lac2 of coolant can cau,e ineffecti#e heat di,,ipation which cau,e, thermal e1pan,ion of cylinder 3 pi,ton which cau,e, engine ,ei:ing. Due to impul,e force acted by the chemical combu,tion5 chance, of pitting occur on the pi,ton head ,urface. Prolong cyclic load, on pi,ton cau,e, bending 3 ,hear failure of gudgeon pin. -#erheating of engine cau,e, burning of pi,ton ring, due to which oil enter, the combu,tion chamber cau,ing white ,mo2e. Connecting Rod: Due to continuou, cyclic ten,ile 3 compre,,i#e load,5 connecting rod tend, to fail in bending moment. E1ternal factor, li2e ,imultaneou, acceleration 3 bra2ing can o#erload the engine re,ulting to the failure of connecting rod. Crankshaft: Engine cran2,haft, are ,ub9ected to tor,ional wind4up 3 #ibration at certain ,peed, due to power impul,e,. ;nder accelerating condition the farthe,t end of cran2,haft connected to the flywheel tend to turn fir,t than the flywheel end due to pre,ence of inertial difference at both the end,. <ice4#er,a in ca,e of engine deceleration. %he,e ,ituation, re,ult, in repeated ,hoc2 load,5 wear 3 noi,e in form of gear clatter impo,ed on the gear teeth in the tran,mi,,ion ,y,tem. %hu, to o#ercome tor,ional #ibration,5 a tor,ion damping de#ice i, incorporated within the dri#en plate hub a,,embly in the tran,mi,,ion ,y,tem.

Operational Requirements

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Piston: 4 Pi,ton, are ,ub9ected to cyclic load, at high temperature4 pre,,ure condition,. 6ence the pi,ton material ,hould ha#e good thermal conductivity to tran,fer the heat from pi,ton to the pi,ton ring, and e#entually through the cylinder bloc2 efficiently. 4 %he pi,ton material ,hould ha#e low thermal co-efficient of expansion ,uch that the pi,ton doe,n=t get 9ammed up in the cylinder bloc2 while operation. 4 Pi,ton material ,hould ha#e high compressive strength to with,tand the impul,i#e load due to combu,tion of air4fuel mi1ture. 4 %he material ,hould ha#e highly stable chemical composition at high temperature, ,uch that it ,houldn=t chemically react with the air4fuel mi1ture during combu,tion. 4 %he pi,ton material ,hould ha#e high melting point to with,tand the high temperature, in the combu,tion proce,,. Connecting Rod: 4 Connecting rod, ,hould ha#e higher buckling strength in order to with,tand buc2ling load, during operation. Crankshaft: 4 Cran2,haft ,hould be well-balanced in order to a#oid #ibration, 3 noi,e during operation. 4 Cran2,haft ,hould ha#e optimum torsional stiffness to a#oid gear clattering5 #ibration, 3 noi,e during operation. 4 Crankpins ,hould ha#e higher shear strength to with,tand radial load acting from the connecting rod. 4 4 4 Cran2,haft, ,hould po,,e,, ,ufficient stiffness to re,i,t bending along their length. >ow #ibration. .e,i,tance to wear in the bearing area,.

Material Characteristics

Piston:
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Due to application of combined load during the combu,tion proce,,5 the pi,ton material ,hould be able to with,tand both mechanical 3 thermal fatigue. It ,hould ha#e good thermal conducti#ity to di,,ipate heat to the cylinder bloc2. %he material ,hould ha#e ,table chemical compo,ition ,uch that it won=t o1idi,e with the air4fuel mi1ture. Pi,ton material ,hould ha#e low thermal co4efficient of e1pan,ion ,o that pi,ton don=t get 9ammed at high temperature. !aterial ,hould be able to with,tand high operating temperature,. "l,o it ha, to be light in weight in order to increa,e the mechanical efficiency of engine. !aterial ,hould be ea,ily forged to with,tand the impul,i#e force on the pi,ton head. Connecting Rod: Connecting rod, operate under high load, re/uiring? 4 4 4 4 4 4 4 4 4 6igh ,trength in both ten,ion and compre,,ion. 6igh fatigue ,trength. 6ighly efficient engine, demand the lowe,t po,,ible component weight. !aterial, with good rigidity @ high ,trength. Aeight con,i,tency to facilitate engine balancing. Forged ,teel offer, the be,t combination of ,trength5 ,tiffne,, 3 co,t. Ca,t iron rod, are hea#ier and ,intered powder product, are more e1pen,i#e. In future the rod and cap will be fracture ,plit to minimi,e co,t for mo,t #olume produced connecting rod,. >ower through co,t pre,,ure, demand? B Elimination of a heat treatment proce,, B Impro#ed machinability for high #olume production B >ow di,tortion on fracture ,plitting Controlled air cooled ,teel, ha#e largely replaced heat treated ,teel, for connecting rod application,. 6igher ,trength grade, are re/uired for the hea#ier load, typically found in die,el engine, and higher performance petrol dri#en car,. Aeight reduction and pac2aging con,traint, are al,o dri#ing up the need for higher ,trength material,.

Crankshafts: %he manufacturing route for forged ,teel cran2,haft, i, u,uallyC hot forging5 heat treatment5 machining and ,urface treatment. Controlled air cooling after forging i, lower co,t than the traditional /uench and temper and i, now the preferred route. Efficient and co,t effecti#e proce,,ing re/uire,?
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4 4 4 4 4 4 4 4

Con,i,tent hardening re,pon,e. Dood machinability in the hardened condition. Predictable re,pon,e to ,urface modification ,uch a, induction hardening5 nitriding or fillet rolling. Controlled hardenability ,teel, en,ure repeatability of mechanical propertie,. -ptimi,ed ,ulphur content balance, the conflicting benefit, of low ,ulphur for fatigue propertie, and high ,ulphur for impro#ed machinability. Controlled carbon content produce, con,i,tent re,pon,e to induction hardening Controlled chromium and aluminium addition, en,ure con,i,tent ,urface hardening through nitriding. Clean ,teel, pro#ide good fatigue re,i,tance from low o#erall inclu,ion content.

ummary
%he Pi,ton ride, in,ide the combu,tion chamber5 around the pi,ton are a ,erie, of pi,ton ring, that ,eal the combu,tion chamber and allow the pi,ton to mo#e up and down. %he pi,ton i, connected to the cran2,haft with a connecting rod. %he cran2,haft con#ert, the up

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and down motion of the pi,ton into a circular motion that i, ultimately tran,mitted to the dri#e wheel,. Care ,hould be ta2en while de,igning 3 ,electing material, for the,e critical component, a, it ad#er,ely affect, the engine=, performance 3 efficiency.

Reference

4 4 4

"d#anced <ehicle %echnology E 6ein: 6ei,ler Internal Combu,tion Engineering 4 Fohn 6. Aea#ing "utomoti#e %echnology E Fredric2 C. Ga,h

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Appendi!
Power tran,mitting ,y,tem in IC Engine Pi,ton Connecting .od Cran2,haft 4 4 4 4 pg. + pg.3 pg.' pg.'

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