Department of Mechanical Engineering

B.E. Mechanical, SEM II [2021-22]

Assignment 3 (Unit 5 and 6)
SUBJECT: Mechanical System Design [Sub. Code: 402048]

Last Date: 05/05/2022

CO 5 (402048.5) : The students will be able to understand and analyze the design of I.C. Engine
Components.

Unit 5
Q1 Design a cylinder, cylinder head and cylinder head studs for a Four-stroke C.I. Engine
with the following data and select the safe dimensions:

 Brake power : (5+Your MSD Sr. No) KW

 Engine speed: 1200 r.p.m.
 Indicated mean effective pressure : 0.35 N/mm2
 Maximum gas pressure : 3.5 N/mm2
 Mechanical efficiency : 75%
 Compression ratio : 12
 Reboring factor (C1) = 4.0 mm
 Cylinder head thickness constant (k1) = 0.35

Allowable tensile stress:

Name of the Part Cylinder Liner Cylinder head Studs

Material Alloy Cast iron Alloy cast iron Alloy steel 40Ni3
Allowable tensile 40 40 70
stress (N/mm2)

Q2. Following data refers to single cylinder four-stroke diesel engine:

 Cylinder bore : (100 +Your’s MSD Sr.No)mm

 Piston stroke : 120mm
  Engine speed: 2200 r.p.m.
 Brake mean effective pressure : 0.75 N/mm2
 Maximum gas pressure : 5.5 N/mm2
 Brake specific fuel consumption : 0.227 kg/kw-hr
 Higher calorific value of fuel : 42000 kJ/kg
 Thermal conductivity of cast iron piston : 46.5 W/m0C
 Allowable temperature difference for piston : 2200C
 Heat conduction through piston crown: 5% of heat generated during combustion.
 Radial pressure between piston ring and cylinder wall : 0.04 N/mm2
 Permissible bearing pressure between piston skirt and cylinder wall : 0.4 N/mm2
 Permissible bearing pressure between alloy steel piston and bronze bush in
connecting rod : 25 N/mm2
 Allowable tensile stress for C.I. : 37.5 N/mm2
 Allowable bearing stress for alloy C.I. piston rings : 100 N/mm2
 Allowable shear stress for alloy steel piston pin : 80 N/mm2
 Allowable bending stress for alloy steel piston pin : 160 N/mm2

Design the following components and select the safe dimensions:

1. Piston head
2. Piston barrel
3. Piston rings
4. Piston skirt
5. Reinforcing ribs
6. Piston pin

Q3. Design a connecting rod, made of alloy steel 40 Ni3 for four-stroke petrol engine with
the following data and select the safe dimensions:

 Piston diameter : (100 +Your’s MSD Sr.No) mm

 Piston stroke : 150 mm
 Length of connecting rod, center to center : 320mm
 Weight of reciprocating parts : 18.2 N
 Speed : 1500 r.p.m. with possible overspeed of 2500 r.p.m.
 Compression ratio: 4:1
 Maximum explosion pressure : 2.45 N/mm2
 Number of bolts used for big end = 2
 Material for bolts : 40 Ni3
 Yield strength of alloy steel 40Ni3 : 600 N/mm2
 Factor of safety : 5
 Permissible bearing pressure between piston pin and small end connecting rod bearing
: 25 N/mm2
  Permissible bearing pressure between crank pin and big end connecting rod bearing :
10 N/mm2

Q4. Design a center crank type crank shaft for four stroke I.C. engine with the following
data and select the safe dimensions:

 Cylinder diameter : (120 +Your’s MSD Sr.No) mm

 Stroke : 180 mm
 Length of connecting rod : 360 mm
 Power: 10 KW @ 1000 r.p.m.
 Maximum explosion pressure : 2.2 N/mm2 at TDC
 Gas pressure at maximum torque position : 1.2 N/mm2 at (θ = 40 degree)
 Mass of reciprocating parts : 2 kg
 material used for crankshaft , crank web and crank pin = Plain carbon steel 45C8
 Yield strength for plain carbon steel 40C8 : 350 N/mm2
 Factor of safety : 5
 Density of connecting rod material : 7.2 kg per 1000 cm3
 Permissible bearing pressure for crank pin bearing : 10 N/mm2

CO 6 (402048.6) : The students will be able to understand and evaluate the optimum design
parameters.

Unit 6

Q1 A shaft is to be designed to transmit a torque of 1500 N-m. The required torsional

stiffness of the shaft is 100 M-m/degree, while the factor of safety based on yield strength in
shear is 3.0. Using the maximum shear stress theory , design the shaft with the objective of
minimizing the weight and Determine the optimum dimensions, out of the following
material.

Material Weight density (w) Tensile yield Modulus of

N/m3 strength (Syt) rigidity G N/mm2
N/mm2
Chromium Steel 77 x 103 420 84 x 103
Plain Carbon Steel 76.5 x 103 230 84 x 103
Titanium Ally 44 x 103 900 42 x 103
Magnesium alloy 17.5 x 103 225 15 x 103

Q2 A cantilever beam of the length 250 mm and a rectangular cross section is to function as a
spring subjected to varying load of (± 100 + 𝑌𝑜𝑢𝑟 𝑀𝑆𝐷 𝑆𝑟 𝑁𝑜 )𝑁. The width to depth ratio
of the beam is 5:1. If the factor required of safety is 1.5. Design the beam for optimum
material cost. Specify the material, cross section at dimensions and the cost for selected
design. Determine the optimum dimensions for the following candidate materials are
available

Material Weight density (w) Material cost per Endurance limit

N/m3 unit weight (c) (Se) N/mm2
Rs/N
M1 8450 100 17
M2 8020 100 37.5
M3 7830 60 32

Q3 A helical compression spring is to be exerting a specified maximum force ‘Fmax’ and is

to have a specified stiffness ‘K’. The factor of safety based on the yield strength in shear
‘Nr’. Design the spring and with the objective of minimizing the material cost. Neglect the
inactive coils. Justify that the design is optimum.