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 CHAPTER 3

PERFORMANCE PARAMETERS

TABLE: 3.1

COMPRESSION RATIO(R)

S.No. Petrol Engine Diesel Engine

ON R Type of Engine R
1 66-72 5.5-7.0 Diesel Engine with open chamber 14-17
2 73-76 7.1-7.7 Swirl chamber diesel engine 16-20
3 77-85 7.6-8.5 Pre-combustion chamber diesel engine 16.5-21
4 86-100 8.6-10.5 Super charged diesel engine 11-17

Where
R = Compression ratio
ON = Octane number of petrol fuel

TABLE : 3.2

INDICATED MEAN EFFECTIVE PRESSURE (Pim)

S. Type Pressure , MPa

No
1 Four stroke petrol engine 0.6 to 1.4
2 Four stroke diesel engine 0.7 to 1.1
3 Four stroke supercharged engine Upto 2.2

TABLE : 3.3

INDICATED THERMAL EFFICIENCY (thi)

S. No Type of engine Thermal Efficiency (%)

1 Petrol engine 26 to 35
2 Diesel engine 38 to 50

TABLE : 3.4

INDICATED SPECIFIC FUEL CONSUMPTION (ISFC)

S. No Type of engine ISFC, Kg/hr-KW

1 Petrol engine 0.24 to 0.32
2 Diesel engine 0.17 to 0.23

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 TABLE : 3.5

MECHANICAL EFFICIENCY (m)

S. No Type of engine Mechanical Efficiency (%)

1 Two/Four stroke Petrol engine 70 - 90
2 Four stroke Diesel engine 70 - 82
3 Two stroke diesel engine 70 - 85

TABLE: 3.6

BORE DIAMETER

S. No Type of engine Bore diameter Standard cylinder bore,

in mm D , in mm
1 Petrol engine for car 60 – 100 30, 32,36,38,40,42,45,48,50,52
2 Petrol engine for truck 70 - 110 56,58,60,63,68,70,75,80,8590,95,
3 Tractor diesel engine 70 - 150 100,105,110,115,120,125,130,
4 Automotive diesel engine 80 - 130 140,145,150,160,170,180,190,200,210

TABLE: 3.7

STROKE TO BORE RATIO(S/D)

S. No Type of engine S/D

1 Petrol engine 0.7 – 1.0
2 Diesel engine 0.9 – 1.2
3 Tractor diesel engine 1.1-1.3

TABLE : 3.8

MEAN PISTON SPEED (Vpm)

S. No Type of engine Mean piston speed

m/sec
1 Petrol engine for Cars 12 - 15
2 Petrol engine for truck 9 – 12
3 Automotive diesel engine 6.5 - 12
4 Tractor diesel engine 5.5 - 10.5

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 CHAPTER: 4

DESIGN OF ENGINE PARTS

TABLE 4.1

PISTON DESIGN

S. Description Details/Relation
No
1 Piston material Type Allowable stress ,Sd , MPa
Cast Iron 35-40
Alloy Steel 100-160
Aluminium Alloy 50-90

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 TABLE : 4.3

ALLOWABLE BEARING PRESSURE IN PISTON PIN MATERIAL

S. Bearing material Bearing Pressure ,

No MPa
1 Babbitt lined shell 120 – 200
2 Bronze shell 200 – 250
3 Needle Roller bearing 300 - 600

TABLE : 4.4A

STRESSES IN PISTON PIN MATERIAL

S. No Material Ultimate stress , Design Stress,

Sut , MPa Sd , MPa
1 Carbon steel (SAE1020) 435 110
2 Alloy steel (SAE3115) 500 – 600 125 – 150
3 Alloy steel (SAE3120) 550 140

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 TABLE : 4.4B

PROPORTIONATE DIMENSIONS OF PISTON

S. No. Description Petrol Engine Diesel Engine

1 Length of Piston (0.8 to 1.3)D (1.0 to 1.7)D
2 Height of piston top part (0.45 to 0.75)D (0.6 to 1.0)D
3 Skirt length (0.6 to 0.8)D (0.6 to 1.1)D
4 Thickness of skirt wall in mm 1.5 – 4.5 2.0 – 2.5
5 Thickness of piston crown wall tc tc
6 Distance of first piston ring groove (0.06 to 0.12)D (0.11 to 0.2)D
7 Thickness of first piston ring groove (0.03 to 0.05)D (0.04 to 0.07)D
8 Difference between free gap and compressed 2.5 to 4 tr
gap of piston ring
9 Radial clearance of ring in piston groove (t)
in mm
For compression ring 0.7 to 0.95
For oil control ring 0.9 to 1.1
10 Inner diameter of Piston D – 2(tc +tr+t)

11 Number of oil holes in piston 6 -12

12 Oil passage diameter (0.3 to 0.5) ta
13 Centre of piston pin (0.02 to 0.04) D
Above centre of skirt
14 Length of pin
Retained pin (0.88 to 0.93)D
Floating pin (0.78 to 0.88)D
15 Length of pin in connecting rod (Lp)
Retained pin (0.28 to 0.32)D
Floating pin (0.33 to 0.45)D
16 Outer diameter of pin (dp) (0.22 to 0.28)D (0.3 to 0.38)D
17 Inner diameter of pin (0.65 to 0.75) dp (0.5 to 0.7) dp
18 Inner diameter of Boss dp
19 Outer diameter of Boss (0.3 to 0.5)D
20 Distance between faces of boss in mm Lp + (3 to 4)
21 Reduction in diameter of piston crown and Part Reduction in diameter
skirt from cylinder Materials
Cast Iron Aluminium
Crown (0.005 to 0.01 D
0.007) D
Skirt (0.001 to (0.0018 to
0.003)D 0.0025) D
22 Side clearance of piston ring, mm Upper 0.15 – 0.2
grooves
Lower 0.08 – 0.12
groove

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5. Maximum Pressure Pmax = 9-10 times Pim
Where
Pim = indicated mean effective pressure

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6 Number of bolts, nb nb = 0.01 D + 4

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 Table 4.8 A

Properties of materials for Bolts, studs and nuts

S.No. Material Ultimate tensile Design stress

strength, MPa, Sut Sd , MPa
1 SAE1120 440 110
2 SAE 2330 580 145
3 SAE 3140 700 175
4 Gun metal 290 72.5
5 Phospher bronze 460 115
6 Monel Metal 600 150

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 Table 4.8 B

Length of Adjacent cylinders for Multi-cylinder Engine

S.No. Engine Type Lo/D

Petrol engine Diesel engine
1 In line engine with dry liners and 1.2-1.24 ----
two span crank shaft
2 In line engine with dry liners and 1.2-1.28 1.25-1.3
one span crank shaft
3 Vee Engine 1.33 1.47-1.55
4 Engine with roller bearings used as 1.3 1.3
the main bearings
5 Air cooled engines 1.15-1.36 ----
Where
Lo = Distance between the centre axis of two adjacent cylinders

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