Department of

IC Engine Components Automobile

Engineering

Automobile
Component Design

Prof. Nikunj Mashru

1
 IC Engine:
✓ Combustion of the fuel takes place inside the
engine cylinder.

• Classification based on fuel:

Introduction ✓Petrol Engine (SI)
- Spark ignition engine
✓Diesel Engine (CI)
- Compression ignition engine
IC Engine
2
 • Classification based on strokes:
Two Stroke Engine Four Stroke Engine
 It requires two strokes of  It requires four strokes
the piston or one of the piston or two
revolution of crankshaft revolutions of
to complete one cycle. crankshaft to complete
Introduction  More fuel consumption one cycle.
& low efficiency.  Less fuel consumption &
 Light weight and higher efficiency.
compact construction.  More weight.
 Used in scooters, motor  Used in cars, buses,
cycles and three trucks and locomotives.
wheelers.

3
Main Parts 1. Cylinder and Cylinder liner
of the IC
Engine

2. Piston
4
 3. Connecting rod

Main Parts
of the IC
Engine

5
 4. Crankshaft 5. Valve gear mechanism

Main Parts
of the IC
Engine

6
 Function of cylinder:
✓ To retain working fluid
✓ To guide the piston.

Design of
• Cooling systems:
Cylinder ✓Air cooling
✓Water cooling
- Cylinder liner…

Cylinder Liner 7
 Types of cylinder liners:

Design of
Cylinder
1. Dry liner 2. Wet liner

8
 • Comparison of dry and wet liners:
Dry liners Wet liners
 It does not have direct  It has outer surface in
contact with cooling direct contact with
Design of water in jacket cooling water in jacket.
 Replacement of liner is
 Easy replacement of
Cylinder liners. difficult.
 No danger of jacket  Danger of jacket water
water leakage leakage
 Heat dissipation is not  Cooling is more effective
very effective. due to direct contact
 Cylinder blocks are  Cylinder blocks are easy
complicated. to manufacture.
9
 Desirable properties of material of
cylinder and cylinder liners:
✓It should be hard enough to resist wear.
✓Good surface finish to reduce friction.
Design of ✓Strong enough to withstand high gas
Cylinder pressure.
✓Strong enough to withstand thermal
stress.
✓ It should be corrosion resistant.

10
 Material of cylinder and liners:

✓Grey cast iron with homogeneous and

closed grain structure.
Design of
Cylinder
✓ For heavy duty cylinders, nickel cast iron
and nickel chromium cast iron.
✓Cast steel and Aluminium alloys are also
used for cylinders.
11
  Bore: inner diameter of cylinder(D).
✓Indicated power:
(pm ×A) 𝑙 n
IP = ,W
Design of ➢Where,
60

Cylinder ❖ pm = indicated mean effective pressure, N/mm2

-Bore (D) and ❖ l = length of stroke, m
πD2
Length (L) of ❖ A = cross sectional area of cylinder = , mm2
4
❖ D = diameter of cylinder or bore, mm
cylinder
❖ n = number of working stroke/min
❖ n = N (for two stroke engine)
❖ n = N/2 (for four stroke engine)
12
 ➢ l/D ratio is assumed from 1.25 to 2.
❖ If not specified, take 1.5
1.5 D
so, l = 1.5 D , mm = [ ], m
Design of 1000
➢ if IP is not given,
Cylinder IP =
BP

-Bore (D) and η

❖ BP = brake power at crankshaft, kW
Length (L) of ❖ η = Mechanical efficiency (take 80% if not given)
cylinder • Length of cylinder (L):
➢ L = 1.15 l
➢Clearance is taken as 15% of stroke length.
13
  Stresses in cylinder:
𝐵𝑜𝑟𝑒 (𝐷)
✓Thin cylinder: > 15
𝑊𝑎𝑙𝑙 𝑇ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 (𝑡)
✓Assumptions:
Design of ➢ stresses are uniformly distributed throughout the
thickness of wall
Cylinder ➢Magnitude of radial stress is very small so it is neglected.
-Thickness of
➢Apparent stress:
cylinder wall ❖ two principal stresses in
(t) engine cylinder:-
1) Longitudinal stress (σ𝑙 )
2) Circumferential stress (σ𝑐 )

14
 1) Longitudinal stress (σ𝑙 )
❖ Directed along length of cylinder.
Design of 𝑝𝑚𝑎𝑥 = maximum gas pressure inside the cylinder.
➢ Equilibrium of force-
Cylinder Bursting force = Resisting force
-Thickness πD2 π
𝑝𝑚𝑎𝑥 ( ) = σ𝑙 [ (D2o -D2 )]
4 4
of cylinder 𝒑𝒎𝒂𝒙 .𝑫𝟐
∴ 𝝈𝒍 = 𝟐 𝟐
wall (t) (𝑫𝒐 −𝑫 )

15
 2) Circumferential stress or hoop stress (σ𝑐 )
❖ Directed along tangent to the circumference of
Design of cylinder.

Cylinder Equilibrium of force-

Bursting force = Resisting force
-Thickness 𝑝𝑚𝑎𝑥 (l × D) = 2 × σc × l × t
of cylinder ∴ 𝝈𝐜 =
𝒑𝒎𝒂𝒙 . 𝐃
𝟐𝐭
wall (t)

16
  Thickness of cylinder wall (t):
𝑝𝑚𝑎𝑥 . D
✓Hoop stress: 𝜎c =
2t
Design of ✓t=
𝑝𝑚𝑎𝑥 . D
2𝜎c

Cylinder ➢ by adding Reboring allowance, C (in mm) ….

𝒑𝒎𝒂𝒙 . 𝑫
✓t= + C , mm
-Thickness 𝟐𝝈𝒄 𝒑𝒆𝒓,
where,
of cylinder 𝜎c = permissible hoop stress for cylinder material
wall (t) (N/mm2 )
𝑝𝑚𝑎𝑥 = maximum gas pressure inside the cylinder.
(N/mm2 )

17
 𝒑𝒎𝒂𝒙 . 𝑫
t = + C , mm
𝟐𝝈𝒄 𝒑𝒆𝒓.
❖ Guidelines from design data book:
Design of ➢ If 𝑝𝑚𝑎𝑥 not specified, take 𝑝𝑚𝑎𝑥 = 10 . 𝑝𝑖𝑚
Cylinder ➢ Hoop stress is allowable tensile stress,
S𝑢𝑡
𝜎c(𝑝𝑒𝑟.) = 𝜎t =
-Thickness FOS
➢ If Sut and FOS are not given, take 𝜎c(𝑝𝑒𝑟.) between
of cylinder 35 to 100 N/mm2
wall (t) ➢ Reboring allowance (mm) is taken from below table:
D 75 100 150 200 250 300 350 400 450 500
C 1.5 2.4 4.0 6.3 8.0 9.5 11 12.5 12.5 12.5
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  Stresses in cylinder:
Design of ➢Net stress:
Cylinder ❖ two principal stresses (𝜎c & 𝜎𝑙 ) are tensile in nature
and act at right angle to each other. So the net stress
-Thickness in these directions are reduced.
1) Net longitudinal stress (σ𝑙 )net = σ𝑙 - µσ𝑐
of cylinder 2) Net hoop stress (σc )net = σc - µσ𝑙
wall (t) where,
𝜎c = apparent hoop stress for cylinder material
𝜎𝑙 = apparent longitudinal stress for cylinder material
µ = Poisson’s ratio (0.25 for cast iron)
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 ❖ cylinder head or cover accommodates…
✓ Inlet and exhaust valves
✓Air and gas ports
✓Spark plug / Atomizer
Design of
Cylinder ❖ Actual cylinder head design is difficult.
❖ In preliminary stage of design, cylinder head is
-cylinder assumed as flat circular plate and its thickness is…
head (th) th = D
K . 𝑝𝑚𝑎𝑥
σc
Where, K = constant (K = 0.162)
σc = allowable circumferential stress, MPa
t h = thickness of cylinder head , mm
20
 K . 𝑝𝑚𝑎𝑥
❑ th = D
σc

Design of ❖ Guidelines….
Cylinder ✓ 𝜎c(𝑝𝑒𝑟.) = 𝜎t =
S𝑢𝑡
FOS
-cylinder ✓ If Sut and FOS are not given, take 𝜎c(𝑝𝑒𝑟.) between
head (th) 30 to 50 N/mm2

21
 ❖ studs are used to make assembly of cylinder,
cylinder head and gasket.
❖ They are subjected to tensile stress due to internal
Design of gas pressure acting on head.
❑ Three parameters…
Cylinder
1) Number of studs
-Studs for 2) Nominal diameter of studs
head 3) Pitch of studs.

22
 1) Number of studs (z) :
✓ minimum no. of studs = 0.01D + 4
✓ maximum no. of studs = 0.02D + 4
Design of 2) Nominal diameter of studs:
Cylinder ✓ core diameter (dc ) of studs is obtained by…
-Studs for max gas force on cover = resisting force by all studs
πD2 πd2c
head 𝑝𝑚𝑎𝑥 ( ) = z . ( ) . 𝜎t
4 4
Where,
𝜎t = allowable tensile stress
for stud material
23
 ❑ Guidelines…
S𝑦𝑡
✓ the studs are made of steel, 𝜎t =
FOS
✓ If Syt (yield strength) and FOS are not given,
Design of take 𝜎t between 35 to 70 N/mm2
Cylinder ✓nominal diameter (d) of studs is obtained by…
-Studs for d=
dc
0.8
head

24
 3) pitch of the studs:
✓ pitch circle diameter of the studs (Dp ) is obtained
by empirical relationship…
Design of Dp = D + 3d
πDp
Cylinder ✓ pitch of stud =
z
-Studs for ✓ In order to maintain leakproof joint, pitch of stud
should be between ..
head
minimum pitch = 19 d
maximum pitch = 28.5 d

25
 ❖Cylinder of four stroke diesel engine has following
specifications:
brake power = 3 kW, speed = 800 rpm, indicated mean
effective pressure = 0.3 MPa, mechanical efficiency =
80%. Determine bore and length of cylinder.
Design of ➢ Solution:
Cylinder ✓ B.P.= 3 kW, N = 800 rpm, η = 0.8, pm = 0.3 MPa. D & L = ?
-Problem 1  IP =
BP
η
=
3000
0.8
= 3750W  IP =
(pm ×A) 𝑙 n
60
,W
N 800 πD2
 n= = = 400 0.3×( )× 1.5D ×400
4
2 2 3750 =
𝑙 60×1000
 Assume, = 1.5 (mm) ∴ D = 116.75 mm
D
1.5D
∴𝑙= (in m) ∴ D ≈ 118 mm.
1000 26
 • Length of cylinder (L):

➢from previous step,  L = 1.15 l

D = 118 mm. ∴ L = 1.15 × 177
Design of ➢ length of stroke l = 1.5 D ∴ L = 203.55 ≈ 204 mm.
Cylinder (in mm)
∴ l = 1.5 × 118
-Problem 1 ∴ l = 177 mm

27
 ❖Cylinder of four stroke diesel engine has following
specifications:
bore= 150mm, max gas pressure pressure= 3 MPa,
allowable tensile stress= 50 MPa. Determine thickness of
cylinder wall. Calculate net and apparent stresses.
Design of ➢ Solution:
Cylinder ✓ D= 150 mm, σc per = 50 MPa, pmax = 3 MPa, t = ?
-Problem 2 D 75 100 150 200 250 300
t =
𝒑𝒎𝒂𝒙 . 𝑫
+C
C 1.5 2.4 4.0 6.3 8.0 9.5 𝟐𝝈𝒄 𝒑𝒆𝒓,
3×150
D 350 400 450 500 = +4
2×50
C 11 12.5 12.5 12.5 ∴ t = 8.5 ≈ 10 mm
• (from design data book) 28
 • Apparent stresses (𝜎c and 𝜎𝑙 ):

➢ 𝜎c =
𝑝𝑚𝑎𝑥 . D  Do = D + 2t
2t
3×150 = 150 + (2 × 10)
=
2×10 ∴ Do = 170 mm.
Design of ∴ 𝝈𝒄 = 22.5 MPa < 50 MPa 𝒑𝒎𝒂𝒙 .𝑫𝟐
➢ 𝝈𝒍 = 𝟐 𝟐
Cylinder (𝑫𝒐 −𝑫 )
𝟑× (𝟏𝟓𝟎)𝟐
-Problem 2 =
(𝟏𝟕𝟎𝟐−𝟏𝟓𝟎𝟐)
∴ 𝝈𝒍 = 10.55 MPa< 50 MPa
• Net stresses (𝜎c net and 𝜎𝑙 𝑛𝑒𝑡 ):
• (σc )net = σc - µσ𝑙 = 22.5 - 0.25(10.55) = 19.86 Mpa
From data book, µ = 0.25 • (σ𝑙 )net = σ𝑙 - µσ𝑐 = 10.55 - 0.25(22.5) = 4.93 Mpa 29
Design of cylinder - Problem 3
❖ The bore of cylinder of four stroke diesel engine is 120 mm. The max gas
pressure inside the cylinder is 4 Mpa. The cylinder head is made of cast iron
and allowable tensile stress is 40 N/mm2 . Determine thickness of head. The
studs, which are made of steel, have allowable stress as 50 N/mm2 .
Calculate: no. of studs, nominal dia. of studs and pitch of studs.
Design
➢ Solution:
of
 No. of studs:
Cylinder
Data given:  Take, K = 0.162
 zmin = 0.01D+4
- Problem
D = 120 mm,3  th = D
K . 𝑝𝑚𝑎𝑥
σc
= 0.01(120)+4 = 5.2
 𝜎𝑐 = 40 MPa ,  zmax = 0.02D+4
0.162 ×4
 𝜎t = 50 Mpa, =120
40 = 0.02(120)+4 = 6.4
• pmax = 4 MPa. ∴ t h = 15.27 ≈ 16 mm. ∴z=6
• t h = ?, z = ?, d = ?
30
Design of cylinder - Problem 3 (continue…)
❖ The bore of cylinder of four stroke diesel engine is 120 mm. The max gas
pressure inside the cylinder is 4 Mpa. The cylinder head is made of cast iron
and allowable tensile stress is 40 N/mm2 . Determine thickness of head. The
studs, which are made of steel, have allowable stress as 50 N/mm2 .
Calculate: no. of studs, nominal dia. of studs and pitch of studs.
Design
➢ Solution:
of
 Pitch of studs:
Cylinder
 Dia. of studs:
▪Dp = D + 3(d) = 120 + 3(18) = 174 mm
 Gas force on cover = resisting force
-Problem
πD 2
3
πd 2
 pitch of stud =
πDp
=
π (174)
= 91.106 mm
c
 𝑝𝑚𝑎𝑥 ( )=z.( ) . 𝜎t z 6
4 4
 (120)2 × 4 = 6 × d2𝑐 × (50)  Min pitch = 19 d = 19 18 = 80.61 mm
∴ 𝑑𝑐 = 13.85 mm.  Max pitch = 28.5 d = 28.5 18 = 120.91 mm
dc 13.85  80.61 < 91.106 < 120.91
• d= = = 17.32 ≈ 18 mm 31
0.8 0.8
 Function of Piston:
✓It transmits the force..
✓It compresses the gas..
✓It dissipates large
Design of amount of heat..
Piston ✓It takes the side thrust..
✓It seals the inside portion
of cylinder..

IC Engine
32
 Construction of Piston:
✓Piston head / Crown
✓Piston rings
✓Compression rings
Design of ✓Oil / scraper ring
Piston ✓Piston skirt
✓Piston pin

Piston
33
 Design requirements:
✓Sufficient strength..
✓Rigidity..
✓Heat dissipation capacity
Design of ✓Minimum weight
✓Sufficient bearing area
Piston ✓It should form an
efficient seal..
✓Noiseless operation
✓Provide support for pin..
Piston
34
 • Cast iron, cast steel, forged steel, Al alloys..

Cast iron piston Al Alloy piston

 High strength  Thermal conductivity is

Design of compared to Al alloy. three times that of cast
Piston (thin section possible) iron (less variation in
temp).
 More wear strength
-Materials compared to Al alloy  Density is about one
piston. third that of cast
 Need less clearance iron.(light in weight)
between cylinder wall
and piston rings.

35
 Two types of head:

Design of
Piston
-Head (tph ) ✓Two criteria:
1. Strength criteria
2. Heat dissipation / Thermal Criteria.

36
  Strength Criteria:
❖ Piston head is treated as flat circular plate of
uniform thickness fixed at outer edge and subjected
Design of to uniformly distributed gas pressure over entire
surface. According to Grashoff’s formula,
Piston t ph = D
3 𝑝𝑚𝑎𝑥

-Head 16 σ𝑏

Where, D = bore of cylinder, mm

(tph ) σb = allowable bending stress, MPa
t ph = thickness of piston head , mm
𝑝𝑚𝑎𝑥 = maximum gas pressure, MPa
37
 3 𝑝𝑚𝑎𝑥
❑ t ph = D
16 σ𝑏

Design of ❖ Guidelines from data book….

Piston ✓ 𝜎𝑏(𝑝𝑒𝑟.) = 𝜎t =
S𝑢𝑡

-Head FOS
✓ If Sut and FOS are not given, take 𝜎𝑏(𝑝𝑒𝑟.) from grey
(tph ) cast iron between 35 to 40 N/mm2 and for Al alloy,
between 50 to 90 N/mm2
✓ Max pressure may rise up to 8 MPa, average of this
is taken as 4 to 5 MPa.

38
 Thermal Criteria:
𝐇
𝐭 𝐩𝐡 = ×𝟏𝟎𝟑 mm
𝟏𝟐.𝟓𝟔 𝐊 (𝐓𝐜 − 𝐓𝐞)
Where..
Design of
✓t ph = thickness of piston head, mm
Piston ✓ H = Heat conducted through piston, W
-Head ✓ K = thermal conductivity of material, W/m/°̇C
(tph ) (grey cast iron: 46.6 W/m/°̇C, Al alloy: 175 W/m/°̇C)
✓ 𝐓𝐜 = Temp at center of piston head, °̇C
✓𝐓e = Temp at the edge of piston head, °̇C
(𝐓𝐜 − 𝐓𝐞 ) = 220 °̇C ( for Grey C.I.)
(𝐓𝐜 − 𝐓𝐞 ) = 75 °̇C ( for Al alloy ) 39
 𝐇
❑ 𝐭 𝐩𝐡 = ×𝟏𝟎𝟑 mm
𝟏𝟐.𝟓𝟔 𝐊 (𝐓𝐜 − 𝐓𝐞 )
✓H = (C × HCV × B.P × m) ×103 W
Where..
Design of ✓HCV = Higher calorific value, kJ/kg
Piston (Diesel: 44000 kJ/kg, Petrol: 47000 kJ/kg)
-Head ✓B.P.= brake power of engine per cylinder, kW
(tph ) ✓m = mass of fuel used per B.P. per second (kg/kW/s)
Avg. value of m for diesel engine: 0.24 to 0.3 (kg/kW/h)
0.24 to 0.3
∴m= (kg/kW/s)
60 ×60
C = ratio of heat absorbed to total heat = 5% or 0.05
40
  Provision of ribs:
✓It strengthen the piston head against gas pressure.
✓It distributes side thrust more uniformly and prevent
distortion.
Design of ✓Heat dissipation.
Piston ❖Guidelines from data book….
- Ribs and ✓ if t ph ≤ 6 mm, (NO ribs)
✓ if t ph > 6 mm, (Provide ribs)
cup ✓ Number of ribs = 4 to 6
✓ Thickness of ribs:
t R = (t ph /3) to (t ph /2)

Piston 41
 Provision of cup:
✓It provides additional space for combustion of fuel.
✓provision of cup depends on volume of combustion
Design of chamber and valve arrangements.
Piston ❖Guidelines from data book….
- Ribs and ✓ if (l/D) ≤ 1.5 mm, (Cup required))
✓ if(l/D) > 1.5 mm, (Not required)
cup ✓ Radius of cup = R
✓ R = 0.7 D

42
  Types of Rings:
✓Compression rings
✓Oil rings
Design of  Function of Rings:
Piston ✓To maintain seal between
cylinder wall and piston…
- Ring ✓It absorbs fluctuation in side
Section thrust
✓It dissipates heat..
✓Provide lubrication of liner Piston Rings
and to prevent leakage of oil
into combustion chamber. 43
  Materials:
✓Grey cast iron and alloy C.I.
✓In some case- chromium plated
Design of  Number of Rings:
Piston ✓Compression rings: 3 to 4 (Automobile)
- Ring ✓Compression rings: 5 to 7 (Stationary diesel
engine)
Guidelines
✓Oil rings: 1 to 3

44
  Dimensions of cross section:
3 𝑝𝑤
✓Radial width, b = D
σ𝑡

Design of Where, b = radial width of ring, mm

Piston pw = allowable radial pressure on cylinder wall, MPa
σt = allowable tensile stress, MPa
- Ring ❖Note:
Guidelines ✓pw taken from 0.025 to 0.042 MPa
✓ σt for C.I. rings: 85 to 110 MPa
✓Axial thickness, h = (0.7b) to b , mm
D
✓ hmin = (z = number of rings) 45
10 z
 • Gap between free ends (mm):
✓G = 3.5 b to 4 b
(before assembly)
Design of ✓G = 0.002 D to 0.004 D
Piston (after assembly)
- Ring • Width of top land(𝐡𝟏 ):
Guidelines ✓h1 = (t h ) to (1.2t h )
• Width of ring land(𝐡𝟐 ):
✓h2 = 0.75 h to h

46
 • Act as a bearing surface for side thrust:
✓Max side thrust occur during expansion stroke..
✓Side thrust = µ × force due to pressure
Design of πD2
= µ . 𝑝𝑚𝑎𝑥 ( )
Piston 4
✓Side thrust taken by skirt:
- Piston = bearing pr. × projected area
skirt (𝑙𝑠 ) = 𝑝𝑏 . D𝑙s
πD2
❖ µ . 𝑝𝑚𝑎𝑥 ( ) = 𝑝𝑏 . D𝑙s
4

47
 πD2
❖ µ . 𝑝𝑚𝑎𝑥 ( ) = 𝑝𝑏 . D𝑙s
4
Where,
Design of ✓ 𝑙s = length of skirt, mm
Piston ✓pb = allowable bearing
- Piston pressure, MPa
skirt (𝑙𝑠 ) ✓µ = 0.1
• Total length of piston:
L = top land + Ring section + 𝑙s Piston Length

48
 • Thickness of piston barrel:
✓At top end:
t 3 = (0.03D + b + 4.9)
Design of
Where,
Piston b = radial width of ring, mm
- Piston ✓At lower or open end:
Barrel t 4 = (0.25t 3 ) to (0.35t 3 )

Piston Barrel 49
  Gudgeon pin or wrist pin:
 Function of Pin:
✓To connect piston to rod.
 Materials for Pin:
Design of
✓Carbon steel or alloy
Piston steel
- Piston Pin ✓Hardened to reduce wear
while turning inside
phosphor bronze bush.

50
  Design criteria:
1) Bearing Consideration:
✓Assumed that..
Design of ✓ 𝑙1 = 0.45 D
Piston 𝑙1 = length of pin in bush
of small end of rod, mm
- Piston Pin
❖Outer dia. of pin(do ):
Force on piston = resisting bearing force
πD2
𝑝𝑚𝑎𝑥 ( ) = 𝑝𝑏1 × (do . 𝑙1 )
4
51
 πD2
❖ 𝑝𝑚𝑎𝑥 ( )
4
= 𝑝𝑏1 × (do . 𝑙1 )
Where,
✓pb1 = bearing pressure at bushing of small end of
rod, MPa
Design of ✓ do = outer dia. of pin, mm
Piston ❖Guidelines from data book….
- Piston Pin ✓ pb1 is taken as 25 MPa
✓Inner dia. of pin, di = 0.6do
✓ Mean dia. of piston boss:
= 1.4do (for C.I. piston)
= 1.5do (for Al alloy piston)
52
Design of Piston – Piston pin
D − 𝑙1
2) Bending Consideration:  𝑙2 = 𝑙1 +
2
πD2 D + 𝑙1
➢ P = 𝑝𝑚𝑎𝑥 ( ) ∴ 𝑙2 =
4 2

 Bending moment @ XX:

Design
✓Mb =
P
×
of
𝑙
-
P 𝑙
× 2
× 1 𝑙1
✓ I=
𝜋 D4o −D4i

Cylinder
2
P 𝑙
2 𝑙
P
2
2𝑙
1
1
4 64

= × - ×
-Problem
2
P
23
1
2
D+𝑙
4
P 𝑙1 ✓ y=
do
= × 1
- × 2
2 2 2 2 4
PD P𝑙1 P𝑙1
= + - 𝐌𝐛 𝐲
8 8 8 ❖ 𝛔𝐛 =
PD 𝐈
∴ Mb = Bending of Pin
8
53
Design of Piston - Problem 4
❖ The following data is given for 4 stroke diesel engine:
cylinder bore = 100 mm, length of stroke = 125mm, speed = 2000 rpm, brake
mean effective pressure = 0.65 MPa, max gas pressure = 5 MPa, fuel
consumption = 0.25 kg/BP/h, HCV = 42000 kJ/kg. Piston material is grey C.I.
and permissible tensile stress is 37.5 MPa. Design the piston head, ribs & cup.
Design
➢ Solution:
of
Cylinder
Data given:  Piston head (strength criteria):
- DProblem
= 100 mm,3l =125 mm
 t ph = D
3 . 𝑝𝑚𝑎𝑥
16 . σb
 N= 2000 rpm, pbm = 0.65 MPa
 pmax = 5 MPa , σt = 37.5MPa = σb = 100
3 ×5
16 ×37.5
• m = 0.25 kg/kW/h, HCV = 42000 kJ/kg
∴ 𝐭 𝐩𝐡 = 15.81 mm
• t ph = ?, t R = ?, R = ? 54
Design of Piston - Problem 4_continue…
❖ Data given: {From data book, K = 46.6 W/m/°C, (𝐓𝐜 − 𝐓𝐞 ) = 220 °C for grey C.I.}
 D = 100 mm, l =125 mm, N= 2000 rpm, pbm = 0.65 MPa, pmax = 5 MPa , σt = 37.5MPa
• m = 0.25 kg/kW/h = (0.25/3600) kg/kW/s, HCV = 42000 kJ/kg, t ph = ?, t R = ?, R = ?

Design
N
of  BP =
(p ×A) 𝑙 n
bm
60000
, kW  Piston head (Thermal criteria):
n = 𝐇
×𝟏𝟎𝟑 mm
Cylinder
2
2000 =
0.65×(
π(100)2
4
)× 0.125 ×1000  𝐭 𝐩𝐡 =
𝟏𝟐.𝟓𝟔 𝐊 (𝐓𝐜 − 𝐓𝐞)
= = 1000
-Problem
2 3 60000
∴ B.P. = 10.63 kW.
=
𝟏𝟓𝟓𝟎.𝟐𝟏
𝟏𝟐.𝟓𝟔 × 𝟒𝟔.𝟔 × 𝟐𝟐𝟎
×𝟏𝟎𝟑
∴ 𝐭 𝐩𝐡 = 12.04 mm
✓ H = HCV × C × B.P. × m × 103 , W
➢ Final ans.:
= 42000 × 0.05 × 10.63 × (0.25/3600) × 103
𝐭 𝐩𝐡 = 15.81 mm ≈ 16 mm.
∴ H = 1550.21 W (From data book, C = 0.05)
(15.81>12.04) 55
Design of Piston - Problem 4_continue…
❖ Data given:
 D = 100 mm, l =125 mm, N= 2000 rpm, pbm = 0.65 MPa, pmax = 5 MPa , σt = 37.5MPa
• m = 0.25 kg/kW/h = (0.25/3600) kg/kW/s, 𝐭 𝐩𝐡 = 16 mm , 𝐭 𝐑 = ?, R = ?
 Piston Ribs:  Piston Cup:
✓ if t ph ≤ 6 mm, (NO ribs) ✓ if (l/D) ≤ 1.5 , (Cup required))
✓ if t ph > 6 mm, (Provide ribs) ✓ if(l/D) > 1.5 , (Not required)
✓ 16 > 6 mm (∴ Required Ribs) ✓ 1.25 ≤ 1.5 mm (∴ Required Cup)
✓ Thickness of rib: ✓ Radius of Cup:
𝑙 125
t R = (t ph /3) to (t ph /2) R = 0.7 D  = = 1.25
D 100
= (16/3) to (16/2) = 0.7 × 100
= 5.33 to 8 ∴ 𝐭 𝐑 = 7 mm ∴ R = 70 mm 56
Design of Piston - Problem 5
❖ The following data is given for 4 stroke diesel engine:
cylinder bore = 100 mm, thickness of head = 16 mm, No. of rings = 4,
allowable radial pressure on cylinder wall = 0.035 MPa,. Piston ring material is
grey C.I. and permissible tensile stress is 90 MPa. Design the Ring section and
calculate thickness of piston barrel.
Design
➢ Solution:
of
Cylinder
 Data given:
 Radial width of ring:  Axial Thickness of ring:
 h = 0.7 b to b D
-DProblem
3 . 𝑝𝑤
= 100 mm 3 b = D  hmin =
σt 10 z
 t ph = 16 mm = 0.7(4) to 4 100
3 × 0.035 =
= 2.8 to 4 10 ×4
 z=4 = 100
90 = 2.5 mm
 pw = 0.035 MPa ∴ h = 3 mm
= 3.42 mm ( h = 3 > 2.5 mm)
 σt = 90 MPa ∴ b ≈ 4 mm 57
Design of Piston - Problem 5_Continue…
❖ Data given:
• D = 100 mm, t ph = 16 mm, z = 4, pw = 0.035 MPa, σt = 90 MPa, b = 4mm, h= 3mm
✓Gap between free ends: ✓ Top land: ✓Barrel thickness:
• G = 3.5 b to 4 b • h1 = (t h ) to (1.2t h ) ➢ at upper end:
(before assembly) = 16 to 1.2(16) • t 3 = 0.03D + b + 4.9
= 3.5 (4) to 4(4) = 16 to 19.2 = 0.03(100) + 4 + 4.9
= 14 to 16 ∴ 𝐆𝐛 = 15 mm ∴ 𝐡𝟏 = 18 mm ∴ 𝐭 𝟑 ≈ 12 mm
• G = 0.002D to 0.004 D ➢ at open end:
✓ Ring land: • t 4 = 0.25t 3 to 0.35 t 3
(After assembly)
• h2 = (0.75h) to h = 0.25 (12) to 0.35(12)
= 0.002 (100) to 0.004(100)
= 0.75(3) to 3 = 3 to 4.2
= 0.2 to 0.4 ∴ 𝐆𝐚 = 0.3 mm ∴ 𝐭 𝟒 = 4 mm
∴ 𝐡𝟐 = 2.5 mm 58
Design of Piston - Problem 6
❖ The following data is given for piston of 4 stroke diesel engine:
cylinder bore = 100 mm, baring pressure at small end of rod = 25 MPa, max gas
pressure = 5 MPa, length of pin in bush of small end = 0.45D, permissible
bending stress for pin is 140 MPa. Design the piston pin.
Design of  Bearing Consideration:
➢ Solution:
 Data given:
Cylinder ✓dia. of pin(do & di):
 D = 100 mm
-Problem 3 πD 2

 pb1 = 25 MPa pmax ( 4 ) = pb1 × (do . 𝑙1 )

π(100)2
 pmax = 5 MPa 5× = 25 × (do × 0.45 × 100)
4
 𝑙1 = 0.45D ∴ 𝐝𝐨 = 35 mm ✓ Mean dia. of boss = 1.4do
 σb = 140 MPa ✓di = 0.6 do = 1.4 (35)
= 0.6(35) ∴ 𝐝𝐢 = 21 mm = 49 mm 59
Design of Piston - Problem 6_Cont…
❖ Data given:
 D = 100 mm, pb1 = 25 MPa, pmax = 5 MPa, 𝑙1 = 0.45D, σb 𝑝𝑒𝑟 = 140 MPa
(From pre. Step: 𝐝𝐨 = 35 mm, 𝐝𝐢 = 21 mm)

 Bending Consideration: πD2

𝜋 D4o −D4i  P = 𝑝𝑚𝑎𝑥 ( )
4
✓I=
64 π×1002
𝜋 354 −214
=5×
4
=
64 = 39270 N
✓∴ I = 64.115 × 𝟏𝟎𝟑 𝐦𝐦𝟒 PD ✓ 𝛔𝐛 =
𝐌𝐛 𝐲
✓ Mb = 𝐈
✓ y = do /2 8
4.91 ×105 ×17.5
39270 ×100 =
= 35/2 = 64.115 ×103
8
∴ y = 17.5 mm ∴ Mb = 4.91 × 𝟏𝟎𝟓 Nmm ∴ 𝛔𝐛 = 134 MPa (< 140) 60
 Function of Connecting rod:
✓It transmits the force..
✓It transmits the
reciprocating motion of
Design of piston to rotary motion of
Connecting crankshaft.
Rod ✓It transfers lubricating oil
from the crank pin to piston
pin.

IC Engine
61
  Construction:
✓Small end.
✓Shank.
Design of ✓Big end.
Connecting
Rod

Connecting Rod
62
  Construction:
✓Importance of ratio of length of
rod to crank radius (L/r)
✓Cross section- I , Circular
Design of
Connecting
Rod

63
 Materials:
✓Subjected to gas force &
inertia force.
✓Medium carbon steel : 0.35
Design of to 0.45 % C. (industrial
Connecting engines)
✓Alloy steel: Nickle chromium
Rod or chromium molybdenum
steel. (automobile & aero
engines).
Connecting Rod
64
 Buckling of Rod:
✓Considerable length in
proportion to its width and
thickness.
Design of ✓Subjected to axial
Connecting compressive force equal to
max gas load on piston.
Rod ✓So it is designed as a column
or strut.

Connecting Rod
65
 Rankine’s Formula:
𝛔𝐜 . 𝐀
Critical buckling load, 𝐏𝐜𝐫 = 𝐋𝐞 𝟐 ,N
𝟏+𝐚
𝐊
Where…
Design of ✓σc = Compressive yield stress, MPa,
Connecting ✓ A = cross sectional area, mm2
Rod ✓ Le = effective length of column, mm
✓ K = least radius of gyration, mm
σc
✓ a = constant depend on material =
E π2
(for steel, a = 1/7500)
66
Design of Connecting Rod – Buckling
➢Buckling in two different planes:
1) Plane of motion
2) Plane perpendicular to plane of
motion
❖ Plane of motion (Fig. a)(@ XX axis):
✓ Ends of rod are hinged.
✓ End fixity coefficient is 1.
❖ Plane perpendicular to plane of
motion (Fig b)(@YY axis):
✓ Both ends are fixed.
➢ So, four times stronger for buckling @ YY
✓ End fixity coefficient is 4.
axis as compared to buckling about XX axis.67
Design of Connecting Rod – Buckling
➢If a connecting rod is designed such a way that it is equally resistance
to buckling in either plane then..
𝐏𝐜𝐫 𝐗𝐗 = 𝐏𝐜𝐫 𝐘𝐘
σc . A σc . A
∴ Lex 2
= Ley 2
1+a 1+a
Kxx Kyy
σc . A σc . A
∴ 2 = 2
➢ This relations proves that I section is ideally
𝐿 𝐿/2
1+a
Kxx 1+a suitable for connecting rod.
Kyy
➢ I section has higher section modulus (I/y)
∴ 𝐊 𝟐𝐱𝐱 = 4 𝐊 𝟐𝐲𝐲 per unit area as compared to other sections
∴ 𝐈𝐗𝐗 = 4 𝐈𝐘𝐘 so it has better resistance to bending and
buckling.
➢For design , 𝐈𝐗𝐗 = (3 to 4) 𝐈𝐘𝐘
➢ It reduce the weight and there by inertia
is considered. force , also it is easy to forge. 68
Design of Connecting Rod – Buckling
➢ Area(A), 𝑰𝐱𝐱 and 𝑰𝐲𝐲 : • 𝑰𝐲𝐲 = 2
1
(t) 4t 3
+
1
(5t – 2t) t 3
12 12
• A = 2(4t × t) + (t × 3t) 1
= 128 t 4 + 3 t 4
= 8t 2 + 3t 2 12
131 4
∴ A = 11𝒕 𝟐 ∴ 𝑰𝒚𝒚 = t
Design 1
of 3 1 3
12
419 t4
• 𝑰𝐱𝐱 = (4t) 5t - (4t – t) 5t – 2t
Cylinder
12
1
12 𝑰𝒙𝒙 12
• = 131 4
= 500 t 4 − 81 t 4 𝑰𝒚𝒚
12 t
-Problem
12
419
3 𝐼𝑥𝑥
∴ 𝑰𝒙𝒙 = t4 ∴ = 3.2
12 𝐼𝑦𝑦
• 𝑰𝒙𝒙 = A . k 2
xx ∴ 𝑰𝒙𝒙 = 3.2 𝑰𝒚𝒚
419 t4
2 𝐼𝑥𝑥 12
k xx = = ∴ 𝐤 𝐱𝐱 = 1.78 t
A 11t2 I Section 69
Design of Connecting Rod – Cross section
✓ P = force due to gas pr., N
✓ Ps = side thrust, N
✓ Pc = force on connecting rod, N
✓ φ = angle of inclination of rod with
line of stroke
✓ θ = angle of inclination of crank from
TDC position
➢ From fig. b, cos φ = P / 𝐏𝐜
P
∴ Pc = ………………. (1) ✓ from equation 1,
cos φ
P
✓But max gas load occurs when φ ≈ 3.3° Pc = = P
1 𝟐
∴ cosφ = cos3.3° = 0.9983 ≈ 1 𝛑𝐃
∴ 𝐏𝐜 = 𝐩𝐦𝐚𝐱 ( )
𝟒 70
Design of Connecting Rod – Cross section
➢Procedure to determine dimensions of cross section:
πD2
✓ Calculate, Pc = pmax ( 4 )
✓ Critical buckling load, Pc𝑟 = Pc (FOS)
✓ Calculate value of t by using Rankine’s formula:
σc . A
Pc𝑟 = 𝐿 2
1+a
Kxx

(σc = 330 MPa, a = 1/7500 for steel)

(for I section: A = 11 t 2 , K xx = 1.78 t)
✓ find B and H at middle section. (fig.) I Section
✓ Height at small end, H1 = 0.75 H to 0.9 H
✓ Height at big end, H2 = 1.1 H to 1.25 H 71
Design of Connecting Rod – Small end
❖ Small end Bearing (Piston pin bearing):
➢ Bearing consideration:
πD2
✓ Force on pin, Pc = pmax ( )
4
✓ force due to bearing pressure,
Pc = pb p × (dp . 𝑙p )
πD2
∴ pmax ( ) = pb p × (dp . 𝑙p )
4
where,
dp = dia. of piston pin or inner dia. of bush, mm ✓ pb p is taken from 10 to
𝑙p = length of pin or bush, mm 12.5 MPa.
𝑙p
pb p = allowable bearing pressure for bush, MPa ✓ is taken from 1.5 to 2.72
dp
Design of Connecting Rod – Big end
❖ Big end Bearing (Crank pin bearing):
➢ Bearing consideration: ✓ pb c = 5 to 10 MPa.
✓ (force)gas = (force)bearing pr. ✓
𝑙c
= 1.25 to 1.5.
dc
πD2
∴ pmax ( ) = pb c × (dc . 𝑙c )
4
dc = dia. of crank pin or inner dia. of bush, mm
𝑙c = length of crank pin or bush, mm
pb c = allowable bearing pressure for bush, MPa
✓ for good seating of bushes in
cap and rod, sleeve height is
slightly more than the half
bore of housing in which it fits
– Bearing crush. 73
Design of Connecting Rod – Big end
❖ Cap and Bolts:
➢ inertia force on cap and bolts:
2 cos2θ
✓ Pi = mr ω r ( cosθ + ) ….........(1)
n1
where, Pi = inertia force, N Slider crank mechanism
mr = mass of reciprocating parts, kg
= { mass of piston + (1/3) mass of rod } ✓ Pi is max when cos θ = 1
ω = angular speed = (2πN/60), rad/s ✓ i.e. θ = 0°
r = (l/2) = crank radius, m ∴ from Equ. 1,
2 1
n1 = obliquity ratio = (L/r) Pi 𝑚𝑎𝑥 = mr ω r 1 +
n1
θ = angle of crank from TDC 74
Design of Connecting Rod – Big end
❖ Cap and Bolts:
➢ Bolts (two):
✓ subjected to tensile force…
Pi 𝑚𝑎𝑥 /2
✓ σt = πd2c
4
𝛑𝐝𝟐𝐜
∴ 𝐏𝐢 𝐦𝐚𝐱 = 2 . 𝛔𝐭 . 𝟒
Where,
dc = core dia. of bolt, mm
σt = permissible tensile stress, MPa
𝒅𝒄
✓ nominal dia. d = Force on Cap & Bolts
𝟎.𝟖 75
Design of Connecting Rod – Big end
➢ Thickness of Cap (𝐭 𝐜 ) :
✓ treated as a beam freely supported at the bolt
centers and loaded intermediate between
uniformly distributed and centrally concentrated
load for which ..
𝐖𝒍 𝐏𝐢 𝐦𝐚𝐱 . 𝒍
✓ 𝐌𝐛 =
𝟔
=
𝟔
where, Bending of Cap
l = distance between bolt centers, mm
= dia. of crank pin + 2 (thickness of bush)
+ nominal dia. of bolt (d) + clearance
𝐌𝐛 𝐲
1 3 tc ❖ 𝛔𝐛 =
✓I= (𝑙c ) t c & y= 𝐈
12 2
76
Design of Connecting rod - Problem 7
❖ Determine dimensions of cross section of connecting rod (as shown in
figure) and small & big end bearings for a diesel engine with following data:
cylinder bore = 100 mm, length of rod = 320 mm, max gas pressure = 2.45
MPa, allowable baring pressure for piston pin and crank pin is 15 MPa & 10
MPa respectively, //d ratio for piston pin and crank pin bearing is 1.5 and 1.4
Design of
respectively.
Solution:
Cylinder
 Data given:  From data book:
-
 DProblem
= 100 mm 3  FOS = 5
 L = 320 mm  A = 11 t 2 , K xx = 1.78 t
 pmax = 2.45 MPa  σc = 330 MPa &
 pb p = 15 MPa, 𝑙p /𝑑p = 1.5  a = 1/7500 for steel
 pb c = 10 MPa, 𝑙c /𝑑c = 1.4 77
Design of Con. rod- Problem 7_Cont…
❖ Data : D = 100 mm, L = 320 mm, pmax = 2.45 MPa, pb p = 15 MPa, 𝑙p /𝑑p = 1.5
pb c = 10 MPa, 𝑙c /𝑑c = 1.4, FOS = 5, A = 11 t 2 , K xx = 1.78 t, σc = 330 MPa, a = 1/7500

πD2 𝛔𝐜 . 𝐀
✓ Pc = 𝑝𝑚𝑎𝑥 ( ) ➢ Critical load, 𝐏𝐜𝐫 = 𝐋 𝟐
,N
4 𝟏+𝐚
𝐊 𝐱𝐱
π×1002
= 2.45 × 330 × 11 t2
4 96211.3 = 1 320 2
1+
𝐏𝐜 = 19242.26 N 7500 1.78𝑡
t2
∴ 26.5045 = 4.31
1+ 2
t
✓ Pc𝑟 = Pc (FOS) t4
= 19242.26 × 5 ∴ 26.5045 =
4.31+t2
∴ 𝐏𝐜𝐫 = 96211.3 N ∴ 114.214 + 26.5045 t 2 = t 4
∴ t 4 - 26.5045 t 2 - 114.214 = 0 78
Design of Con. rod- Problem 7_Cont…
❖ Data : D = 100 mm, L = 320 mm, pmax = 2.45 MPa, pb p = 15 MPa, 𝑙p /𝑑p = 1.5
pb c = 10 MPa, 𝑙c /𝑑c = 1.4, FOS = 5, A = 11 t 2 , K xx = 1.78 t, σc = 330 MPa, a = 1/7500
✓ t 4 - 26.5045 t 2 - 114.214 = 0
2 − −26.5045 ± (−26.5045)2 −4 (1)(−114.214)
∴t =
2(1)
∴ t 2 = 30.2768
∴ t = 5.5 ≈ 6 mm.
✓ height and width at middle section:
H = 5t = 5(6) = 30mm, B = 4t = 4(6) = 24 mm
✓ height at small end, ✓ height at big end,
H1 = 0.75 H to 0.9 H H2 = 1.1 H to 1.25 H
= 0.75(30) to 0.9(30) = 1.1(30) to 1.25(30)
H1 = 25 mm H2 = 35 mm 79
Design of Con. rod- Problem 7_Cont…
❖ Data : D = 100 mm, L = 320 mm, pmax = 2.45 MPa, pb p = 15 MPa, 𝑙p /𝑑p = 1.5
pb c = 10 MPa, 𝑙c /𝑑c = 1.4, FOS = 5, A = 11 t 2 , K xx = 1.78 t, σc = 330 MPa, a = 1/7500
✓ Piston pin bearing: ✓ Crank pin bearing:
• (force)gas = (force)bearing pr. • (force)gas = (force)bearing pr.
πD2 πD2
∴ pmax ( ) = pb p × (dp . 𝑙p ) ∴ pmax ( ) = pb c × (dc . 𝑙c )
4 4
π×1002 π×1002
∴ 2.45 × = 15 × dp × (1.5 × dp ) ∴ 2.45 × = 10 × dc × (1.4 × dc )
4 4
∴ 𝐝𝐩 = 29.24 ≈ 30 mm ∴ 𝐝𝐜 = 37.07 ≈ 38 mm
𝑙p 𝑙c
• = 1.5 , 𝑙p = 1.5 dp • = 1.4 , 𝑙c = 1.4 dc
dp dc

∴ 𝑙p = 1.5 × 30 ∴ 𝒍𝒑 = 45 mm ∴ 𝑙c = 1.4 × 38 ∴ 𝒍𝒄 = 54 mm
80
Design of Connecting rod - Problem 8
❖ Design a cap and bolts of big end of connecting rod with following data:
Engine speed = 1500 rpm, length of rod = 320 mm, length of stroke = 140 mm,
mass of reciprocating parts = 1.75 kg, length & diameter of crank pin = 54 & 38
mm, permissible tensile stress for bolt = 120 MPa, permissible bending stress
for cap = 120 MPa.
Design
Solution:
of
Cylinder
 Data given: ➢ Design of bolts:
 -NProblem
= 1500 rpm,3L = 320 mm ✓ core dia. of bolts:
 l = 140 mm, mr = 1.75 kg Pi max = 2 . σt .
πd2c
4
 𝑙c = 54 mm, Dc = 38 mm
 σt = 120 MPa, 𝒅𝒄
 σb = 120 MPa ✓ nominal dia. d =
𝟎.𝟖
81
Design of Con. rod- Problem 8_Cont…
❖ Data : σt = 120 MPa , σb = 120 MPa
N = 1500 rpm, L = 320 mm, l = 140 mm, mr = 1.75 kg, 𝑙c = 54 mm, Dc = 38 mm
➢ Design of bolts:
2 1
2πN ✓ Pi 𝑚𝑎𝑥 = mr ω r 1 +
✓ω= n1
60
2 × π ×1500 2 70 1
= = 1.75 × (157.08) × 1000
× 1+
4.57
60
∴ ω = 157.08 rad/s ∴ 𝐏𝐢 𝐦𝐚𝐱 = 3683.98 N
✓ r = l / 2 = 140/2 ✓ Core dia. of bolts: ✓ nominal dia. of bolts:
dc
∴ r = 70 mm πd2c d=
• Pi max = 2 . σt . 0.8
4
✓ n1 = (L/r) π d2c =
4.42

= (320/70) ∴ 3683.98 = 2 × 120 × 0.8

4
∴ d = 5.525 ≈ 6 mm.
n1 = 4.57 ∴ 𝐝𝐜 = 4.42 mm 82
Design of Con. rod- Problem 8_Cont…
❖ Data : σt = 120 MPa , σb = 120 MPa 𝐏𝐢 𝐦𝐚𝐱 = 3683.98 N
N = 1500 rpm, L = 320 mm, l = 140 mm, mr = 1.75 kg, 𝑙c = 54 mm, Dc = 38 mm
 Design of cap (thickness 𝐭 𝐜 ):
✓ assume thickness of bush = 3 mm 1
✓ I = (𝑙 ) t 3 1
= (54) t 3
12 c c 12 c
and clearance = 3 mm tc
✓ y=
✓l = Dc + 2 (thickness of bush) + d + clearance 2

= 38 + 2(3) + 6 + 3 ✓ 𝛔𝐛 =
𝐌𝐛 𝐲
𝐈
∴ l = 53 mm t
𝐏𝐢 𝐦𝐚𝐱 . 𝒍 32541.82 × c
2
✓𝐌𝐛 = 120 = 1
𝟔
12
(54) tc 3
3683.98 ×53
= ∴ 𝐭 𝐜 = 5.49 mm ≈ 6 mm.
6
∴ 𝐌𝐛 = 32541.82 Nmm 83
 Definition:
✓small end- reciprocating motion
Design of ✓Big end- rotary motion
Connecting ✓Intermediate points- elliptical..
Rod- ✓ so, lateral oscillation of rod induced inertia force
along the length.
Whipping ✓ Bending stress due to inertia force acting on
stress connecting rod is called ‘Whipping Stress’.

84
Design of Con. Rod – Whipping stress
 The mass of the connecting rod per meter length is given by,
 m1 = volume × density
= area × length × density
m1 = A (1)(ρ)
m1 = A ρ
Where, For steels
ρ = 7800 kg/m3

m1 = (11t2) ρ kg/m
Design of Con. Rod – Whipping stress
 It can be shown that the maximum bending moment occurs at a distance of
L/ 3 from the piston pin and its magnitude is given by,

m ω2 r𝐿
(Mb) 𝑚𝑎𝑥 =
(9 3)

 Substituting (m = m1 L ) in the expression

m1 ω2 r𝐿2
(Mb) 𝑚𝑎𝑥 =
(9 3)
 Whipping stress:
m r ω2 l
Design of ✓ Mb =
(9 3)
Connecting ✓ Ixx =
419 4
t
12
Rod- ✓ y=
5t
2
Whipping
stress ❖ 𝛔𝐛 =
𝐌𝐛 𝐲
(should be less than permissible value)
𝐈

87
Design of Connecting rod
 The following data is given for a connecting rod:
 Engine speed = 1800 rpm, length of rod = 350 mm, length of stroke = 175
mm, Density of material = 7800 kg/m3, Thickness of web or flanges = 8 mm,
Assume the cross-section illustrated in Fig. Calculate whipping stress in the
connecting rod.
Design
Solution:
of
✓r = l / 2 = 0.175 / 2
Cnder
 Data given:
N = 0.0875 m
-Problem
= 1800 rpm, 3
 L = 350 mm = 0.350 m
2πN
 l = 175 mm = 0.175 m ✓ω =
60
2 × π ×1800
 𝑡 = 8 𝑚𝑚 = 0.008 𝑚 =
60
 ρ = 7800 kg/m3 ∴ ω = 188.50 rad/s
Design of Con. rod-Problem Cont…
❖ Data : N = 1800 rpm, L = 0.350 m, l = 0.175 m, 𝑡 = 0.008 𝑚, ρ = 7800 kg/m3

➢ Whipping Stress:
m1 ω2 r𝐿2
✓m1 = (11t2) ρ ✓(Mb) 𝑚𝑎𝑥 =
(9 3)
= 11(0.008)2 (7800) = 134.13 Nm
= 5.49 kg/m = 134.13 × 103 Nmm

𝐌𝐛 𝐲
𝛔𝐛 =
𝐈
= 134.13 × 103 × 20
419
(8)4
12
= 18.76 MPa
 Function :
✓It converts the
reciprocating motion of
piston into rotary motion
through the connecting rod.
Design of
Crankshaft

IC Engine
90
 Construction :
✓ three portions..
1) Crank pin
2) Crank web
Design of 3) Shaft
Crankshaft

Crankshaft
91
 Side crankshaft Centre crankshaft
 One crank web and  Two crank webs and three
two bearings. bearings
Design of  Used in medium size  Used in radial aircraft engine,
and large size stationary engine, marine
Crankshaft horizontal engines. engine & more popular in
- types automotive engines.

92
 Single throw c.s. Multi throw c.s.
 Only one crank pin.  More than one crank pin.

Design of
Crankshaft
- types

93
 Design requirements:
✓Sufficient strength to withstand bending and
twisting moment.
✓Sufficient rigidity to keep lateral and angular
deflection within permissible limits.
Design of ✓For fluctuating stress, it should have sufficient
Crankshaft endurance limit stress.

94
 Materials:
✓Plain carbon steel : 40C8, 45C8, 50C4
✓Alloy steel: Nickle chromium steels

Design of
Crankshaft

95
 Force acting on
crankshaft:
✓ subjected to bending &
twisting moment due to..
Design of 1) Force by connecting
rod on pin
Crankshaft 2) Weight of flywheel (↓)
3) Resultant belt tension
in horizontal direction
Forces on Crankshaft
96
 Two cases for design:
1) Crank is at TDC position and subjected to max
bending moment only
2) Crank is at an angle and subjected to max
Design of torsional moment
Crankshaft

Case 1 Case 2 97
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
✓ Pp = force acting on crank pin, N
✓ W = weight of flywheel, N
✓ P1 = tension on tight side of belt, N
✓ P2 = tension on slack side of belt, N
✓ b = distance between main beg. 1 & 2
✓ c = distance between bearing 2 & 3
❑ at TDC position,
𝛑𝐃𝟐 Centre C.S. at TDC position
𝐏𝐩 = 𝐩𝐦𝐚𝐱
𝟒
➢ Assumption: crankshaft is simply supported on bearings. 98
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
❖ bearing reactions:
1) R1 & R 2 : reaction at beg 1 & 2 due to Pp
2) R′2 & R′3 : reaction at beg 2 & 3 due to W
and (p1 +p2 )
▪ portion of c.s. between beg. 1 & 2:
✓ ΣM1 = 0
Pp × b1
∴ (Pp × b1 ) - (R 2v × b) = 0 ∴ R 2v = b
✓ ΣFY = 0 Centre C.S. at TDC position
∴ Pp - R1v - R 2v = 0 ∴ R1v = Pp - R 2v
99
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
▪ portion of c.s. between beg. 2 & 3:
✓ ΣM2 = 0 (vertical)
′ ′ W × c1
∴ (W × c1 ) - (R 3v × c) = 0 ∴ R 3v = c
✓ ΣFY = 0
′ ′
′ ′
∴ W - R 2v - R 3v = 0 ∴ R 2v = W - R 3v
✓ΣM2 = 0 (horizontal)
∴ {(p1 +p2 ) × c1 } - (R′3h × c) = 0 ′ (p1 +p2 ) × c1
∴ R 3h = Centre C.S. at TDC position
✓ ΣFX = 0 c

∴ (p1 +p2 ) - R′2h - R′3h = 0 ∴ R′2h = (p1 +p2 ) - R′3h

100
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
▪ Resultant reactions at the bearings
✓ R1 = R1v
✓ R 2 = (R 2v + R′2v )2 +(R′2h )2
✓ R 3 = (R′3v )2 +(R′3h )2

Centre C.S. at TDC position

101
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
❖ Crank pin (dc & 𝑙c ):
❑ central plane of crank pin is subjected to
max bending moment…
✓ bending moment at central plane of pin..
Mb = R1v × b1
π d4c dc 𝐌𝐛 𝐲
✓I= ✓ 𝛔𝐛 =
,Y= ….dia. of pin
64 2 𝐈
Pp
❑ Allowable bearing pressure, pb =
d ×𝑙 c c
Pp Design of crank pin
∴ 𝑙c = ………length of crank pin
dc × pb 102
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
❖ Shaft under flywheel (ds ):
❑ central plane of shaft is subjected to
max bending moment…
✓ bending moment in vertical plane..
Mbv = R′3v × c2
✓bending moment in horizontal plane..
Mbh = R′3h × c2
✓ Resultant Mb = (Mbv )2 +(M )2 Design of shaft
bh
π d4𝑠 ds 𝐌𝐛 𝐲
✓I= ,Y = ✓ 𝛔𝐛 = ….dia. of shaft (ds )
64 2 𝐈 103
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
❖ Left hand crank web (w & t):
❑ empirical relationships..
t = 0.7 dc and w = 1.14 dc
✓Left hand web subjected to eccentric load (R1v )..
✓ two types of stresses @ central plane of web:
▪ 1) direct compressive stress:
R1v
σc = t × w
▪ 2) bending stress due to eccentricity: Design of web
Mb y
σb =
I 104
Design of crankshaft – Case 1
➢ Centre crankshaft at TDC position:
❖ Left hand crank web (w & t):
2) bending stress due to eccentricity:
𝑙𝑐 𝑡
✓ Mb = (R1v ) 𝑏1 − − @ central plane of web
2 2
𝑤 t3 t
✓I= ,Y =
12 2
Mb y
✓ σb =
I
❑ total compressive stress…
(σc )t = σc + σb
Design of web
✓ it should be less than allowable bending stress.
105
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
✓ θ = crank angle with line of dead centers
✓ φ = angle of inclination of rod with line of d.c.
✓ Pp = force acting on piston top due to gas pressure, N
✓ Pq = thrust on connecting rod, N
✓ Pr = radial component of force on crank pin, N
✓ Pt = tangential component of force on pin, N
✓ torque is maximum when Pt is max and for this…
▪ θ = 25° to 35° for petrol engine &
▪ θ = 30° to 40° for diesel engine Force acting on pin
106
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ components of force on crank pin:
✓ p’ = pressure on piston top when torque is max..
πD2
▪ Pp = p’
4
✓ from fig., AB = L sinφ = r sinθ
sinθ
∴ sinφ = L/r B
Pp
✓ Pq cosφ = Pp ∴ Pq =
cosφ
▪ 𝐏𝐫 = 𝐏𝐪 cos(θ+ φ)
▪ 𝐏𝐭 = 𝐏𝐪 sin(θ+ φ) Force acting on pin
107
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ bearing reactions:
1) R1 & R 2v , R 2h : at beg 1 & 2 due to Pr & Pt
2) R 3 & R′2h , R′2v : at beg 2 & 3 due to W
and (p1 +p2 )
▪ portion of c.s. between beg. 1 & 2:
✓ ΣM1 = 0 (horizontal plane)
Pt × b1
∴ (Pt × b1 ) - (R 2h × b) = 0 ∴ R 2h = b
✓ ΣFx = 0
∴ Pt - R1h - R 2h = 0 ∴ R1h = Pt - R 2h Centre C.S. (max torque)
108
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ bearing reactions:
▪ portion of c.s. between beg. 1 & 2:
✓ similarly for vertical plane…
Pr × b1
R 2v =
b
R1v = Pr - R 2v
▪ portion of c.s. between beg. 2 & 3:
✓ similar to case 1…
W × c1
′
✓ R 3v = ✓ R′2v = W - R′3v
c
(p1 +p2 ) × c1 ✓ R′ = (p1 +p2 ) - R′ Centre C.S. (max torque)
′
✓ R 3h = 2h 3h 109
c
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
▪ Resultant reactions at the bearings..
✓ R1 = (R1h )2 +(R1v )2
✓ R 2 = (R 2v + R′2v )2 +(R 2h + R′2h )2
✓ R 3 = (R′3v )2 +(R′3h )2

Centre C.S. (max torque)

110
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ Crank pin (dc & 𝑙c ):
❑ central plane of pin is subjected to max
bending moment Mb due to R1v and
torsional moment Mt due to R1h
✓ bending moment at central plane of pin..
Mb = R1v × b1
π d4c dc 𝐌𝐛 𝐲
✓I= ,Y = ✓ 𝛔𝐛 =
64 2 𝐈
d
Mb ( c ) 𝟑𝟐 𝐌𝐛
2
∴ σb = π d4
∴ 𝛔𝐛 = ……..(1)
c 𝛑 𝐝𝟑𝐜
64 Design of crank pin 111
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque: Crank pin (dc & 𝑙c ):
✓ torsional moment: Mt = R1h × r
π d4c dc
✓J= ,R= ✓τ=
𝐌𝐭 𝐑
32 2 𝐉
d
Mt ( c ) 𝟏𝟔 𝐌𝐭
2
∴τ= π d4
∴τ = ……..(2)
c 𝛑 𝐝𝟑𝐜
32

𝛔𝐛 𝟐
✓max shear stress theory, 𝛕𝐦𝐚𝐱 = + 𝛕𝟐
𝟐
32 Mb 2 16 Mt 2
∴ 𝜏𝑚𝑎𝑥 = +
2π d3c π d3c

16
∴ 𝜏𝑚𝑎𝑥 = Mb 2 + Mt 2 …… dia of pin
π d3c Design of crank pin 112
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ Crank pin (dc & 𝑙c ):
Pq
❑ Allowable bearing pressure, pb =
dc × 𝑙c
Pq
∴ 𝑙c = ………length of crank pin
dc × pb

Design of crank pin 113

Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ Shaft under flywheel (ds ):
❑ central plane of shaft is subjected to
max bending moment…
✓Mbh = R′3h × c2 (horizontal plane)
✓Mbv = R′3v × c2 (vertical plane)
✓ Resultant Mb = (Mbv )2 +(Mbh )2
π d4𝑠 ds 𝐌𝐛 𝐲
✓I= ,Y = ✓ 𝛔𝐛 =
64 2 𝐈
𝟑𝟐 𝐌𝐛
∴ 𝛔𝐛 = ……..(1) Design of shaft
𝛑 𝐝𝟑𝐬 114
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque: shaft under flywheel (ds ):
✓ torsional moment: Mt = Pt × r
π d4s ds 𝐌𝐭 𝐑
✓J= ,R= ✓τ=
32 2 𝐉
𝟏𝟔 𝐌𝐭
∴τ = ……..(2)
𝛑 𝐝𝟑𝐬
✓max shear stress theory:
𝛔𝐛 𝟐
✓𝛕𝐦𝐚𝐱 = + 𝛕𝟐
𝟐
32 Mb 2 16 Mt 2
∴ 𝜏𝑚𝑎𝑥 = +
2π d3s π d3s

16 2 2
∴ 𝜏𝑚𝑎𝑥 = Mb + Mt …… dia of shaft
π d3s
115
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ Right hand crank web (w & t):
❑ empirical relationships..
t = 0.7 dc and w = 1.14 dc
✓ right hand web is subjected to….
▪ 1) direct compressive stress:
(Pr /2) R2v
σc d = = ……… (1)
t×w t×w
▪ 2) bending stress in vertical & horizontal
plane due to Pr and Pt :
Mb y
σb = Design of web
I 116
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ Right hand crank web (w & t):
✓ bending moment (B.M) due to radial comp…
𝑙𝑐 𝑡
Mbr = (R 2v ) 𝑏2 − − @ central plane of web
2 2
𝑤 t3 t w t2
✓I= ,Y = , ✓Z=
I
=
12 2 Y 6
Mbr y Mbr
✓ σbr = = ………………(2)
I Z
✓ B.M. due to Pt @ junction of shaft & web..
ds I t w2
Mbt = Pt (r -
2
) ✓Z= =
Y 6
Mbt y Mbt Design of web
✓ σbt = = ………………(3) 117
I Z
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ Right hand crank web (w & t):
❑ Max comp stress, 𝛔𝐜 = 𝛔𝐜𝐝 + 𝛔𝐛𝐫 + 𝛔𝐛𝐭
▪ 3) torsional shear stress (τ):
𝑙c
on arm, Mt = R 2h (b2 - )
2
J w t2
✓ polar section modulus, Zp = =
R 4.5
Mt R Mt
✓τ= = …….(4)
J Z
▪ max compressive stress theory:
𝛔𝐜 𝟏
𝛔𝐜 𝐦𝐚𝐱 = 𝟐 +
𝟐
𝛔𝐜 𝟐 + 𝟒𝛕𝟐
✓ it should be less than allowable 𝛔𝐜 Design of web 118
Design of crankshaft – Case 2
➢ Centre c.s. at an angle of max torque:
❖ Crankshaft bearing:
✓ bearing 2 is subjected to max. stress…
✓ R 2 = (R 2v + R′2v )2 +(R 2h + R′2h )2
✓ diameter of journal for bearing 2 is 𝐝𝐬
✓ length of bearing 𝒍𝟐 is calculated by..
R2
Allowable bearing pressure, pb =
ds × 𝑙2
R2
∴ 𝑙2 =
ds × pb

Centre C.S. (max torque)

119
Design of Crankshaft- Problem 9
❖ Design a centre c.s. of single cylinder vertical engine with following data:
Cylinder bore= 150 mm, (L/r) ratio= 4.75, max gas pressure= 4 MPa, length of stroke
= 200mm, weight of flywheel= 3.5 kN, total belt pull = 1.8 kN, allowable bending &
compressive stress = 75 MPa, allowable shear stress= 40 MPa, allowable bearing
pressure = 10 MPa. The main bearings are 350 mm apart and third bearing is 400 mm
Design of
apart from main bearing. Assume l/d ratio for crank pin is 1. Consider the case of
crankshaft at TDC position.
Cylinder
Solution:
-Problem
 Data given: 3
 Pb = 10 MPa, 𝑙c /dc = 1
 D = 150 mm, L/r = 4.75  b = 350 mm, τ = 40MPa
 pmax = 4 MPa, l = 200 mm 𝐛 = 𝐛 =b/2 = 175 mm
𝟏 𝟐
 W = 3.5 kN, P1 +P2 = 1.8 kN  c = 400 mm
 σb = 75 MPa, σc = 75 MPa 𝐜 = 𝐜 =c/2 = 200 mm
𝟏 𝟐 120
Design of C.s.- Problem 9_Cont…
❖ Data : D = 150 mm, L/r = 4.75, pmax = 4 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W = 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 = 𝐛𝟐 = 175 mm, 𝐜𝟏 = 𝐜𝟐 = 200 mm
πD2 ✓R1v = Pp - R 2v
✓ Pp = 𝑝𝑚𝑎𝑥 ( )
4
π×1502 = 70685.82 – 35342.91
=4×
4 ∴ 𝐑 𝟏𝐯 = 35342.91 N
∴ 𝐏𝐩 = 70685.82 N ✓R′2v = R′3v = W/2 ∵ (𝐜𝟏 = 𝐜𝟐 )
= 3500/2
Pp × b1
✓ R 2v = ∴ 𝐑′𝟐𝐯 = 𝐑′𝟑𝐯 = 1750 N
b
p +p
=
70685.82 ×175 ✓ R′2h = R′3h = 1 2 2
350
∴ 𝐑 𝟐𝐯 = 35342.91 N = 1800/2
∴ 𝐑′𝟐𝐡 = 𝐑′𝟑𝐡 = 900 N 121
Design of C.s.- Problem 9_Cont…
❖ Data : D = 150 mm, L/r = 4.75, pmax = 4 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W = 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 = 𝐛𝟐 = 175 mm, 𝐜𝟏 = 𝐜𝟐 = 200 mm
❖ Crank pin (dc & 𝑙c ):
✓ Mb = R1v × b1 (@ central plane of pin..)
= 35342.91 × 175
∴ 𝐝𝐜 = 95 mm
∴ Mb = 6.185 × 106 Nmm
✓ 𝑙c /𝑑c = 1
π d4c dc
✓I= ,Y = ∴ 𝒍𝐜 = 𝐝𝐜 = 95 mm
64 2
𝐌𝐛 𝐲 pp
✓ 𝛔𝐛 = 𝐈 … dia. of pin ✓ pb =
𝑙c × 𝑑c
6.185 × 106×d2c =
70685.82
∴ 75 = π d4
95 × 95
c
64 ∴ 𝐩𝐛 = 7.83 MPa < 10 MPa (allowable) 122
Design of C.s.- Problem 9_Cont…
❖ Data : D = 150 mm, L/r = 4.75, pmax = 4 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W = 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 = 𝐛𝟐 = 175 mm, 𝐜𝟏 = 𝐜𝟐 = 200 mm
❖ Left hand crank web (w & t):
✓ empirical relationships..
t = 0.7 dc w = 1.14 dc
= 0.7 (95) = 1.14 (95)
t = 66.5 ≈ 70 mm w = 108.3 ≈ 110 mm

✓ two types of stresses @ central plane of web:

▪ 1) direct compressive stress:
R1v 35342.91
σc = =
t×w 110 × 70
∴ 𝛔𝐜 = 4.59 MPa 123
Design of C.s.- Problem 9_Cont…
❖ Data : D = 150 mm, L/r = 4.75, pmax = 4 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W = 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 = 𝐛𝟐 = 175 mm, 𝐜𝟏 = 𝐜𝟐 = 200 mm
❖ Left hand crank web (w & t): (w = 110 mm & t = 70 mm)
▪ 2) bending stress due to eccentricity:
𝑙𝑐 𝑡
✓ Mb = (R1v ) 𝑏1 − − @ central plane of web
2 2
= 35342.91 [ 175 – 95/2 – 70/2 ]
∴ Mb = 3.27 × 106 Nmm 𝐌𝐛 𝐲 𝐌𝐛
𝑤 t3 t I w t2
✓ 𝛔𝐛 = 𝐈
=
𝐙
✓I= ,Y = ✓ Z= =
12 2 Y 6 3.27 × 106
110 × 702 =
Z= 89833.33
6
∴ 𝛔𝐛 = 36.4 MPa
∴ Z = 89833.33 mm3 124
Design of C.s.- Problem 9_Cont…
❖ Data : D = 150 mm, L/r = 4.75, pmax = 4 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W = 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 = 𝐛𝟐 = 175 mm, 𝐜𝟏 = 𝐜𝟐 = 200 mm

❖ Left hand crank web (w & t): (w = 110 mm & t = 70 mm)

✓ total compressive stress… σc = 4.59 MPa
σb = 36.4 MPa
(σc )t = σc + σb
= 4.59 + 36.4
∴ (𝛔𝐜 )𝐭 = 40.99 MPa
✓ it is less than (𝛔𝐜 )𝐚𝐥𝐥𝐨𝐰𝐚𝐛𝐥𝐞 75 MPa
so, w = 110 mm & t = 70 mm are safe.

125
Design of C.s.- Problem 9_Cont…
❖ Data : D = 150 mm, L/r = 4.75, pmax = 4 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W = 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 = 𝐛𝟐 = 175 mm, 𝐜𝟏 = 𝐜𝟐 = 200 mm
❖ shaft under flywheel(ds ):
✓ Mbv = R′3v × c2 (@ central plane of shaft..)
= 1750 × 200
∴ Mbv = 3.5 × 105 Nmm π d4𝑠 ds
′ ✓I = ,Y =
✓ Mbh = R 3h × c2 64 2
𝐌𝐛 𝐲
= 900 × 200 ✓ 𝛔𝐛 = 𝐈
∴ Mbh = 1.8 × 105 Nmm 3.936 × 105 × d2s
✓ Mb = (Mbv )2 +(Mbh )2 ∴ 75 = π d4
s
64
= (3.5 × 105 )2 +(1.8 × 105 )2
∴ 𝐝𝐬 = 37.7 ≈ 40 mm
∴ 𝐌𝐛 = 3.936 × 105 Nmm 126
Design of C.s.- Problem 9_Cont…
➢ Solution summary:

✓ bearing reactions due to W and (p1 +p2 ):

𝐑′𝟐𝐯 = 𝐑′𝟑𝐯 = 1750 N & 𝐑′𝟐𝐡 = 𝐑′𝟑𝐡 = 900 N
✓ diameter and length of crank pin:
𝒍𝐜 = 𝐝𝐜 = 95 mm
✓ diameter of shaft under flywheel:
𝐝𝐬 = 40 mm
✓ thickness and width of crank web:
t = 70 mm, w = 110 mm Centre C.S. (TDC_case 1)
127
Design of Crankshaft- Problem 10
❖ Assume the data of example 9 for a centre c.s. of single cylinder vertical engine:
The torque on crankshaft is max when crank turns through 25° from TDC and at this
position, the gas pressure is 3.75 MPa. Consider this position of crank and calculate:
1) Components of force on pin, 2) reactions at bearings, 3) dia. & length of crank pin,
4) diameter of shaft under flywheel, 5) max. compressive stress in right hand crank
Design of
web and 6) bearing pressure at main bearing.
Cylinder
Solution:
-Problem
 Data given: 3
 Pb = 10 MPa, 𝑙c /dc = 1
 D = 150 mm, L/r = 4.75  b = 350 mm, τ = 40MPa
 p’ = 3.75 MPa, l = 200 mm
𝐛𝟏 = 𝐛𝟐 =b/2 = 175 mm
 W = 3.5 kN, P1 +P2 = 1.8 kN  c = 400 mm
 σb = 75 MPa, σc = 75 MPa 𝐜 = 𝐜 =c/2 = 200 mm
𝟏 𝟐 128
Design of C.S.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Components of force acting on crank pin:
sinθ Pp
✓ sinφ = ✓ Pq =
L/r cosφ
sin25 66267.97 ✓Pt = Pq sin(θ+ φ)
sinφ = =
4.75 cos 5.104
= 66531.81 sin(25+5.1)
∴ φ = 5.1044° ∴ 𝐏𝐪 = 66531.81 N
∴ 𝐏𝐭 = 33370.78 N
πD2
✓Pp = p’ × ( )
4
✓Pr = Pq cos(θ+ φ)
π×1502
= 3.75 × = 66531.81 cos(25+5.1)
4
∴ 𝐏𝐩 = 66267.97 N ∴ 𝐏𝐫 = 57560 N 129
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, pb = 10 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Reactions at bearings: ➢ 𝐛𝟏 = 𝐛𝟐 & 𝐜𝟏 = 𝐜𝟐

✓R1v = R 2v = Pr /2 ✓R′2v = R′3v = W/2

= 57560/2 = 3500/2
∴ 𝐑 𝟏𝐯 = 𝐑 𝟐𝐯 = 28780 N ∴ 𝐑′𝟐𝐯 = 𝐑′𝟑𝐯 = 1750 N

✓ R1h = R 2h = Pt /2 p1 +p2
✓ R′2h = R′3h = 2
= 33370.78/2 = 1800/2
∴ 𝐑 𝟏𝐡 = 𝐑 𝟐𝐡 = 16685.4 N ∴ 𝐑′𝟐𝐡 = 𝐑′𝟑𝐡 = 900 N
130
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Crank pin (dc & 𝑙c ): ➢ From case 1: 𝒅𝒄 = 𝒍𝒄 = 95 mm
✓ Mb = R1v × b1 ✓ Mt = R1h × r
= 28780 × 175 = 16685.4 × (200/2)
6 ∴ 𝐌 = 1.67 × 10 6 Nmm
∴ 𝐌𝐛 = 5.037 × 10 Nmm 𝐭

16
✓ τmax = 3 Mb 2 + Mt 2
π dc

16
40 = 3 (5.037 × 106 )2 +(1.67 × 106 )2
π dc
∴ 𝐝𝐜 = 87.75 mm < 95 mm. ∴ Ans.:𝐝𝐜 = 95 mm = 𝒍𝐜 131
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ shaft (ds ): ➢ From case 1: 𝒅𝒔 = 40 mm

✓ R 3 = (R′3v )2 +(R′3h )2 ✓ Mt = Pt × r
= (1750)2 +(900)2 = 33370.78 × (200/2)
∴ 𝐑 𝟑 = 1967.87 N ∴ 𝐌𝐭 = 3.34 × 106 Nmm

✓Mb = R 3 × c2 16
✓ τmax = 3 Mb 2 + Mt 2
π ds
= 1967.87 × 200
∴ 𝐌𝐛 = 3.94 × 105 Nmm
132
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ shaft (ds ): ➢ From case 1: 𝒅𝒔 = 40 mm
✓ M = 3.34 × 106 Nmm
t
✓ Mb = 3.94 × 105 Nmm
16
✓ τmax = 3 Mb 2 + Mt 2
π ds

16
40 = 3 (3.94 × 105 )2 +(3.34 × 106 )2
π ds
∴ 𝐝𝐬 = 75.35 mm > 40 mm.
∴ Ans.:𝐝𝐬 = 75.35 ≈ 80 mm 133
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Right hand crank web (w & t): ➢ From case 1: t= 70 mm, w= 110 mm
✓ empirical relationships..
t = 0.7 dc w = 1.14 dc
= 0.7 (95) = 1.14 (95)
t = 66.5 ≈ 70 mm w = 108.3 ≈ 110 mm

➢ Max comp stress, σc = σcd + σbr + σbt

➢ torsional shear stress (τ)
✓ max compressive stress theory:
σc 1
σc max = 2 +
2
σc 2 + 4τ2 < σc per. 134
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Right hand crank web (w & t): (w = 110 mm & t = 70 mm)
▪ 1) direct compressive stress: w t2
R2v 28780 ✓ Z=
6
σc d = =
t×w 110 × 70 110 × 702
∴ 𝛔𝐜 = 3.73 MPa =
𝐝 6
▪ 2) bending stress (σbr & σbt ): ∴ Z = 89833.33 mm3
𝑙𝑐 𝑡 𝐌𝐛r 𝐲 𝐌𝐛r
✓ Mbr = (R 2v ) 𝑏2 − − ✓ 𝛔𝐛r = 𝐈
=
𝐙
2 2
= 28780 [ 175 – 95/2 – 70/2 ] 2.66 × 106
=
89833.33
∴ Mbr = 2.66 × 106 Nmm
∴ 𝛔𝐛𝐫 = 29.63 MPa 135
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Right hand crank web (w & t): (w = 110 mm & t = 70 mm)
▪2) bending stress (σbr & σbt ):
ds
✓ Mbt = (Pt ) (r - ) 𝐌𝐛t
2
✓ 𝛔𝐛𝐭 = 𝐙
= 33370.78 [ 100 – 80/2]
2 × 106
∴ Mbt = 2 × 106 Nmm =
141166.67
t w2
✓ Z=
6
∴ 𝛔𝐛𝐭 = 14.17 MPa
70 × 1102
=
6
∴ Z = 141166.67 mm3 136
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Right hand crank web (w & t): (w = 110 mm & t = 70 mm)
➢ Max comp stress:
w t2
σc = σcd + σbr + σbt ✓ Zp =
4.5
= 3.73 + 29.63 + 14.17 110 × 702
=
4.5
∴ 𝛔𝐜 = 47.53 MPa
∴ Z = 119777.78 mm3
▪ 3) torsional shear stress (τ): 𝐌t
𝑙c ✓τ=
𝐙
Mt = R 2h (b2 - )
2
2.127 × 106
= 16685.4 (175 – 95/2) =
119777.78
∴ Mt = 2.127 × 106 Nmm ∴ τ = 17.76 MPa 137
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Right hand crank web (w & t): (w = 110 mm & t = 70 mm)
σc = 47.53 MPa
➢ max compressive stress theory: τ = 17.76 MPa
σc 1
σc max = + σc 2 + 4τ2
2 2
47.53 1
= + (47.53)2 + 4(17.76)2
2 2
∴ 𝛔𝐜 𝐦𝐚𝐱 = 53.44 MPa
✓ it is less than allowable 𝝈𝒄 (75 MPa)
✓ so w = 110 mm & t = 70 mm are safe.
138
Design of C.s.- Problem 10_Cont…
❖ Data : D = 150 mm, L/r = 4.75, p’ = 3.75 MPa, l = 200 mm, τ = 40 MPa, 𝑙c /𝑑c = 1
W= 3.5 kN, P1 +P2 = 1.8 kN, σb & σc = 75 MPa, 𝐛𝟏 =𝐛𝟐 = 175 mm, 𝐜𝟏 =𝐜𝟐 = 200 mm , θ= 25°
❖ Bearing pressure at main bearing: (ds = 80 mm)
✓ R 2 = (R 2v + R′2v )2 +(R 2h + R′2h )2
= (28780 + 1750)2 +(900 + 16685.44)2
∴ R 2 = 35232.47 N
✓ diameter of journal for bearing 2 is 𝐝𝐬
✓ take l/d ratio for bearing = 1
R2
✓ bearing pressure at 2, pb =
ds × 𝑙2
35232.47
=
80 ×80
∴ 𝐩𝐛 = 5.51 MPa 139
 Function :
✓To open & close the inlet and exhaust valves at a
proper time with respect to the position of the
piston and crankshaft.
Design of
Valve Gear
Mechanism

IC Engine 140
 Construction & Working :

Design of
Valve Gear
Mechanism
Valve gear mechanism
for vertical engine

141
 Construction & Working :

Design of
Valve Gear
Mechanism

Valve gear mechanism for horizontal engine

142
Design of Valve
 Types of valve :
✓Sleeve valves
✓Poppet or mushroom valve – frequently used.

 Construction of Poppet valve :

✓Face angle: 30° to 45°
✓Conical face- self centering property
✓ Margin: to avoid sharp edge
& provision for regrinding
✓Slow speed engine: cast iron head & steel stem
✓ high speed engine: one piece construction (forged) Poppet Valve
143
Design of Valve
 Desirable properties of material:
✓It should be heat resistant
✓ should have good thermal conductivity
✓ should be corrosion resistant
✓ should have wear resistant surface
✓ should have shock resistant
 Materials for valve :
✓Inlet valve: Nickle chromium steel (Tinlet < Texhaust ) Poppet Valve
✓Exhaust valve: heat resistant silicon chromium steel (T=1900°C to 2200 °C)
✓ Heavy duty engine: chromium-vanadium steel
✓ valves are heat treated and surface hardness for both valves : 250 to 300 HB 144
Design procedure of valve
❖ Diameter of valve port (𝐝𝐩 ): Allowable vp
✓ a = area of piston
✓ v = mean velocity of piston
✓ ap = area of port
✓ vp = mean velocity of gas through the port
➢ ap × vp = a × v
a×v π d2p
✓ ap = = ✓Inlet ports are made 20%
vp 4
to 40% larger than exhaust
Where, dp = dia of valve port, mm port for better cylinder
• v = mean velocity of piston = 2l × (N/60), m/s charging & scavenging
• allowable (vp ) given in table. 145
Design procedure of valve
❖ Diameter of valve head (𝐝𝐯 ):
✓ empirical relationship:
w = (0.05 to 0.07) dp ……..(for α = 45°)
✓ dv = dp + 2w
❖Thickness of valve disc (t):
✓It is assumed as a circular disc freely supported
around its periphery & subjected to UDL pmax
pmax
✓ t = k dp , mm
σb
Force on Valve
Where, k = constant (0.42 for steel & 0.54 for C.I.)
• σb = permissible bending stress, MPa ✓Margin = (0.75 to 0.85) t
• pmax = max gas pressure, MPa 146
Design procedure of valve
❖ Diameter of valve stem (𝐝𝐬 ):
✓ empirical relationship:
dp dp
ds = + 6.35 to + 11 , mm
8 8

❖ Maximum valve lift (𝐡𝐦𝐚𝐱 ):

dp
✓ hmax =
4 cosα
dp
✓ for flat head valve, hmax = (∵α = 0)
4

Force on Valve
147
Design of V.G.M. - Problem 11
❖ Design an exhaust valve for a horizontal diesel engine with following data :
cylinder bore = 250 mm, length of stroke = 300 mm, max gas pressure = 4
MPa, Engine speed = 600 rpm, seat angle = 45°, mean velocity of gas through
port = 50 m/s, allowable bending stress for valve = 50 MPa.
➢ Solution:
 Data given:
❖ Diameter of valve port (𝐝𝐩 ):
 D = 250 mm, π D2 a×v π d2p
✓a= ✓ v = 2l (N/60) ✓ ap = =
 l = 300 mm 4 vp 4
π (0.250)2 = 2×0.3 (600/60) 0.049 × 6 π d2p
 pmax = 4 MPa, = ∴ =
4 50 4
= 6 m/s
 N = 600 rpm a = 0.049 m 2
∴ 𝐝𝐩 = 86.52 mm
 α = 45°, vp = 50 m/s
𝐝𝐩 ≈ 90 mm
 σb = 50 MPa 148
Design of V.G.M. - Problem 11_Continue…
❖ Data given: α = 45°, ➢ From step 1: 𝐝𝐩 = 90 mm
• D = 250 mm, l= 300 mm, N = 600 rpm, pmax = 4 MPa, σb = 50 MPa, vp = 50 m/s

❖ Dia. of valve head (𝐝𝐯 ): ❖ thickness of valve head (t):

✓ w = (0.05 to 0.07) dp pmax
✓ t = k dp
or 0.06 dp σb

= 0.06 × 90 ✓ take k = 0.42 for steel valve

= 5.4 mm 4
t = 0.42 × 90
✓ dv = dp + 2w 50

= 90 + 2(5.4) ∴ t = 11 mm
∴ 𝐝𝐯 = 101 mm

149
Design of V.G.M. - Problem 11_Continue…
❖ Data given: α = 45°, ➢ From step 1: 𝐝𝐩 = 90 mm
• D = 250 mm, l= 300 mm, N = 600 rpm, pmax = 4 MPa, σb = 50 MPa, vp = 50 m/s

❖ Dia. of valve stem (𝐝𝐬 ): ❖ max lift of valve (𝐡𝐦𝐚𝐱 ):

dp dp dp
✓ds = + 6.35 to + 11 ✓ hmax =
8 8 4 cosα
90 90 90
= + 6.35 to + 11 =
8 8 4 cos45
= 17.6 to 22.25 ∴ 𝐡𝐦𝐚𝐱 = 31.82 mm
∴ 𝐝𝐬 = 20 mm

150
Design of Rocker arm
 Function:
✓ to operate inlet and exhaust valve by
changing the direction of force.
 Construction & Materials:
✓One end is forked – cam side end
✓ other end – plain boss & tappet
✓ Cross section of arm- I section
✓ a = b for moderate & low speed engine
✓ (a/b) is (1/1.3) for high speed engine
✓ made of grey cast iron, malleable cast
iron or cast steel.
Rocker arm for exhaust valve
151
Design of Rocker arm
❖ Force acting on arm:
✓ max force consist of three factors:
1) Gas pressure on valve when it opens:
gas load Pg = area of valve × gas pressure
π dv 2
Pg = pc
4
✓Where, dv = dia. of valve head, mm
✓ pc = cylinder pr. or back pr.
when exhaust valve opens
2) Inertia force (opposite to motion):
Pa = m α
✓ m =mass of valve, kg & α = acc. in m/s 2 Force acting on rocker arm
152
Design of Rocker arm
❖ Force acting on arm:
3) Initial spring force:
Pi = area of valve × max suction pr.
π dv 2
Pi = ps
4

Where, ps = max suction pr., MPa

✓Total force (exhaust valve):
Pex = Pg + Pa + Pi
✓Total force (inlet valve):
Pin = Pa + Pi
Force acting on rocker arm
153
Design of Rocker arm
❖ Design of fulcrum pin:
✓ Reaction,R f = Pe 2 + Pc 2 − 2Pe Pc cosθ
✓ Pe = Pc when a = b
✓ d1 & 𝑙1 : dia. & length of pin, mm
(1) bearing consideration:
Rf
pb =
d1 × 𝑙1

✓ pb is taken as 5 MPa
𝑙1
✓ = 1.25 , if not given
d1
Fulcrum pin reaction 154
Design of Rocker arm
❖ Design of fulcrum pin:
(2) Double shear stress:
Rf
τ=
π d1 2
2
4

✓ permissible shear stress: 42 MPa

✓ phosphor bronze bush of 3 mm thickness
is press fitted in pinhole of arm to reduce
friction.
➢ outside dia. of boss = 2 d1
Fulcrum pin design 155
Design of Rocker arm
❖ Design of Fork end:
✓d2 & 𝑙2 : dia. & length of roller pin, mm
(1) bearing consideration:
Pc
pb =
d2 × 𝑙2

✓ pb is taken as 5 MPa
𝑙2
✓ = 1.25 , Design of Fork End
d2

(if not given)

156
Design of Rocker arm
❖ Design of fork end:
(2) Double shear stress:
Pc
τ=
π d2 2
2
4

✓ permissible shear stress: 42 MPa

𝑙2
➢ Thickness of each eye = ➢ outer dia. of roller:
2
➢ outer dia. of eye = D2 = 2 d2 D2 + 5 mm
➢ when the roller pin is tight in two eyes of fork,
failure is due to shear. When the pin is loose,
it is subjected to bending moment. Design of Fork end 157
Design of Rocker arm
❖ Design of fork end:
(3) Bending of pin:
✓ assumed: UDL on pin in contact with roller
& UVL on pin in two parts of eye.
1 𝑙2 𝑙2
✓ For UVL: x = =
3 2 6
1 𝑙2 𝑙2
✓ For UDL: z = =
2 2 4
✓ Max. bending moment @ central plane:
Pc 𝑙2 Pc
Mb = +x - (z)
2 2 2
Pc 𝑙2 𝑙2 Pc 𝑙2
= + - Bending of roller pin
2 2 6 2 4 158
Design of Rocker arm
❖ Design of fork end:
(3) Bending of pin: 𝜋 d42
✓ I=
64
Pc 𝑙2 𝑙2 Pc 𝑙2
✓Mb = + - ✓ y=
d2
2 2 6 2 4 2
Pc 2𝑙2 Pc 𝑙2 𝐌𝐛 𝐲
=
2 3
-
2 4 ❖ 𝛔𝐛 =
𝐈
Pc 5𝑙2 < 𝛔𝐛 𝐩𝐞𝐫.
=
2 12
𝟓
∴ 𝐌𝐛 = 𝟐𝟒
𝐏𝐜 𝒍𝟐

159
Design of Rocker arm
❖ Design of cross section of arm:
✓ Bending due to Pe :
✓ consider cross section or arm near the boss
of fulcrum (X-X) & at X-X bending moment:
✓ Mb X−X = Pe a − d1
1 3 1 3
✓ 𝐼xx = (2.5t) 6t − (1.5t) 4t
12 12
∴ 𝐼xx = 37 t 4
✓ y = (6t/2) = 3t
𝐌𝐛 𝐲
➢ 𝛔𝐛 𝒑𝒆𝒓. =
𝐈
160
Design of Rocker arm
❖ Design of Tappet:
✓ subjected to compressive force Pe
✓ dc = core diameter of tappet, mm
✓ σc = permissible comp. stress, MPa
Pe
✓ σc = …(σc 𝑝𝑒𝑟. for steel stud: 50 MPa)
πd2c
4
dc
✓ nominal dia. of stud, d =
0.84
✓ dia. and depth of plain boss:
D3 = 2d and t 3 = 2d
161
Design of V.G.M. – Problem 12
❖ Design a rocker arm for exhaust valve for 4 ➢ Solution:
stroke engine with following data:
 Data given:
Effective length of each arm = 150 mm, angle
between arms = 150°, dia. of valve head = 56 mm,  a = b = 150 mm, θ = 150°
lift of valve = 20 mm, mass of valve = 0.3 kg,  dv = 56 mm, hmax = 20 mm
Design of
engine speed = 500 rpm, back pressure when
 m = 0.3 kg, N = 500 rpm
exhaust valve opens = 0.35 MPa, max. suction
Cylinder
pressure = 0.025 MPa, (l/d) ratio for fulcrum &  pc = 0.35 MPa, ps = 0.025 MPa
-Problem 3
roller pin = 1.25.
 (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25
permissible values:
 σb = 70 MPa, σc = 50 MPa
𝛔𝐛 = 70 MPa, τ = 42 MPa, 𝛔𝐜 = 50 MPa, 𝐩𝐛 = 5 MPa.
 τ = 42 MPa, pb = 5 MPa
The valve opens 39° before ODC and closes 8°
after IDC. The motion of valve is SHM without
dwell in fully opened condition. Assume
proportion of cross section of arm. 162
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pc = 0.35 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & σc = 50 MPa
❖ Acceleration of valve:
✓ Time taken by valve
✓ speed of camshaft ✓ total crankshaft angle
to open & close (t)
speed of crankshaft = N/2 when valve is open angle of cam action
= =
2
= 39 + 180 + 8 = 227° angle of camshaft/s
= 500/2 = 250 rpm
✓Total angle of cam action = 113.5/1500 = 0.076 s
✓ angle turned by camshaft ✓ r = h/2 = 20/2
angle of crankshaft
per second = = 10 mm = 0.01 m
2
= no. of revolution/s × 360° = 227/2 𝟐𝛑 𝟐 2π 2
𝟐
250 ✓α = r𝛚 =r = 0.01
= × 360° = 1500° per s = 113.5° 𝐭 0.076
60 ∴ α = 68.35 m/𝐬 𝟐 163
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pc = 0.35 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & σc = 50 MPa
❖ Total force on arm: ✓ initial spring force:
π dv 2 π dv 2
✓ Gas load, Pg = pc ✓ Pi = ps
4 4
π × 562 π × 562
= × 0.35 = × 0.025
4 4
Pg = 862.05 N Pi = 61.575 N
✓ Inertia force, Pa = mα ✓ Total force: 𝐏𝐞𝐱 = 𝐏𝐠 + 𝐏𝐚 +
= 0.3 × 68.35 𝐏𝐢

Pa = 20.505 N Pex = 862.05 + 20.51 + 61.58

164
∴ 𝐏 = 944.14 N
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & τ = 42 MPa
❖ Fulcrum pin:
2 2
✓ Rf = Pe 2 + Pc 2 − 2Pe Pc cosθ = 944.14 + 944.14 − 2(944.14)(944.14)cos150

∴ R f = 1823.93 N
Rf
✓ pb =
d1 × 𝑙1
1823.93
5=
d1 × (1.25 d1 )

∴ 𝐝𝟏 = 17.08 mm ≈ 20 mm
✓ 𝑙1 = 1.25 d1 = 1.25 × 20
∴ 𝒍𝟏 = 25 mm Force on fulcrum pin 165
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & τ = 42 MPa
❖ Fulcrum pin:
✓ Double shear stress: ✓ outside dia. of boss
Rf = 2 × d1
τ=
π d1 2
2 = 2 × 20
4

=
1823.93 = 40 mm
π 202
2 ✓ inside dia. of boss
4

∴ τ = 2.90 MPa < 42 MPa = d1 + 2(3)

∴ 𝐝𝟏 = 20 mm & 𝒍𝟏 = 25 mm = 20 + 6
…..Answer = 26 mm 166
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & τ = 42 MPa
❖ Fulcrum pin:
➢ check for bending stress in
c/s of arm near fulcrum pin:
40
✓ Mb = Pe × a ✓ y = 2 = 20 mm
= 944.14 × 150 ✓𝛔𝐛 =
𝐌𝐛 𝐲
𝐈
∴ Mb = 141621 Nmm 141621×20
=
25×403 25×263 96716.67
✓I= - 𝛔𝐛 = 29.28 MPa
12 12
3
∴ I = 96716.67 mm < 𝛔𝐛 𝐩𝐞𝐫. (70) 167
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & τ = 42 MPa
❖ Fork end:
➢ Bearing Pressure: ➢ Double shear stress:
Pc Pc
✓ pb = τ=
d2 × 𝑙2 π d2 2
2
4
944.14
5= 944.14
d2 × (1.25 d2 ) = π 152
2
∴ 𝐝𝟐 = 12.29 ≈ 15 mm 4

✓ 𝑙2 = 1.25 d2 = 1.25 × 15 ∴ τ = 2.67 MPa

∴ 𝒍𝟐 = 18.75 ≈ 20 mm < 42 MPa
168
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & τ = 42 MPa
❖ Fork end: ➢ d2 = 15 mm
𝑙2
✓Thickness of each eye = 𝑙2 = 20 mm
2
= 20/2 = 10 mm
✓ outer dia. of eye = D2 = 2 d2
D2 = 2 × 15 = 30 mm
✓ outer dia. of roller = D2 + 5
= 30 + 5
= 35 mm Fork end of Rocker arm 169
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & τ = 42 MPa
❖ Fork end: ➢ d2 = 15 mm, 𝑙2 = 20 mm
𝜋 d42
➢ Bending of pin: ✓ I= 64
5
✓ Mb = Pc 𝑙2 =
𝜋 154
24
64
5
= × 944.14 × 20 = 2485.049 mm4
24
𝐌𝐛 𝐲
∴ Mb = 3933.92 Nmm ✓𝛔𝐛 =
𝐈
d2 3933.92 ×7.5
✓y= =
2485.049
2 Rocker arm
15
= = 7.5 mm ∴ 𝛔𝐛 = 11.87 MPa
2
< 𝛔𝐛 𝐩𝐞𝐫. (70 MPa) 170
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σb = 70 MPa & τ = 42 MPa
❖ Cross section of arm: ➢ d1 = 20 mm
➢ subjected to bending: 𝐌𝐛 𝐲
✓𝛔𝐛 =
𝐈
✓ Mb X−X = Pe a − d1 122738.2 × 3t
70 =
= 944.14 (150 – 20) 37 t4
∴ t = 5.22 ≈ 6 mm
∴ Mb = 122738.2 Nmm
✓ height = 6t
✓ y = 6t/2 = 3t
= 6(6) = 36 mm
✓ I = 37 t 4
✓width = 2.5t
= 2.5(6) = 15 mm
171
Design of V.G.M- Problem 12_Cont…
❖ Data : a= b= 150 mm, θ = 150°, dv = 56 mm, hmax = 20 mm, m= 0.3 kg, N = 500 rpm,
pb = 5 MPa, ps = 0.025 MPa, (𝑙1 /d1 ) = (𝑙2 /d2 ) = 1.25, σc = 50 MPa & τ = 42 MPa
❖ Tappet end: ➢ Pe = 944.14 N
Pe
✓ core dia.: σc = πd2 ✓nominal dia. d =
dc
c
4
0.84
4.90
50 =
944.14 =
0.84
πd2c
4 ∴ d = 5.83 ≈ 6 mm
∴ 𝐝𝐜 = 4.90 mm
✓ Outer dia. (𝐃𝟑 ) and depth (𝐭 𝟑 ) of boss = 2 d
= 2(6)
= 12 mm 172
 1. To store and release energy when needed during the work
cycle.

2. To reduce the power capacity of the electric motor or engine.

3. To reduce the amplitude of speed fluctuations.

Function of
Flywheel Flywheel does not maintain a constant speed but reduces
fluctuation of energy.

173
 1. Flywheel reduces the fluctuations of energy of the engine.
The governor controls the ‘mean’ speed of the engine by
Difference varying the fuel supply to the engine.
between 2. Flywheel has no influence on the ‘mean’ speed of the
Flywheel engine. It does not maintain a constant speed. Governor
and has no influence on ‘cyclic’ speed fluctuations.

Governor 3. Flywheel will be acting when engine is operated but

Governor is acting when speed is fluctuated due to
variation in load.
174
 4. A flywheel may not be used if the cyclic fluctuations of
energy output are small or negligible. A governor is
Difference essential for all types of engines to adjust the fuel supply as
between per the demand.
Flywheel 5. The kind of energy stored in flywheel is kinetic energy.
and The kinetic energy is all available, 100% convertible into

Governor work without friction. The governor mechanism involves

frictional losses.

175
 Flywheels are made of cast iron. From design considerations,
cast iron flywheels offer the following advantages:

 Cast iron flywheels are the cheapest.

Material of  Cast iron flywheel can be given any complex shape without
Flywheel involving machining operations.

 Cast iron flywheel has excellent ability to damp vibrations.

176
• Cast iron has poor tensile strength compared to steel. The failure of cast iron
flywheel is sudden and total. The machinability of cast iron flywheel is poor
compared to steel flywheel.
• More recently, flywheels are made of high strength steels and composites in
vehicle applications. Graphite-Fiber Reinforced Polymer (GFRP) is considered as
an excellent choice for flywheels fitted on modern car engines.

177
Types of Flywheel:

Solid Disk Flywheel Rimmed Flywheel

178
  The difference between the maximum and minimum speeds during
a cycle is called the maximum fluctuation of speed.

 The ratio of the maximum fluctuation of speed to the mean speed is

Coefficient called coefficient of fluctuation of speed.
of  Let N1 = Maximum speed in r.p.m. during the cycle,
Fluctuation N2 = Minimum speed in r.p.m. during the cycle, and

of Speed N = Mean speed in r.p.m.

𝑁1+𝑁2
=
2

179
• The coefficient of fluctuation of speed is a limiting factor in the design of
flywheel. It varies depending upon the nature of service to which the flywheel is
employed.

180
The reciprocal of coefficient of fluctuation of speed is known as coefficient of steadiness
and it is denoted by m.

181
  The fluctuation of energy may be determined by the turning
moment diagram for one complete cycle of operation.

 Consider a turning moment diagram for four stroke I. C.

Engine as shown in figure.
Fluctuation
of Energy

182
  The variations of energy above and below the mean
resisting torque line are called fluctuation of energy.

Fluctuation
of Energy

183
  A turning moment diagram for a compound steam engine
having three cylinders and the resultant turning moment
diagram is shown in figure.

 The resultant turning moment diagram is the sum of the

turning moment diagrams for the three cylinders.
Fluctuation
of Energy

184
  A turning moment diagram for a multi-cylinder engine is shown by a
wavy curve in Fig. The horizontal line AG represents the mean torque
line.

 These areas represent some quantity of energy which is either added or

subtracted from the energy of the moving parts of the engine.
Maximum
Fluctuation of
Energy

185
Maximum Fluctuation of Energy
Let the energy in the flywheel at A = E

186
  It is defined as the ratio of the maximum fluctuation of
energy to the work done per cycle.

Coefficient of
Fluctuation of
Energy

187
188
189
Energy Stored in a Flywheel:
 when a flywheel absorbs
energy its speed increases
and when it gives up energy
its speed decreases.

190
191
192
The turning moment diagram for a petrol engine is drawn to the following scales:
Turning moment, 1 mm = 5 N-m; Crank angle, 1 mm = 1º. The turning moment diagram repeats
itself at every half revolution of the engine and the areas above and below the mean turning
moment line, taken in order are 295, 685, 40, 340, 960, 270 mm2.
Determine the mass of 300 mm diameter flywheel rim when the coefficient of fluctuation of
speed is 0.3% and the engine runs at 1800 r.p.m. Also determine the cross-section of the rim
when the width of the rim is twice of thickness. Assume density of rim material as 7250 kg / m3.
Given data:
D = 300 mm or R = 150 mm = 0.15 m ;
ρ = 7250 kg / m3 , CS = 0.3% = 0.003 ;
N = 1800 r.p.m. or ω = 2 π × 1800 / 60 = 188.5 rad/s ; 193
194
195
Prof. Naitik L. Mehta

196