Mechanical efficiency a factor called Indicated Power (ip) is

considered. It is defined as the power developed by combustion of

fuel in the combustion chamber. It is always more than brake power.
The power developed by an engine and measured at the output shaft is
called the Brake Power (BP)

BP(BRAKE POWER) =

2 NWL
60000

kw

Indicated power =Brake power +friction power

Mechanical efficiency =

BP
IP

So the mechanical efficiency is defined as ratio of brake power to the

indicated power.
Volumetric Efficiency
It is the ratio of the actual volume of the charge drawn in during the
suction stroke to the swept volume of the piston. The amount of air
taken inside the cylinder is dependent on the volumetric efficiency of
an engine and hence puts a limit on the amount of fuel which can be
efficiently burned and the power output. The value of volumetric
efficiency of a normal engine lies between 70 to 80 percent, but for
engines with forced induction it may be more than 100 percent.

The engine output is limited by the maximum amount of air that can
be taken in during the suction stroke, because only a certain amount
of fuel can be burned effectively with a given quantity of air
Mean effective pressure
Mean effective pressure is an important parameter for comparing the
performance of different engines. It is defined as the average pressure
acting over piston throughout a power stroke.
If mean effective pressure is based on brake power(bp) then it is
referred to as brake mean effective pressure(bmep).
If it is based on indicated power(ip) it is called indicated mean
effective pressure(imep).
imep is a fictitious constant pressure that would produce the same
work per cycle if it acted on the piston during the power stroke.
Friction mean effective power is the difference of imep and bmep,

Indicated mean effective pressure =

Brake mean effective pressure =

Volumetric efficieny

IP 60000
L . A . N /2

BP 60000
L . A . N /2

In a four-stroke naturally aspirated engine, the theoretical

maximum volume of air that each cylinder can ingest during the
intake cycle is equal to the swept volume of that cylinder .
Since each cylinder has one intake stroke every two revolutions of the
crankshaft, then the theoretical maximum volume of air it can ingest
during each rotation of the crankshaft is equal to one-half its
displacement. The actual amount of air the engine ingests compared
to the theoretical maximum is called volumetric efficiency (VE). An
engine operating at 100% VE is ingesting its total displacement every
two crankshaft revolutions.

Volumetric Efficiency =

Volume of air admitted during suction stroke

swept volume

ma

Brake thermal efficiency =

a(

2
n
d l)
4
60

BP 3600
TFC CV

Indicated thermal efficiency =

IP 3600
TFC CV

THERMAL
ANALYSIS

FUEL CONSUMPTION AND AIR

CONSUMPTION
AT 2500 RPM
S.n Speed(rpm Load(kg Fuel
o
)
)
consumption(ti
me in sec)

Air
consumptio
n
H1 H2 H2-

2500

23.35

H1
16 21 5

2500

11.98

17 24 7

2500

10

9.21

14 24 10

2500

15

6.76

13 26 13

2500

20

5.65

30 30

2500

25

4.95

35 30

AT 4000 RPM

S.no Speed(rpm) Load(kg Fuel

Air
)
consumption consumption
(time in sec)

4000

11.80

H1 H2 H2H1
26 64 38

4000

7.05

34

73

39

3
4

4000
4000

10
15

5.06
3.64

36
40

76
80

40
40

4000

20

3.56

41

82

41

4000

25

2.9

48

MODEL CALCULATIONS
AT 2500 RPM:
At load =15kg and speed =2500rpm
BP(BRAKE POWER) =
=

2 NWL
60000

kw

2 2500 15 9.81 0.4

60000

=15.41kw
Total fuel consumption (TFC) =

10 specific gravity 3600

1000 time for 10 cc of fuel

90

42

TFC=

10 0.83 3600
1000 6.76

=4.42 kg/hr
Indicated power =Brake power +friction power
=15.41+6.5
=21.91kw
Indicated mean effective pressure =

IP 60000
L . A . N /2

39.655 60000

IMEP =

0.0823.804 103

2500
2

=3.37MPa
Brake mean effective pressure =

BP 60000
L . A . N /2

24.655 60000

BMEP =

0.0823.804 10

2500
2

=1.48 MPa

Specific fuel consumption (SFC) =

=

TFC
BP
4.42
15.41

=0.287 kg/Kwhr

BP
IP

Mechanical efficiency =
=

15.41
21.91

=0.703
=70.3%
Brake thermal efficiency =

BP 3600
TFC CV
15.41 3600
42 42000

=29.86%
Indicated thermal efficiency =

IP 3600
TFC CV

21.91 3600
4.42 42000

=42.4%
Volume of air admitted during suction stroke
swept volume

Volumetric Efficiency =

n=

ma

a(

where

2
n
d l)
4
60

N
where N is speed rpm
2
0.02889

1
(

= 0 .911

0.0696 0.4)

2500
2 60

=91.1%

For air fuel ratio:

w

hw

air

=1000 kg/

hair

w h w
air

=
=

hair
m

hw

= 13mm at 15 kg

1000 13
1

=1300 mm
=13mts

Velocity = 2 g hair
= 2 9.81 13
h
s

=15.97
Discharge Q= AV
A= Area of orifice =

2
d
4

0.0482
4

=1.809
Mass of air =Q

103 m2

Q= AV =1.809

10 15.97

=0.02889
ma

= 0.02889

=0.02889
ma

m3
s

=0.02889
=103.68

kg
s

3600

kg
hr

Air 103.68
=
fuel
4.42

=23.45

At load =15kg and Speed =4000rpm

2 NWL
60000

BP =
=

kw

2 4000 15 9.81 0.4

60000

=24.655kw

Total fuel consumption (TFC) =

10 specific gravity 3600

1000 time for 10 cc of fuel

10 0.83 3600
1000 03.80

TFC=

=8.208 kg/hr

Indicated power =Brake power +friction power

=24.655+15
=39.655kw

Indicated mean effective pressure =

IP 60000
L . A . N /2

39.655 60000

IMEP =

0.0823.804 10

4000
2

=3.813MPa

Brake mean effective pressure =

24.655 60000

BMEP =

0.0823.804 103

= 2.37 MPa

4000
2

BP 60000
L . A . N /2

Specific fuel consumption (SFC) =

=

TFC
BP

8.208
211.655

=0.333 kg/Kwhr

Mechanical efficiency =
=

BP
IP

24.655
39.655

=0.622
=62.2%
BP 3600
TFC CV

Brake thermal efficiency =

=

24.655 3600
8208 42000

=25.74%

Indicated thermal efficiency =

=

IP 3600
TFC CV

21.91 3600
8.208 42000

=38.27%

Volumetric Efficiency =

Volume of air admitted during suction stroke

swept volume

n=

ma

a(

2
n
d l)
4
60

where

N
where N is speed rpm
2

( )0.0696 2 0.4
4
0.0506

4000
1
2 60

= 0.8391
= 83.91%

For air fuel ratio:

w

hw

air

=1000 kg/

hair

w h w
air

=
=

1000 40
1

=4000mm
=40mts

hair
m3

hw

= 40mm at 15 kg

Velocity = 2 g hair
= 2 9.81 40
m
s

28.01

Discharge Q= AV
2
d
4

A= Area of orifice =

0.0482
4

=1.809
Mass of air =Q
Q= AV =1.809

10 28.01

ma

m
0.0507
s

= 0.0507

=0.0507
ma

1
kg
s

=0.0507

3600

=182.52

kg
hr

Air 182.52
=
fuel 8.208

=22.236

m
s

103 m2

TABLES

CALCULATED PARAMETERS
AT 2500 RPM

Load(kg
)

Indicated
power(kw
)

Brake
power(kw
)

Total fuel
consumption(kg/hr
)

Specific fuel
consumption(kg/kwhr
)

Indicate mean
effective
pressure(Mpa
)

Brake mean
effective
pressure(Mpa
)

Air
fuel
ratio
(a/f)

6.5

1.279

50.3
8

11.636

5.136

2.494

0.485

1.79

0.79

30.6

10

16.773

10.273

3.244

0.316

2.58

1.58

28.0
7

15

21.91

15.41

4.42

0.287

3.37

2.37

23.4
5

20

27.04

20.546

5.288

0.257

4.16

3.16

29.8

25

32.18

25.682

6.03

0.274

4.95

3.95

26.1
4

AT 4000 RPM

Load(kg
)

Indicated
power(kw
)

Brake
power(kw
)

Total fuel
consumption(kg/h
r)

Specific fuel
consumption(kg/kwh
r)

Indicate
mean
effective
pressure(Mpa
)

Brake mean
effective
pressure(Mpa
)

Air
fuel
ratio
(a/f)

15

2.532

1.44

70.23
7

23.218

8.218

4.238

0.515

2.233

0.79

42.55
7

10

31.436

16.436

5.905

0.359

3.022

1.58

30.84
8

15

39.655

24.655

8.208

0.33

3.813

2.37

22.19

20

47.875

32.876

8.393

0.255

4.603

3.16

22.00
1

25

56.09

41.09

10.800

0.252

5.393

3.95

17.3

EFFICIENCIES
Load(kg)

Mechanical
efficiency

Brake thermal
efficiency

Indicated
thermal
efficiency

Volumetric
efficiency

43.5

56.52

44.1

17.65

39.9

66.94

10

61.2

27.14

44.3

79.89

15

70.3

29.86

42.4

91.11

20

75.9

33.33

43.8

138.3

25

79.8

36.5

45.74

138.3

50.74

81.92

35.4

16.62

46.95

83.084

10

52.2

23.85

45.63

83.91

15

62.2

25.74

38.277

83.91

20

68.6

33.5

48.89

85.07

25

73.2

32.6

44.52

86.06

At 2500 rpm

At 4000 rpm

GRAPHS

Total fuel consumption vs B.P AT 2500 RPM

7
6
5
4
T.F.C(Kg/hr)

Total fuel
consumption(kg/hr)

3
2
1
-10 -5

0
0

5 10 15 20 25 30
B.P(KW)

Total fuel consumption vs B.P AT 4000 RPM

12
10
8
Total fuel
consumption(kg/hr)

T.F.C(Kg/hr)

4
2
-20 -10

0
0

10

20

B.P(KW)

30

40

50

B.P vs IMEP
6
5

IMEP(MPa)

Indicate mean effective

pressure(Mpa AT2500 RPM)

Indicate mean effective

pressure(Mpa AT 4000
RPM)

2
1
0
0

5 10 15 20 25 30 35 40 45
B.P(KW)

B.P vs B.M.E.P
4.5
4
3.5
3

Brake mean effective

pressure(Mpa AT 2500 RPM)

2.5
B.M.E.P(MPa)

Brake mean effective

pressure(Mpa AT 4000 RPM)

2
1.5
1
0.5
0
0 5 10 15 20 25 30 35 40 45
B.P(KW)

B.P vs Mechanical Efficiency

90
80
70
60

Mechanical efficiency AT
2500 RPM

50
% efficiency

Mechanical efficiencyAT 4000

RPM

40
30
20
10
0
0

5 10 15 20 25 30 35 40 45
Brake Power(KW)

B.P vs Volumetric efficiency AT 2500 RPM

160
140
120
100
Volumetric efficiency

Volumetric efficiency

80
60
40
20
0
0

10

15
B.P

20

25

30

B.P vs Volumetric efficiency AT 4000 RPM

87
86
85
84
Volumetric efficiency
83
82
81
80
79
0

10

15

20

25

30

35

40

45

THERMAL
DESIGN
INTRODUCTION
Critical Temperature
Gases can be converted to liquids by compressing the gas at a suitable
temperature.
Gases become more difficult to liquefy as the temperature increases
because the kinetic energies of the particles that make up the gas also
increase.
The critical temperature of a substance is the temperature at and
above which vapor of the substance cannot be liquefied, no matter
how much pressure is applied.
Every substance has a critical temperature
Critical Pressure

The critical pressure of a substance is the pressure required to liquefy

a gas at its critical temperature.

For a diesel cycle we have

( ) 1
k

T 2 =T 1

P2
P1

T2
=
T1

P2=P1

T2
T1

Q=

brake power
brake thermal efficiency

At 2500 rpm , w =15 kg

For a diesel cycle we have
T 2 =T 1

( ) 1
k

=944.77k
Also

= 300

(17.6)1.4 1

P2
P1

T2
=
T1

P2=P1

T2
T1

1
944.77
300

= 1(

1.4
1.41

= 55.42 bar
P2=

=55.42 bar

THE ABOVE PRESSURE IS THE CRITICAL PRESSURE

Q=

brake power
brake thermal efficiency

Q=

mf =

Q 60
N
n
2
Q1
CV

T 3 T 2

=
=

51.6 60
2500
4
2

0.6192
42000
Q1
ma c p k

15.41
0.2986

=51.6 kw

= 0.6192 KJ

=1.47

=1374.86 K
T 3 =T 2 +1374.86 K

10

Kg

0.6192
1.3 1.47 105 23.45 1.005

= 944.77 + 1374.86
=2319.639 K

At 4000 rpm , w =15 kg

For a diesel cycle we have
( ) 1
k

T 2 =T 1

= 300

(17.6)1.4 1

=944.77k
Also
P2
P1

T2
=
T1

P2=P1

T2
T1

= 1(

944.77
300
1.4

1.41

= 55.42 bar
P2=

=55.42 bar

THE ABOVE PRESSURE IS THE CRITICAL PRESSURE

Q=

brake power
brake thermal efficiency

Q=

24.655
0.2574

Q 1=

Q 60
N
n
2

Q
CV

T 3 =T 2

=95.784 KW

0.6192
42000

95.784 .6 60
4000
4
2

=1.47

Q
ma c p k

= 0.7183 KJ

105

Kg

0.6192
5
1.3 1.4 10 23.45 1

=1374.86 K
T 3 =T 2 +1374.86

=2319.639K

CRITICAL TEMPERATURES

S.no

Load(kg)

Total heat
supplied(Q)
(Kw)

Mass of the
fuel (kg)

49.44

7.4 10

1700.155

10

68.91

1.2310-5

1987.28

15

95.784

1.7110-5

2393.68

20

98.128

1.810-5

2405.33

25

126.043

2. 2510-5

2802.975

S.no

Load(kg)

Total heat
supplied(Q)
(Kw)

Mass of the
fuel (kg)

Critical
temperature
(T3 K)

29.099

8.31 10

1995.86

10

37.85

1.0810-5

2091.5

15

51.6

1.4710-5

2319.639

20

61.64

1.7610-5

2024.25

25

70.36

2. 0110-5

2174.71

Critical
temperature
(T3 K)

MECHANIC
AL DESIGN

CYLINDER:
MATERIAL: High Grade Cast Iron
D=Bore Diameter
L=Stroke Length = 1.4D
I = Idicated power
P

m= Meaneffective pressure
P

D=
=

60 10 6 8 PI
P m L N

60 106 8 56.09
3.95 1.6 D 4000

=72.9 mm
L=102.06 mm

CYLINDER HEAD
MATERIAL:HIGH GRADE CAST IRON
th= Allowable Gas Pressure=35 MPa
S
th

= Thickness of Cylinder Head

t h=0.5 D

Pcr
Sth

= 0.5 x 72.9 x

= 14.5 mm
= 1.45 cm

PISTON

5.5426
35

MATERIAL: ALUMINIUM ALLOY

3 Pcr D2
t1 =
16 S tp
S tp

t1

= 70
=

N
mm2

For aluminium alloy

3 5.5426 72.9
16 70

= 8.88 mm

PISTON RINGS
MATERIAL: FINE GRAINED ALLOY CAST IRON
THICKNESS OF RIB = (0.3 0.5)

t1

= 0.4 D
= 0.4

8.88

= 3.552 mm

Axial thickness of piston rings =

i=Number of rings=3
t ax

72.9
10 3

D
10 i

where

= 2.43 mm

Radial Thickness of Piston Ring

tr

= 0.045D
= 0.045

72.9

= 3.28 mm

GUDGEON PIN
MATERILAL: CASE HARDENED STEEL
Length = 0.45D
= 0.45

72.9

= 32.8 mm
Maximum Load ( F )= A
F=

Pcr

72.92 5.546
4

=23148.603 N
M max

FD
8

23148.609 X 72.9
8

= 210941.65 N-mm
For diameter of Gudgeon pin

We know

d g3 f cr =M max
32
d g3

210941.65 32
480

= 16.48 mm

CONNECTING ROD
MATERIAL : ALLOY STEEL
MAX LOAD(F) = 23148.603 N
AREA OF CROSS SECTION =
Fcr

= ALLOWABLE ULTIMATE STRESS OF ALLOY STEEL

= 1425 MPa

Fcr =

11t 2

11 t

F
A

23148.603
1425

=1.215=flange thickness

Width of flange=4t = 4.86 mm

Depth of Web =5t = 6.075 mm