Design of IC Engine

Stroke Type
Number of Cylinders
Brake/Engine Power (in kW)
RPM

Design of Bore (D) and Stroke (L)

Engine Type for (Pim) Table 3.2 Four Stroke Diesel Engine

(Pim): Range in (MPa)

Four Stroke Diesel Engine 0.70 - 1.1

S/D Ratio Table 3.7 Diesel Engine

L Ratio Range
Diesel Engine 0.9 - 1.2

Mechanical Efficiency Table 3.5 Four Stroke Diesel Engine

hmech( Engine Type): Efficiency Range

Four Stroke Diesel Engine 70 - 82

Pi : 15.7894736842105

Formula : Pi = Pim*L*A*N*nc

D (in mm) 126.654590224098

Standard Bore Table 3.6 130

Length of Cylinder 143

Sr.No Type

1 Four Stroke Petrol Engine

2 Four Stroke Diesel Engine
3 Four Stroke Super Charged Diesel Engine

Sr.No Type

1 Petrol Engine
2 Diesel Engine
3 Tractor Diesel Engine

4 stroke
600 net rpm
1200 rpm
10 net rps

Sr.No Type of Engine

1 Two/Four Stroke Petrol Engine

2 Four Stroke Diesel Engine
3 Two Stroke Diesel Engine

D 2031715.07227826

30
32
 36
38
40
42
45
50
52
56
58
60
63
68
70
75
80
85
90
95
100
105
110
115
120
125
130
140
145
120
160
170
180
190
200
210
e
4 Fill the Data
1 Select the Data
12 Formulated cell
1200 Final Answer

<-- Select from DropDown

P(avg) in Mpa
0.9

<-- Select from DropDown

Avg. Ratio
1.1

<-- Select from DropDown

Avg Efficiency (hmech)

76

<-- Select from DropDown

Pressure Range (Mpa) Avg. Pressure H1 H2 H3

0.60 - 1.40 1 1 2
0.70 - 1.1 0.9 2 2
upto 2.2 2.2 3

S/D Avg. S/D H1 H2 H3

0.7 - 1 0.85 1 2
0.9 - 1.2 1.1 2 2
1.1 - 1.3 1.2 3

Efficiency Range Avg. Efficiency H1 H2 H3

70- 90 80 1 2
70 - 82 76 2 2
70 - 85 77.5 3
 Design of Cylinder Liner Thicknesss
Material Selection Grey CI <-- Select from DropDown

Material Sd Sx E
Grey CI 55 45 100000

Compression Ratio
Select Engine Type DE with open chambers <-- Select from DropDown
Table 1.1

Type Engine Type R

Diesel Engine Open Chambers 15.5

Formula: Pmax = P2 = R*P1

P1 (Mpa) 0.101325
Pmax 4.701

=(𝑆𝑑+0.4∗𝑃𝑚𝑎𝑥)/
Formula: t1/min
(𝑆𝑑−1.3∗𝑃𝑚𝑎𝑥)

t1/min 5.11

Pressure Stress Criteria

Sx' 59.78

Design Fails because Sx'>Sx

t1' 6.790

Thermal Stress Criteria(St)

(𝐸∗𝑎 "* ΔT " )/(2(1−𝑢))

St =

St 90.88
Sx'' 45
S_tot 135.88

Design Fails because S_tot>ST

Final Thickness
115 =(𝑃𝑚𝑎𝑥 ∗𝐷)/(2∗𝑡1) + St
t1f (mm) 12.67
 Sr.No Material Sd

1 Grey CI 55
2 Steel 90

Type Type Engine Type

PE Octane No: 66-72 Petrol Engine Octanne no. 66-72
PE Octane No: 72-76 Petrol Engine Octanne no. 72-76
PE Octane No: 76-85 Petrol Engine Octanne no. 76-85
PE Octane No: 85-100 Petrol Engine Octanne no. 85-100
DE with open chambers Diesel Engine Open Chambers
DE of Swirl Chambers Diesel Engine Swirl Chambers
Pre-combustion chamber DE Diesel Engine Pre-combustion chambe
Supercharged DE Diesel Engine Supercharged

t1/min 56.8803599008703 Diameter

48.8888303221714
cknesss

a m ΔT ST
0.0000106 0.271 125 115
 Sx E a m ΔT ST H1 H2 H3

45 100000 0.0000106 0.271 125 115 1 1 1

100 204000 0.0000111 0.3 125 200 2

R H1 H2 H3
6.25 1 5
7.6 2
8 3
9.5 4
15.5 5 5
18 6
18.75 7
14 8

130 Design Fails because Sx'>Sx

Design is Safe

Design Fails because S_tot>ST

 Design of Cylinder Head Thicknesss
Material for Bolts, Stud and Nuts SAE 3140

Material Sut Ϭt
SAE 3140 700 175

No. of Bolts: 6

(𝑃𝑚𝑎𝑥∗3.14∗𝐷^2)/
Ϭt =
(𝑛𝑏∗𝐶𝑜𝑟𝑒𝐴𝑟𝑒𝑎)

Core Area (mm^2) 59.414

Select the standard Core Area Coarse -98.4 <--Select from DropDown

Core Area (mm^2) Designation Diameter (db)

98.4 M14.0 14

Dp 168.5

tc = K2 * Dp * (Pmax/Sd)^0.5

Considering Water Cooled Type

tc (mm) 26.60

Thickness of Water Pockets

tw 14.75
 Sr.No Material Sut

1 SAE 1120 440

2 SAE 2330 580
3 SAE 3140 700
4 Gun Metal 290
5 Phosphor Bronze 460
6 Monel Metal 600

Pmax 4.701
D 130
Sd 55

Type Core Area (mm^2) Designation

Coarse -0.42 0.42 M1.0
Coarse -0.68 0.68 M1.2
Coarse -0.91 0.91 M1.4
Coarse -1.17 1.17 M1.6
Coarse -1.93 1.93 M2.0
Coarse -4.75 4.75 M3.0
Coarse -8.25 8.25 M4.0
Coarse -13.4 13.4 M5.0
Coarse -16.55 16.55 M6.0
Coarse -24.55 24.55 M7.0
Coarse -30.6 30.6 M8.0
Coarse -41.2 41.2 M9.0
Coarse -48.92 48.92 M10.0
Coarse -71.5 71.5 M12.0
 Coarse -98.4 98.4 M14.0
Coarse -136.7 136.7 M16.0
Coarse -164.73 164.73 M18.0
Coarse -213.38 213.38 M20.0
Coarse -278.9 278.9 M22.0
Coarse -307.4 307.4 M24.0
Coarse -407.72 407.72 M27.0
Coarse -493.8 493.8 M30.0
Coarse -619 619 M33.0
Coarse -724.68 724.68 M36.0
Coarse -874.92 874.92 M39.0
Coarse -999.68 999.68 M42.0
Coarse -1174.9 1174.9 M45.0
Coarse -1318.2 1318.2 M48.0
Fine-0.41 0.41 M1.0
Fine-0.66 0.66 M1.2
Fine-0.98 0.98 M1.4
Fine-1.58 1.58 M1.6
Fine-2.13 2.13 M2.0
Fine-4.94 4.94 M3.0
Fine-8.53 8.53 M4.0
Fine-14.5 14.5 M5.0
Fine-19.2 19.2 M6.0
Fine-27.75 27.75 M7.0
Fine-34.14 34.14 M8.0
Fine-45.28 45.28 M9.0
Fine-57.99 57.99 M10.0
Fine-76.81 76.81 M12.0
Fine-111 111 M14.0
Fine-152 152 M16.0
Fine-188 188 M18.0
Fine-251 251 M20.0
Fine-311 311 M22.0
Fine-353 353 M24.0
Fine-459 459 M27.0
Fine-580 580 M30.0
Fine-716 716 M33.0
Fine-813 813 M36.0
Fine-950 950 M39.0
Fine-1121 1121 M42.0
Fine-1306 1306 M45.0
Fine-1505 1505 M48.0
icknesss
<-- Select from DropDown

<--Select from DropDown

 Sd H1 H2 H3 -140.619
Water Cooled 26.6013
110 1 3
145 2 a 1
175 3 3 b 260
72.5 4 c 2648.174
115 5
150 6

Diameter (db) H1 H2 H3
1 1 15
1.2 2
1.4 3
1.6 4
2 5
3 6
4 7
5 8
6 9
7 10
8 11
9 12
10 13
12 14
14 15 15
16 16
18 17
20 18
22 19
24 20
27 21
30 22
33 23
36 24
39 25
42 26
45 27
48 28
1 29
1.2 30
1.4 31
1.6 32
2 33
3 34
4 35
5 36
6 37
7 38
8 39
9 40
10 41
12 42
14 43
16 44
18 45
20 46
22 47
24 48
27 49
30 50
33 51
36 52
39 53
42 54
45 55
48 56
 Design of Piston

Crown Thickness

Select Material Aluminium

Material Allowable Stress Avg. Sd (Mpa)

Aluminium 50-90 70

Maximum Pressure Criteria

tc1 14.59

Thermal Stress Criteria

ISFC
Select Engine Type Diesel Engine <-- Select from DropDown

ISFC (kg/kW-hr) 0.2

BSFC (kg/kW-hr) 0.152

Cv 43000

q 44.33

tc

tc2(mm) 31.43

Empirical Criteria

tc3(mm) 5.66

From the above tc's Selecting the max tc

tc 31.433
 C1
delta T

220 0.56
220 0.56
75 1.986

t11 31.433
Design of Piston

<-- Select from DropDown

 Allowable
Sr. No Material Avg. Sd (Mpa) H1 H2
Stress

1 Cast Iron 35-40 37.5 1

2 Alloy Steel 100-160 130 2
3 Aluminium 50-90 70 3 3

D 130 Sr.No Type of Engine ISFC

Pmax 4.701
1 Petrol Engine 0.28
M.P tc 0.01259169576 2 Diesel Engine 0.2

D(cm) 13
Area 132.707
nc 1
Pb 12
K 0.075
nmech 76

C1 1.986
delta T 75

tc 3.14330206383
 H3

CV H1 H2 H3

47000 1 2
43000 2 2
 Design of Piston Rings

a. Radial Thickness of Piston Ring

1 By Bearing Pressure Criteria

tr 4.15

2 By Empirical Relationship

For Compression Ring

trc 5.525 ~ 5.5

For Oil Cooling Ring

tro 5.265 ~ 5.3

No. of piston Rings

n 5

Axial Thickness of Rings

tax 2.6

By Empirical Relationship

For Compression Ring

taxc 4.4

For Oil Cooling Ring

taxo 4.2
D 130
 Design of Piston Pin
Select Pin Material Alloy Steel SAE 3120 <-- Select from DropDown

Material Sut Sd
Alloy Steel SAE 3120 550 140

Bearing Stress Criteria

Fmax 62384.35
Sb (Mpa) 17.5
Ab 1.5*dp^2

dp 48.75

lp 73.125

Bending Stress Criteria

Z 11372.016

Bm_max 50.1432664756447

Design is Safe because Sbc<Sb

 Sr.No Material Sut Sd H1
1 Carbon Steel SAE 1020 435 110 1
2 Alloy Steel SAE 3115 500-600 137.5 2
3 Alloy Steel SAE 3120 550 140 3

D 130
Pmax 4.701

Design is Safe because Sbc<Sb

Design Failed because Sbc>Sb
H2 H3
3

3
 Additional Dimension
Select Type Diesel

Length/Height of Piston 175.5

Height of Piston Top Part 104

Skirt Length 110.5

Thickness og Skirt Wall 3.5

31.43
Thickness of Piston Crown Wall

Distance of First Piston Ring 20.15

Groove

Thickness of Piston Ring Land 7.15

 D 130

Sr.No Type Length Heigth Skirt length Thickness SThickness

1 Diesel 1.35 0.8 0.85 3.5 31.43

2 Petrol 1.05 0.6 0.7 3 31.43
Distance Thickness of PR

0.155 0.055
0.09 0.04