LESSON PLAN

Week: 06 Taught By: Engr. Kashif Usman

Subject: Problem in Internal Combustion Engine Class: 2nd Year

Mechanical Department Time: 70 minutes
Topic: Problems of Piston Pins
Objective(s): Students will be able to:
 Understand Expansion
 Understand Contraction
 Understand Floating and Knock
Skill focused on: Piston Pins
Resources:
White Board, Marker, PowerPoint Presentations
Methodology:

Importance and Problems Related To Piston Pin:

Piston pin, also called wrist pin allows the piston swing in the connection rod.
It is a thermal fit in piston bosses in the modem engines. Knocking of the pin is a problem due to
excessive clearance in the piston boss.
Piston pins in modern engines are normally held in the piston by one or two means: snap rings or
pressure fit, both are common.
Expansion and Contraction of Piston Pin:
In many modem engines the gudgeon pin or piston pin is made a thermal fit in the piston bosses.
Thus when the piston is heated to the temperature of boiling water, the holes in the bosses
expand sufficiently to enable the cold piston pin to be pushed readily to its working position.
The piston pin is usually made hollow to save weight and to give as much bearing surface as
possible. The material used is a high-grade carbon or low nickel content steel, casehardened and
ground to size.
Various methods have been used, in the past to secure the pin in piston bosses. Of these only
with split spring ring has survived.
The usual method employed in modern aluminum alloy piston is to make the pin a push fit in the
small end bearing and piston bosses. It is secured against end movement by means of spring clips
or with a special design of clip known as circlip this has lugs at its ends for facilitating its removal
with a pair of round-nosed pliers. The circlip springs into a groove turned in the piston boss.
In certain modem designs the piston pin is centrally clamped tightly in the small end of
connecting rod and allows to rock in the piston bosses.
When the piston is made of high strength aluminum alloy, the floating piston pin will operate
satisfactorily in this alloy without the necessity for bronze bushes.

Floating and Knocking of Piston Pin:

Depending upon the type and make of engine, the piston may either be free-floating pin will turn
in both rod and piston or press-fit (pin force’ fitted on rod but turn in piston).
Piston pin knock occurs when too much clearance exists between the piston pin and piston bore
or connecting rod bushing. Excessive clearance allows the pin to hammer against the rod or
piston as the piston changes direction the cylinder.
Piston pin knock will usually make a DOUBLE KNOCK (two rapid knocks and then a short pause). Ii
does NOT change much with engine load.

Problems of Piston Pin and Their Remedies:

Defects of piston pins (gudgeon pin) are wear or breakage. Theses give rise to small end knock, or
much more serious damage if the rod detaches itself.
Due to wear of the piston pin clearance occurs on both floating and pressed in pins.
In free floating, when the pin is worn, it should be replaced. If the pin bore in the piston measure
larger than specified replace the piston. The pin bore may also be reamed larger. Oversize piston
pins can than be used.
In case of pressed in pin service measure pin and pin bore wear compare to specify and replace or
repair parts as needed. Many shops send new pistons and pins to a machine shop for fitting
Activity– 1:Discussion on engine overheating by Group-1
Success Criteria:

C.W: Nil
H.W: Maintain Practical Notebook

HoD Sign: ______________ Date: __________________