(DESIGN OF I.C.

ENGINE COMPONANTS)
1. The cylinder of four stroke diesel engine has following specification

Stroke power = 3 Kw
Speed = 800 rpm
Indicated mean effective pressure = 0.3 Mpa
mech = 80 %

Ans.
Given data :Bp = 3 Kw = 3000 w
N = 8000 rpm
Pn = 0.3 mpa
= 80 %
1) cylinder bore :assumption of ratio of cylinder diameter is 1.5
D = cylinder bore
A = C/S area of cylinder
( D2 )
mm
4
Length of stroke =

N=

800
2

IP =

13 p
n

= 400 stroke / min.

pm /an
IP =
60
3750.05 =

( 1.5 D )
1800

3000
0.8

= 3750.05 w

pm 1.5 D
60 1000

0.3 1.5 D
60 1000

d2
(n )
4

)( )
2

)( )

d
( 400 )
4

1.5 10
2

) 0.78 D

= 5 10

1875 = 1170

D = 117 mm
L = 1.5 D = (1.5)(117)
L = 175.5 mm
l = 1.15 L
l = 205 mm

Ans.

Example 2
The following data given for the piston of a four stroke diesel engine.
Cylinder bore = 100 mm
Material of piston ring = gray cast iron
2
Allowable tensile stress = 90 N/ mm
Allowable radial pressure on well = 0.035 mm
No. of piston rings = 4
Calculate 1) radial width of piston rings
2) axial thickness of piston rings
3) gap between piston ring and assembly
4) gap between free end
5) thickness of piston barrel
6) thickness of piston barrel
Ans.GIVEN DATA :D = 100 mm
2
6t = 90 N / mm
2
Pw = 0.035 N / mm

Z=4
1. Radial width of piston ring
3 Pw
b =D
= 100
6t

3(0.035)
90

b = 3.41 mm
2. Axial thickness of piston rings
H = (0.7b) to b (0.7 3.441 ) to 3.41
H = 2.38 mm

Hmin =(

D
100
2 ) (
4
10
10 ) = 2.5 mm

3. Gap between free and of piston ring and assembly

G1 = 3.5 b to 4 b
3.5(3.41) to 4 (3.41)
G1 = 12 mm
4. Gap between free end of piston ring after assembly
G2 = 0.002 D to 0.004 b
= 0.002 (100) to 0.4
= 0.3
5. Width of top end
H1 = (th) + 0 (12+h)
= 16 +0 (1.2 16 )
= 16 to 19.2

6. Width of radial grooves

H2 = 0.75 h to oh
= 0.75 (3) to 3
H2 = 2.5 mm
7. Thickness of piston barrel
T3 = (0.03 D) + b +4.9
= 0.03 (100) + 3+4.9
T3 = 12 mm
8. Thickness of barrel of open
T4 = (0.25 t3 ) to ( 0.35 t3)
= (0.25 1.2 ) to (0.35 12)
T4 = 3 to 4.2

Example 3
The following data is given for COP and bolts of big end of connecting road .
Engine speed = 1500 rpm
Length of connecting road = 320 mm
Length of stroke = 140 mm
Mass of reciprocating parts =1.75 kg
Length of crank pin = 38 mm
2
Permissible tensile stress for bolt = 120 N/ mm

Permissible tensile stress for cop = 120 N/ mm

Calculate nominal :N = 1500 rpm

L = 320 mm
l = 140 mm
mr = 1.7 kg
de = 38 mm
le = 54 mm
2
6t = 120 N/ mm
2
6b = 120 N/ mm

1. Inertia force
r= (l/2) =
m = (l/r) =
w=(

140
2 = 70
320
70 m

N /m

= 4.57

2 N
2 1500
)
=
(
) = 157.07 rad/sec
60
60

2
(pi)max = mr w r ( 1 +

1
n )

= 1.7 (157.07) (0.070) (1 +

= 3669.80 N
2. Diameter of bolt

1
9 )

 dc
4

(pi)max = 2(
dc

) 6 + 3669.86

= 188.9

dc = 13.72
dc
d = 0.8 = 17.65
=20 m
3. Thickness of COP
Assume thickness of brass = 3
l = dia. Of crank pin + 2 (thickness of high) + (nominal dia. of bush) +
= 38 + 2(3) + 18 + 3
l = 65 mm

Mb =

( pi)max l
6

= 397756.16

tc

( 3 )
T=
/12
(6 t )

tc

( 3 )
=
/12
( 54 )

3
= 4.5 tc

V=

6b =

tc
2
MbY
I

6.5

= 3669.80

clearance

39756.16
3
120 = (
)(
45 tc

tc
2 )

Example 4
Design of an exhust valve for horizontal diseal enging using following data :
Cylinder bore = 250 mm , length of stroke = 300mm , engine speed = 600 mm , Maximum pressure =
4Mpa , set angle = 45 , mean velocity of gas through port = 50 m/s , Allowable bending stress value =
50 N/mm2
Calculate: 1) dia of vave port 2) dia of vave head 3) thickness of value head 4) dia value steam and ,
maximum lift of value.

GIVEN DATA :D = 250 mm

2
6b = 50 N/ mm

Pmax = 4 N/ mm

L = 300 mm
3

Vp = 50 10
Ns = 600 rpm

1. Dia. Of valve port (p)

Ns
V = 2 l ( 60 )
= 2 300 600/60
m
= 6000 sec


4
dp

2
2
dp p = /4 d v

50 10

= 250

6000

2. Dia. Of valve head

Co = 0.66 dp
= 45 = 0.06 90 = 54
w = 5.4
dy = dp + 2w = 90+ (254) = 100.8 mm
3. thickness of valve disk
dp
dp
ds = [ 8 + 6.35] to [ 8

+ 11 ] [m]

90
90
+
6.35]
to
[
8
8

+ 11 ] [m]

=[

= 17.6 to 22.25
= 20
4. max lift of valve
dp
hmax. = 4 cosd
=

90
4 cos 45

hmax = 31.82 mm