The internal combustion engine In an Internal Combustion Engine a supply of air-&-fuel mixture is fed to the inside of the cylinder

where it is compressed & then burnt. This internal combustion releases heat energy which is then converted into useful mechanical work as the high gas pressures generated force the piston to move along its stroke in the cylinder.It can be said therefore that a heat-engine is merely an energy transformer. To enable the piston movement to be harnessed the driving thrust on the piston is transmitted by means of a connecting-rod to a crankshaft whose function is to convert the linear piston motion in the cylinder to a rotary crankshaft movement !"ig. #.#-#$. The piston can thus be made to repeat its movement to & fro due to the constraints of the crankshaft crankpin%s circular path & the guiding cylinder. The backward-&-forward displacement of the piston is generally referred to as the reciprocating motion of the piston so these power units are also known as reciprocating engines &iston This is a pressure-tight cylindrical plunger which is sub'ected to the expanding gas pressure. Its function is to convert the gas pressure from combustion into a concentrated driving thrust along the connecting rod. It must therefore also act as a guide for the small end of the connecting-rod. Connecting (od )-The connecting rod !conrod$ is the 'oining element between piston & crankshaft. It is sub'ect to extreme tensile compression & flex stresses while it also houses the wristpin bushings & crankshaft bearings. Connecting-rod length is determined by the piston stroke & the counterweight radius* whereby the engine height can also be an important factor !usually the case in vehicle engines$.. Crankshaft + simple crankshaft consists of a circular-sectioned shaft which is bent or cranked to form two perpendicular crank-arms & an offset big-end 'ournal. The unbent part of the shaft provides the main 'ournals. The crankshaft is indirectly linked by the connecting-rod to the piston.This enables the straight line motion of the piston to be transformed into a rotary motion at the crankshaft about the main-'ournal axis. Operational Requirements Piston It should be silent in operation both during warm-up & the normal running. The design should be such that the sei,ure does not occur. It should offer sufficient resistance to corrosion due to some properties of combustion It should have the shortest possible length so as to decrease overall engine si,e. -aterial should have a high thermal conductivity for efficient heat transfer so that higher compression ratios may be used with out the occurrence of detonation. It must have a long life It should be lighter in weight so that inertia forces created by its reciprocating motion are minimum. The surface of the piston should be smooth & groove free. Crankshaft It must be capable of withstanding the intermittent variable loads acting on it. It should offer sufficient resistance to corrosion. It should have enough strength to withstand the forces to which it is sub'ected i.e. the bending & twisting moments. It should have enough rigidity to keep the distortion a minimum. It should have enough stiffness to minimi,e & resist the stresses due to torsional vibrations of the shaft. It should have sufficient mass properly distributed to see that it does not vibrate critically at the speeds at which it is operated.

It should have sufficient pro'ected areas of crankpins & 'ournals to keep down the bearing pressure to a value dependent on the lubrication available It should have minimum weight. Connecting Rod It must be able to withstand great power loads inspite of it%s low weight. It should have high strength in both tension & compression. It should have high fatigue strength. Material Selection Criteria Piston : &iston are exposed to very high temperature during operation due to direct contact with the combustion gases the piston head & the top land area reaches the maximum temperature.The energy from combustion heats the crown of the piston which gets gradually dissipated through the rings & skirt to the cylinder walls.+ll these factors calls for a very careful piston design. The materials selected for manufacturing pistons should meet below the criterion. .ood castability. .ood resistance to surface abrasion to reduced skirt & ring groove wears. .ood thermal conductivity to keep piston temperatures low. /igh hot strength. /igh strength-to-mass ratio. 0ow thermal expansion to maintain lower clearance between piston and cylinder walls. Crankshaft The crankshaft converts the reciprocating motion of the pistons conveyed to it by the connecting rods into rotary motion making effective tor1ue available at the crankshaft%s end. The forces acting upon the crankshaft are characteri,ed by highly variable periodicities & vary greatly according to location. These tor1ues & flex forces & the secondary vibrations which they generate all represent intense & highly complex stress factors for the crankshaft itself. The materials selected for manufacturing pistons should meet below the criterion. .ood -achinability /igh /ot 2trength /igh "atigue 2trength /igh Toughness /igh /ardness (esistance to fatigue in torsion & bending 0ow vibration (esistance to wear in the bearing areas Connecting Rod The connecting rod !conrod$ is the 'oining element between piston & crankshaft. It is sub'ect to extreme tensile compression & flex stresses. The materials selected for manufacturing pistons should meet below the criterion. /igh strength & stiffness to withstand the high loads in modern engines & to offer opportunities for downsi,ing & weight reduction Material For Piston :- l-Si-Cu-Mg llo! -aterial Characteristics)0owest density !34.5 g6cm7$ of all metallic constructional materials /igh specific strength .ood castability suitable for high pressure die-casting .ood machinability /igh thermal conductivity /igh dimensional stability .ood electromagnetic shielding property /igh damping characteristics

"ustification For Selection Of l-Si-Cu-Mg llo! For Piston +luminum has a density of only 4.5 g6cm7 approximately one-third as much as steel !5.87 g6cm7$ copper !8.97 g6cm7$ or brass !8.:7 g6cm7$. It displays excellent corrosion resistance in most environments including atmosphere water petrochemicals & many chemical systems.It also has excellent thermal conductivity about :; to <;= that of copper.+lso it is light in weight & has good fabricability. Material For Connecting Rod :- Spheroidi#ed $raphite Cast %ron -aterial Characteristics )0ow tooling & production cost .ood machinability without burring +bility to cast into complex shapes Excellent wear resistance /igh hardness /igh inherent damping capabilities .ood dry bearing 1ualities due to graphite "ustification For Selection Of Spheroidi#ed $raphite Cast %ron For Connecting Rod 2pheroidi,ed .raphite Cast Iron is more flexible & elastic as compared to Cast Iron. In it graphite is in the form of spherical nodules rather than flakes thus inhibiting the creation of cracks & providing the enhanced ductility.+lso it has improved corrosion resistance & improved resistance to high temperature oxidation.+lso it has superior mechanical properties at both elevated & low temperatures & controlled expansion. Material For Crankshaft :- luminium llo! -aterial Characteristics )/igh thermal conductivity /igh specific strength /igh dimensional stability /igh damping characteristics .ood machinability .ood electromagnetic shielding property .ood castability suitable for high pressure die-casting

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