DESIGN AND STRUCTURAL ANALYSIS OF IC ENGINE
COMPONENTS USING ANSYS
NAME – ARINDAM MAJUMDER
Under the Supervision of
CLASS – BME4
PROF. DR. SUSENJIT SARKAR SEC – A3
ROLL – 002011201115
ABSTRACT
Internal combustion engines play a pivotal role in various
industries, powering a wide array of vehicles and
machinery. Understanding the dynamic behaviour of
engine components is crucial for optimizing
performance, reliability, and efficiency. Among these
components, bearings serve as critical elements that
support rotating shafts, transmitting loads and
facilitating smooth operation.
The aim of the present paper is to identify the crucial
parameters for designing the components & after that
design the components and check, under certain
pressure the components are safe or not.
The applied pressure is 2.5MPA.
INTRODUCTION
The study is concerned with the dynamic behavior of
some specific components like pistons, connecting
rod, crank & bearing. Dynamic analysis involves
studying how these components move and interact
over time, considering factors such as forces,
accelerations, and velocities. The primary focus is on
understanding the forces that affect the mentioned
components.
The components taken for design the mechanism:
1. Piston
2. Piston pin
3. Connecting rod
4. crankshaft
5. Bearing
DESIGNED
COMPONENTS
PROBLEM TAKEN AS REFERENCE
Design a center crankshaft for a single cylinder
vertical engine using the following data :
Cylinder bore = 125 mm
(L/r) ratio = 4.5
Maximum gas pressure = 2.5 Mpa
Length of stroke = 150 mm
The torque on the crankshaft is maximum when
the crank turns through 25 degree from the top
dead center and at this position the gas
pressure inside the cylinder is 2 Mpa.
DESIGN OF THE
COMPONENTS
PISTON :
Thickness of piston head = 14 mm
Thickness of the piston barrel (t3) =
13.05 mm
Radial width of ring = 4.4 mm
Axial thickness = 3.08 mm
Length of piston = 150 mm
Diameter of piston = 125 mm
Material = grey cast iron
Piston pin :
ength of piston pin = 56.25 mm
Outer dia of piston pin = 22 mm
nner dia of piston pin = 14 mm
Connecting rod :
Length of connecting rod : 337.5 mm
Inner dia of small end : 22 mm
Outer dia of small end : 44 mm
Inner dia of big end : 65 mm
Outer dia of big end : 98 mm
Crankshaft :
Diameter of crank pin : 65 mm
Length of crank pin : 65 mm
Thickness of crank web : 46 mm
Width of crank web : 75 mm
Diameter of crank shaft : 55 mm
Bearing :
l/d ratio is taken as 1
Length of bearing = 56 mm
Diameter of bearing = 56 mm
MOTION ANALYSIS OF THE ASSEMBLY :
Meshing of the components
A fine mesh is generated using ANSYS to divide the whole
section into many tetrahedral elements. This will enable us
to analyze the stress of the components at distinct
locations. A typical drawing of the meshing of the
Ic engine components is shown :-
Boundary Conditions
• The bearing end is fixed.
• pressure of 2.5 mpa is applied on the top of the piston.
Total Deformation Analysis
Grey cast iron
Max Deformation = 0.013256 mm
Strain Energy
Grey cast iron
Max Strain Energy = 0.00013501 j
Normal Stress
Grey cast iron
Max Normal Stress = 28.915 MPa
Shear Stress
Grey cast iron
Max Shear Stress = 16.569 MPa
Conclusion
So maximum deformation is experienced at the top of the
piston
value of maximum deformation = 0.013256 mm
The elongation experienced by the components are less and
can be used safely for the application.
Maximum strain energy in the components = 0.00013501 j
Maximum normal stress = 28.915 Mpa
The permissible stress is more than tha stress which is acting
so the component is safe.
Based on ANSYS analysis it clearly states that the design of
the components can sustain an applied pressure of 2.5 Mpa
hence the design is safe.
REFERENCES
[Link] Analysis and Optimization of Piston using CATIA and ANSYS,
[Link] Rajam1, P.V.K.Murthy2, [Link] Krishna3, [Link] Rao4
2. FEA of NX-11 unigraphics modeled connecting rod using different
Materials, Yadavalli Basavaraj, Raghavendra Joshi, G. Raghavendra Setty
3. Distortion Optimization of Engine Cylinder Liner Using
Spectrum Characterization and Parametric Analysis, Zhaohui Yang,1
Baotong Li,2 and Tianxiang Yu1
THANK YOU