‘Design of reciprocating machine parts’

[Recap: Design <?> → Engineering Design <?> → Mech. Engg Design<?> → Machine/
Equipment1 Design2 <?>]

1. Assembly of sub-assemblies of sub-sub-assemblies of …. parts/devices/elements

2. The process may involve;
(a) Deciding qualitative & quantitative functional parameters and useful life.
(b) Synthesizing or selecting ‘shape’ (geometry) to achieve (a).
(c) Finding ‘size’ (space dimensions for functional output parameters and cross-
sectional dimensions to prevent against probable modes of failures* <?> by judging
and estimating causing factors, selecting Material of Construction (MoC), and Factor
of Safety (FoS)’.
(d) Communicating ‘design’ through drawing for manufacturing, assembling, testing,
using, maintaining.

Adoption of Slider-crank mechanism for reciprocating machines <?>

Reciprocating fluid machines like pumps, compressors, and Internal Combustion egnine are
adoption of slider-crank mechanism to convert reciprocating motion in to rotary or vice
versa. <How about other positive displacement pumps/compressor and hydraulic/pneumatic
cylinders?> In IC engines the slider & crank are transformed in to piston and crankshaft
respectively and connected by connecting rod (conrod) while ‘guides’ becomes cylinder. Their
shapes and sizes have been decided on the basis of several criteria (hinted earlier) requires
details explanation that are beyond the scope of this subject.

IC engine (basics: types, working, important parts/‘elements’…)

Capacity, Compression ratio, Bore/Stroke, Crank/Conrod length, Clearance volume, …. etc.

S R Patel, Mech Engg Dept, Faculty of Tech & Engg, MSU of Baroda
Piston(s)
It is the key component in reciprocating fluid machines. There are quite a number of
different designs of pistons are existing in the world of ICE today.

Development of basic ‘shape’ & ‘size’ of piston:

Diameter of this cylindrical slider/disc depends on volumetric capacity of single cylinder and
bore-stroke ratio <?> while ‘height’ includes added ‘features’ necessary to perform several
functions.

Functions required to be performed by ICE pistons are to; <?> Working of piston

• withstand and transfer major force of combustion pressure to connecting rod (through
piston pin) at high temperature.
• bear other/minor forces developed through cycle; viz. side thrusts, inertia forces…
• seal high pressure & temperature combustion gases.
• dissipate heat generated due to combustion & friction between moving surfaces to
maintain temperature of affected material within limit.
• ‘apply’ lubricating oil to rubbing surfaces and wipe/scrap back.
• accommodate ‘opened’ valve(s) near TDC (esp. in high-speed engines).
• provide ‘space for combustion’ (esp. in diesel engines).
• ‘adjust’ clearance volume/compression ratio.
• give ‘crosshead’ + ‘anti-rocking’ effect, crank rotation clearance, and reduce ‘wear
pressure’.
• maintain-acquire shape-size at working temperature… Etc.

Thus pistons are designed to perform above functions against possible failure modes to have
‘long & useful life’ with lower weight and cost…. Including design considerations like
manufacturing, assembly, repair etc. <How to achieve all?>

A near realistic yet simplified generic piston for SIE is depicted in following diagram. The
actual one may differ due to other criteria as explained in brief later.

S R Patel, Mech Engg Dept, Faculty of Tech & Engg, MSU of Baroda
 A
‘Generic’ piston for a 4S, SI Engine (Simplified) <for CI?, 2S?>
Further modfication in shape of piston(s) at;
• Crown/top; valve clash pockets (reliefs), clearance volume controlling features,
combustion space,…
• Barrel/skirt; recess to reduce weight reduction & crank clash, thermal expansion
compensating taper & ellipticity…<?>

Determining size of piston features for functioning with strength and/or rigidity:
For such complex shape, stress and deformation analysis would be extremely difficult using
simple equations. Numerical techniques like Finite Element Analysis have greatly helped these
days but the engineering done for the same in early days must be appreciated. <?>
Simplified analyses of stresses induced using strength equations may be made as follows just
to get ‘light flavour’ only;

i. Considering deck/top of the piston as a uniformly loaded

circular plate fiexd at edges would induce maximum stress
and deflection, could be used for finding piston thickness at
top; <which one is important? How to reduce?>
3 p  D2 0.011  p  D 4
 t max = MPa and y max = mm,
16 tT 2 E  tT 3
ii. Forces of combustion pressue and piston inertia are
transferred to bosses through the barrel and the webs.
These would induce tensile and compressive stresses

S R Patel, Mech Engg Dept, Faculty of Tech & Engg, MSU of Baroda
 cyclically respectively, ‘raised’ further due to ring grooves and oil holes, could be
considered for finding barrel thickness.. <?>
Annulus of piston barrel at oil ring groove = thickness - ring groove
+ ‘web’ connecting boss and crown under compression and tension;
<to be demonstrated>
iii. Boss with web would experience same forces said in ii. and its size
may be caclulated using shear and bending considerations. <?>
iv. Side thrust of the piston due to pressure force and conrod inertia
would cause deformation and crushing stress on the barrel with
sliding motion to cause and wear of the piston. These may be used
to set skirt thickness and height.
FST
Deformation <to be demonstrated> and crushing for wear  c =
D  hBeff

v. etc.

Thus, finding ‘size’ (dimensions) of ‘features’ of piston using strength or

stiffness-rigidity would be considerably complex and ‘standard formula’
are not readily available. Even the basis of their proportions with
respect to ‘the bore’ as given in ‘desi’ or ‘Russian’ books are not
explained or justified. However, the easiest ‘design
calculations’ can be made for piston pin.
Piston pin:
Connects piston bosses (the fork) to small end of
conrod (the eye) with a ‘head-less’, hollow<?>, and
floating (free to rotate) <?> pin under variable
loading. The strength consideration would be same
as the pin-jointed links under tension or
compression as described at MD-1.

S R Patel, Mech Engg Dept, Faculty of Tech & Engg, MSU of Baroda
 Dome piston Dish piston Flat piston with ‘pockets’
‘Real-world’ pistons (out of many designs)

MoC and Manufacturing process:

Desirable properties of piston material are; good strength and wear resistance at operating
temperature with lower density, …..easy to manufacture through Casting, Forging, and
Machining ….. Generally aluminium alloys and cast iron-steel are used. Some times
combination/‘locally’ different material may be used. <?>

Piston rings:

Two types of piston rings are employed. Functionally upper set (head side) seal high pressure
gases of combustion while lower ring (skirt side) maintains proper lubrication between
rubbing surfaces. Rings also improve heat transfer from piston to cylinder. Though looking
simplee detailed design of rings is avoided here due to limited literature available.

Piston ring sets

MoC and Manufacturing process(es):

Alloyed cast iron having good wear resistance at high temperature is employed..
Manufacturing <?>. Where as ‘elastomeric’ materials are used for rings of hydaulic and
pneumatic pumps/cylinders….<?>

S R Patel, Mech Engg Dept, Faculty of Tech & Engg, MSU of Baroda
A modern piston and associated terminology

S R Patel, Mech Engg Dept, Faculty of Tech & Engg, MSU of Baroda
 A ‘real’ CIE piston

‘Simplified’ CIE piston (relatively easy to draw)

(compare with SIE piston)

However, ‘well designed’ pistons may also see premature failure/damage. Why? How? When?

Review/Exam PoV questions:

• What decides shape & size of a piston? (diameter, ‘height’, etc.)

• Sketch a 4-s SIE piston with important features and explain basis/consideration.
• Sketch a 4-s CIE piston with important features and explain basis/consideration.
• Describe MoCs and possible manufacturing process of a piston
• Strength equations applicable to ‘piston design’.
• …

S R Patel, Mech Engg Dept, Faculty of Tech & Engg, MSU of Baroda