Maruti Swift Engine Design

Table of Contents
1. Design Procedure
1.1 Specifications of Maruti Swift Engine
1.2 Engine Parameters
1.2.1 Calculation of Brake Mean Effective Pressure
1.2.2 Calculation of reactive forces on bearings
1.2.3 Design of Crank Pin
1.2.4 Design of Left hand Crank Web
1.2.5 Design of Right Hand Crank Web
1.2.6 Design of Shaft under flywheel
2. Manufacturing Processes and machines used
3. Outline Process Chart
4. Layout of the operations
5. Drawing
Click here to see the Old ( Before incorporating changes) Knol
1. Design Procedure
1.1 Specifications of Maruti Swift Engine
Capacity 1197cc
Number of Cylinders 4
Number of Valves 16
Bore x Stroke 73.0mm x 71.5mm
Compression Ratio 10.1:1
Maximum Power 85ps @ 6,000rpm
Maximum Torque 113Nm @ 4,500rpm
2.1 Calculation of Brake Mean Effective Pressure

BMEP = 2 x π x Torque x no. of strokes / Displacement Volume
Since the no. of cylinders = 4
Torque to be developed by single cylinder = Total torque/No. of cylinders
= 113/4 = 28.5 Nm
From the specifications given,
Displacement volume can be estimated by the stroke and bore. (Volume of the cylinder)
Torque and RPM are also given in the specifications.
BMEP = 1.35 KN/mm2
Maximum combustion pressure = 5 x BMEP (approx.)
Maximum combustion pressure = 6.75 KN/mm2
2.2 Calculation of Reactive Forces on Bearings

Force on the Piston Fp = Area of the bore x Max. Combustion pressure
= π x D2 x Pmax /4
= 28.25 KN
Assuming that the distance between the 2 bearings is equal to twice the piston diameter D
Distance between bearings, b = 2 x D = 146 mm
Distance from the bearings to the piston axis = b1=b2 = b/2
b1 = b2 = 73 mm.
Where,
b1 = distance from the bearing 1 to the piston axis in mm
b2 = distance from the bearing 2 to the piston axis in mm

Horizontal reaction at bearing 1, H1 = Fp x b1 / b = 14.125 KN
Horizontal reaction at bearing 2, H2 = Fp x b2 / b = 14.125 KN
2.3 Design of Crank Pin

dc –Diameter of the crank pin
lc –Length of the crank pin
Mb- Allowable bending stress (Assumed to be 75 N/mm2)
Bending moment at the centre of crank pin, Mc = H1 x b2 = 1031.125 N-mm
We know that, Mc = π x dc3 x Mb /2
From this we have the diameter of the crank pin, dc = 52 mm
Length of the crank pin, lc = Fp / dc x pb
Taking bearing pressure =10 N/mm2
We have the length of the crank pin, lc = 55 mm
Results:
Diameter of the crank pin = 52 mm
Length of the crank pin = 55 mm
2.4 Design Left Hand Crank Web

Thickness of the web, t = 0.65dc + 6.35 mm
t = 40 mm
Width of the crank web, w = 1.125dc + 12.7 mm
w = 71 mm
Crank web is subjected to bending and direct compressive stresses
Max. Bending moment, M = H1x (b2 – lc/2 –t/2)
From this we have M = 24792.2 KN-mm

Bending stress = M / Z
Where Z is the section modulus which is given by Z = w x t2 / 6
Bending stress is coming to 18.933 N/mm2
Direct compressive stress = H1 / w x t =4.97 N/mm2
Total stress on the crank web = Bending stress + Direct compressive stress =23.906 N/mm2
It is less than the limiting stress of 75 N/mm2. Hence the design is safe.
Results:
Thickness of the Left hand crank web = 40 mm
Width of the Left hand crank web = 71 mm
Fig.1 Crank Shaft at dead centre
2.5 Design of Right Hand Crank Web

From the balancing point of view the dimensions of the right hand crank web (Width and
Thickness) are made equal to the Left hand crank web
Results:
Thickness of the Right hand crank web = 40 mm
Width of the Right hand crank web = 71 mm

2.6 Design of the shaft under flywheel
Assuming that the length of the main bearings are equal i.e c1=c2=c/2.
We know that due to the weight of the flywheel acting downwards, there will be two vertical
reactions at bearings
We have the vertical reactions V1 and V2 to be 3453 N (V1 and V2 are equal since the load is
distributed equally and assumed to act at the centre)
Let ds = Diameter of the shaft in mm.
Since the lengths of the main bearings are equal, therefore
l1 = l2 = l3 = 2 (b/2 – lc/2 - t) = 56 mm
Assuming width of the flywheel as 30 mm, we have
c = 56 + 30 = 86 mm
Allowing space for gearing and clearance, let us take c = 100 mm.
c1 = c2 = c/2 = 50 mm
Bending moment due to the weight of the flywheel
Mw = Vertical reaction x distance = 3453 × 50 = 172650 N-mm
From this we have the diameter of the shaft,
Considering the maximum permissible bending moment to be 40 N/mm2
172650 = π x ds3 x Mb /32x 4
On simplification we get, ds = 38 mm
Result:
Diameter of the shaft = 38 mm
2.7 Design of Crankshaft when the crank is at an angle of maximum twisting

moment
Force on the Piston Fp = Area of the bore x Max. Combustion pressure
= π x D2 x Pmax /4
= 28.25 KN
In order to find the thrust in the connecting rod (FQ), we should first find out the angle of
inclination of the connecting rod with the line of stroke (i.e. angle φ). We know that
Sin φ = Sin θ/ (L/R)
= Sin 35/ 4
Which implies φ = 8.75°
We know that thrust in the connecting rod
Fq = Fp / cos φ
From this we have,
Thrust on the connecting rod = 28.58 KN

Thrust on the crank shaft can be split into Tangential component and the radial component.
Tangential force on the crank shaft = 19.49 KN
Radial force on the crank shaft = 20.90 KN
Reactions at bearings (1 & 2) due to tangential force is given by,
Ht1 = Ht2 = 9.745 KN (Since b1=b2=b/2)
Similarly, Reactions at bearings (1 & 2) due to tangential force is given by,
Hr1 = Hr2 = 10.45 KN (Since b1=b2=b/2)
2.8 Design of Crank Pin

Let dc = Diameter of crankpin in mm.
We know that the bending moment at the centre of the crankpin,
MC = HR1 × b2 = 10.45 × 73 = 762.85 KN-mm
Twisting moment on the crankpin,
TC = Ht1 × r = 9.745 × 75 = 730.87 KN-mm
From this we have the equivalent twisting moment = 1056.37 KN-mm
Shear stress value is limited to 35 N/mm2
dc = 49 mm
Since this value of crankpin diameter (i.e. dc = 49 mm) is less than the already calculated value
of dc = 52 mm, therefore, we shall take dc = 52 mm.
RESULT:
Diameter of the crank pin = 52 mm
2.9 Design of shaft under the flywheel

Let ds = Diameter of the shaft in mm.
The resulting bending moment on the shaft will be same as calculated earlier, i.e.
MS = 172650 N-mm
Twisting moment on the shaft, TS = FT × r = 146175 N-mm
∴ Equivalent twisting moment on shaft, Te = 226219 N-mm
We know that equivalent twisting moment (Te),

226219 = π x ds3 x τ /16
Limiting the value of shear stress to 35 N/mm2
We have ds = 33 mm
Since this value of Shaft diameter (i.e. ds = 38 mm – calculated on basis of Max. bending
moment) is greater than the calculated value of ds = 33 mm (Through maximum twisting
moment), therefore, we shall take ds = 38 mm.
RESULT:
Diameter of the Shaft = 38 mm

Fig.2 Crank Shaft at maximum twisting moment
2.10 Design of Right Hand Crank Web

Let Sbr = Bending stress in the radial direction.
Sbt = Bending stress in the tangential direction.
We also know that bending moment due to the radial component of FQ,
Max. Bending moment, Mr = Hr1x (b2 – lc/2 –t/2)
We have, Mr = 271700 N-mm
We also know that, Mr = Sbr x Z
We have Section modulus, Z = t x w2/6
From this we have, Sbr = 7.07 N/mm2
Now bending moment due to the Tangential component of FT,
Max. Bending moment, Mt = Ft x (r – ds/2)
We have, Mt = 1091440 N-mm

We also know that, Mt = St x Z
We have Section modulus, Z = t x w2/6
From this we have, St = 15.52 N/mm2
Total bending stress = Sbr + St = 22.59 N/mm2
Max. Twisting moment, T = Ht x (b1 – lc/2) = 448270 N-mm
Shear stress = T/Zp (where Zp is the polar moment of Inertia given by wx t2 /4.5)
From this we get Shear stress = 10.04 N/mm2
We know that total or maximum combined stress,
(Sb) max = Sb / 2 +1/2 (Sb2 + 4 τ2) ^1/2
On simplification we get (Sb) max =22.74 N/mm2
Since the maximum combined stress is within the safe limits, therefore, the dimension
w = 71 mm is accepted.
RESULT:
Width of the Right hand web = 71 mm
2.11 Design of Left Hand Crank Web

The dimensions for the left hand crank web may be made same as for right hand crank web.
RESULTS
DIAMETER OF THE CRANK PIN = 52 mm
LENGTH OF THE CRANK PIN = 55 mm
DIAMETER OF THE SHAFT = 38 mm
WEB THICKNESS (BOTH LEFT AND RIGHT HAND) = 40 mm
WEB WIDTH (BOTH LEFT AND RIGHT HAND) = 71 mm

3. Manufacturing Procedure
3.1 Material Selection
Crank shafts uses Medium carbon steel along with some alloying elements. Medium-carbon
steel alloys are composed of predominantly the element iron, and contain a small percentage of
carbon (0.25% to 0.45), along with combinations of several alloying elements, the mix of which
has been carefully designed in order to produce specific qualities in the target alloy, including
hardenability, surface and core hardness, ultimate tensile strength, yield strength, endurance limit
(fatigue strength), ductility, impact resistance and corrosion resistance. The alloying elements
typically used in these carbon steels are manganese, chromium, molybdenum, nickel, silicon,
cobalt and vanadium. Each of those elements adds specific properties in a given material. The
carbon content is the main determinant of the ultimate strength and hardness to which such an
alloy can be heat treated.
Operation 1: Forging of crank shaft
Crankshafts are formed by the Hot Forging process, in which a billet of suitable size is heated
to the appropriate forging temperature, typically in the range of 1050 - 1250°C, and then
successively pounded or pressed into the desired shape by squeezing the billet between pairs of
dies (Closed die forging) under very high pressure. These die sets have the concave negative
form of the desired external shape. Complex shapes and / or extreme deformations often require
more than one set of dies to accomplish the shaping.
After Forging, the flash formed is removed by Gas cutting.
Machine specifications:
Type : Frame type
Mould : Tested and made out of mild steel plates
Capacity: 500 tonnes
Type of press : Up stroke
Closing time: 0.5 minutes

Space required : 4 feet X 7 feet
Click here to see the machine details
Process parameters :
Speed of stroke: 15 sec per stroke
Proposal by IE Team:
1. Initially a machine with a stroke speed of 30 sec per stroke was chosen with a tonnage of 200
tonnes. Since we are going for mass production IE team proposed a change in the machine tonnage of
500 tonnes and a stroke speed of 15 sec per stroke
Operation 2: Centering and Facing
After this the raw material is held in the chuck and facing is done on one
side. It involves moving the cutting tool at right angles to the axis of rotation of the
rotating work piece. This can be performed by the operation of the cross-slide (Radial
feed) as distinct from the longitudinal feed (turning).An allowance of about 5 mm is
given for facing on one side. After this the other side is also faced for about 5 mm along
the length. For both the processes, Lathe is used with the specification of distance
between centers more than 1000 mm.
After Facing, the centre drill is used and centering is done on both sides which will
enable to hold the work piece between centers
Machine used : CNC Lathe ECONO CNC 26.
Maker : HMT
Height of centres : 260 mm
Swing over bed : 575 mm
Swing over cross slide : 340 mm
Distance between centres : 1000 mm
Speed range : 40-2040 rpm

Process parameters:
Centering:
Drill speed : 400 rpm
Feed : 0.2 mm per rev
Facing:
Speed : 25 m/s
Depth of cut : 0.2 mm
1. IE team is satisfied with the machine to be used since we are using same machine for Rough
turning, finish turning and facing operations.
2. For Facing process IE team suggested a cutting speed of 25 m/s instead of 20m/s and the
cutting tool of High Speed Steel has the ability to perform machining at those speeds
Operation 3: Rough turning
After facing, the work piece is held between centers and turning is done. That is,
the part is rotated while a single point cutting tool is moved parallel to the axis of
rotation. Turning is done on all diameters. Turning allowance of 4 mm is provided on all
the diameters..
Maker : HMT

Process parameters:
Rough turning:
Speed : 25 m/s
Satisfied with the parameters as proposed by Design team
Operation 4: Finish turning (CAM turning)
After rough turning, Finish turning is done on a CNC lathe. Here the job is initially

held between centers. The CNC turning is similar to normal turning except that the
operations to be performed are already pre-programmed and the numerical controller
actuates and controls the process. Allowance of 1 mm is provided for this process
Maker : HMT
Process parameters:
Finish turning:
Speed : 40 m/s
Operation 5: Oil Hole drilling
Oil holes deliver vital lubrication to contact points between piston connecting rods
and crankshafts in truck and car engines. For this, crankshaft in a horizontal position
and is mounted on a radial drilling machine since oil holes have to be drilled
perpendicular and at angles to the horizontal axis. Total of 8 oil holes (2 per Journal) of
diameter 4 mm are to be drilled at angles of 45 and 135 degrees. To drill the holes at
the angles (with respect to axis), the radial arm which can be swiveled about the vertical
axis is used.
Oil Hole in a crank shaft
Machine used : Radial drilling machine - KML -40A
Maker : KML
Drill capacity (in steel) : 40 mm
Drill depth : 180 mm
Taper spindle nose socket :MT-4
No. of speeds and range : 6 (45-660 rpm)
Drill power : 10 KW
Process parameters:
Drilling:
Speed : 20 m/s
1. Since the shape of the crank shaft is complex and the oil holes have to be drilled at an angle a
special jig has to be designed for the drilling process
Operation 6: Heat Treatment
Regarding the steel alloys typically used in high-grade crankshafts, the desired
ultimate (and hence yield and fatigue) strength of the material is produced by a ‘heat
treatment’.
The typical heat-treating process for carbon-steel alloys is first to transform the
structure of the rough-machined part into austenite crystalline structure by heating the
part in an oven until the temperature throughout the part stabilizes in the neighborhood
of 1550°F to 1650°F) in an Induction furnace for about 2 hrs (Hardening). Next, the part
is removed from the heating oven and rapidly cooled in a medium of oil (Quenching) to
extract heat from the part at a rate sufficient to transform a large percentage of the
austenitic structure into fine-grained martensite. The desired martensitic post-quench
crystalline structure of the steel is the high-strength, high-hardness, form of the iron-
carbon solution. The rate of cooling required to achieve maximum transformation varies
with the harden-ability of the material, determined by the combination of alloying
elements.
After quenching the alloy steel material has reached a very high strength and
hardness, but, it lacks sufficient ductility and impact resistance. In order to produce the
combination of material properties deemed suitable for a given application, the part is
placed in a ‘Tempering’ oven and soaked for a specific amount of time at temperature
of 800 to 900 degree Celsius in order to reduce the hardness to the desired level, hence
producing the desired strength, ductility, impact resistance and other desired
mechanical properties.
Machine used : Induction furnace
No. of heating coils : 4
Current : 40 A
Voltage : 440 V
Temperature control : +/- 5 degree celcius
Rate of heating : 100 degree celcius per min.
Process parameters:
Heat Treatment:
Temperature : 1050 to 1150 degree celcius
Time : 2 hours
Operation 7: Shot Blasting
Black oxide layer formed during heat treatment process is removed by Shot blasting.
Shot blasting is a process that is often used to clean the surface of a material. The
process usually involves a gun that is used to shoot various types of media, or shot, at
the object being blasted. This is a particularly effective method for removing scale, rust,
paint, and minor surface flaws from metal objects. Also it helps to reduce the residual
stresses developed during the Heat treatment process.
Machine used :Shot blasting machine
Type : Rotary barrel type

Table : Swing table type
Process parameters:
Speed of balls: 5 m/s
Flow rate : 1135 Kg per hour
Operation 8: Straightening
For straightening of Crank shafts at the seat of distortion / bent due to mechanical
and thermal stresses, Hydraulic press (of 2 Tonne capacity) is used. Crank shaft is
mounted on a V- Block and the dial indicator is moved along the length to check for any
bents. From the dial indicator reading it can be identified whether the crank shaft is bent
or not.
Type : Frame type
Mould : Tested and made out of mild steel plates
Capacity: 5 tonnes
Type of press : Up stroke
Closing time: 0.5 minutes
Space required : 3 feet X 5 feet
Process parameters :
Speed of stroke: 15 sec per stroke

Operation 9: Rough Grinding and CAM Grinding
The crankshaft nose is placed into the head stock chuck and the crankshaft end
where the flywheel is to be mounted is held in the tail stock chuck. At this point the main
journals can be ground. The rod journals are ground after the grinding of the rod
journals. Grinding allowance of 50 microns is provided for the rough grinding process.
After this process the crank shaft is taken to CNC grinding machine. Process
and holding the Job is similar to the rough grinding except that process is more of a
finishing process rather the material removal process. Grinding allowance of 10 microns
is provided for finish grinding
Machine used : CNC Grinding machine - PMT-AWH-100
Maker : PMT
Grinding length (max) : 1000 mm
Grinding diameter (max) : 450 mm
Grinding wheel diameter : 350 mm
Process parameters:
Rough Grinding:
Speed of wheel : 20 m/s
Feed of workpiece : 1 mm per min
Finish grinding:
Feed of workpiece : 0.5 mm per min
1. Depth of cut of .03 mm was proposed was proposed by the design team . IE team suggested a
Depth of cut of .05 mm since this is a rough grinding process and importance need not be given on
surface finish
Operation 10: Face Grinding

After grinding the rod journal and main journal portions of the crank shaft, Face grinding has to be
done. Face grinding has to be done on the end faces of crank shaft. Grinding allowance of 25 microns is
provided on each face.
Machine used : Surface Grinding machine - LOESER - MODEL FS-384
Maker : LOESER
Grinding length (max) : 3000 mm
Belt drive, Motor power : 10 HP
Process parameters:
Feed of wheel : 2 mm per sec
Operation 11: Greasing

Grease or Lubricating oil is applied on all the areas of the crank shaft which helps to prevent the
corrosion on the faces.
Operation: Inspection
Detailed and proper documentation of all inspection results are maintained at various quality
assurance stages. The required results of the inspection are also being communicated to the production
and other departments for further follow-up
Laboratory:
 Record for Raw Material Analysis.
 Record of Chemical Analysis of each lot.
 Record of forging hardness.
Inspection:
 Record of Forging Dimensional check up.

 Record of dimensional check at different stages of machining and grinding.
 Measurement of surface roughness using surface roughness meter.
 Using Dial Indicators for the measurement of run out.
 Using Vernier calipers for dimensional checks.
Others
 Record of dimension of Jigs, Fixtures, Gauges and Fixtures.

 Record of calibration of Tools and Gauges.
Operation: Packing and Dispatch
 The Products are packed in wooden crates, corrugated box, cargo rated boxes, keeping in view
of the need and advice of the customers.
 Rust preventive material like oil coating is given to the machined surface of the product just prior
to the packing wherever necessary.
 Tag identification is being done as per the customer’s requirement.
Outline process chart

Manufacturing drawing of Crank Shaft
Layout and Material movement diagram
References:
1. "Design of Machine Elements", R.S.Khurmi.

2. "Production Technology", O.P.Khanna
3, "Internal Combustion Engine concepts", V.Ganesan.
4. Machine specifications:
http://www.loeser.de/index.php?id=127&L=1
http://pmtmachines.com/cnc_cylindrical_grinding.हतं
http://www.bajajmachinetools.com/power-press-machines.html
http://www.surfaceint.com/rotarybarrel.htm

Maruti Swift Engine Design

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Table of Contents

1.1 Specifications of Maruti Swift Engine

1.2 Engine Parameters

1.2.1 Calculation of Brake Mean Effective Pressure

1.2.2 Calculation of reactive forces on bearings

1.2.3 Design of Crank Pin

1.2.4 Design of Left hand Crank Web

1.2.5 Design of Right Hand Crank Web

1.2.6 Design of Shaft under flywheel

2. Manufacturing Processes and machines used

3. Outline Process Chart

4. Layout of the operations

Click here to see the Old ( Before incorporating changes) Knol

1.1 Specifications of Maruti Swift Engine

2.1 Calculation of Brake Mean Effective Pressure

Since the no. of cylinders = 4

Torque to be developed by single cylinder = Total torque/No. of cylinders

= 113/4 = 28.5 Nm

From the specifications given,

Torque and RPM are also given in the specifications.

BMEP = 1.35 KN/mm2

Maximum combustion pressure = 5 x BMEP (approx.)

Maximum combustion pressure = 6.75 KN/mm2

2.2 Calculation of Reactive Forces on Bearings

Distance between bearings, b = 2 x D = 146 mm

b1 = b2 = 73 mm.

Where,

b1 = distance from the bearing 1 to the piston axis in mm

b2 = distance from the bearing 2 to the piston axis in mm

Horizontal reaction at bearing 2, H2 = Fp x b2 / b = 14.125 KN

2.3 Design of Crank Pin

lc –Length of the crank pin

Mb- Allowable bending stress (Assumed to be 75 N/mm2)

Bending moment at the centre of crank pin, Mc = H1 x b2 = 1031.125 N-mm

We know that, Mc = π x dc3 x Mb /2

From this we have the diameter of the crank pin, dc = 52 mm

Length of the crank pin, lc = Fp / dc x pb

Taking bearing pressure =10 N/mm2

We have the length of the crank pin, lc = 55 mm

Diameter of the crank pin = 52 mm

Length of the crank pin = 55 mm

2.4 Design Left Hand Crank Web

Width of the crank web, w = 1.125dc + 12.7 mm

Crank web is subjected to bending and direct compressive stresses

Max. Bending moment, M = H1x (b2 – lc/2 –t/2)

From this we have M = 24792.2 KN-mm

Where Z is the section modulus which is given by Z = w x t2 / 6

Bending stress is coming to 18.933 N/mm2

Direct compressive stress = H1 / w x t =4.97 N/mm2

Thickness of the Left hand crank web = 40 mm

Width of the Left hand crank web = 71 mm

Fig.1 Crank Shaft at dead centre

2.5 Design of Right Hand Crank Web

Thickness of the Right hand crank web = 40 mm

Width of the Right hand crank web = 71 mm

Let ds = Diameter of the shaft in mm.

Since the lengths of the main bearings are equal, therefore

Assuming width of the flywheel as 30 mm, we have

Bending moment due to the weight of the flywheel

Mw = Vertical reaction x distance = 3453 × 50 = 172650 N-mm

From this we have the diameter of the shaft,

Considering the maximum permissible bending moment to be 40 N/mm2