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PISTON

PISTON HEAD OR CROWN


x To withstand gas load
Thickness of the piston head

(tH) =

Where p = max gas pressure or explosion


pressure in N/mm2
D = cylinder bore or outside dia of
piston in mm
= permissible bending or tensile
stress in N/mm2 or MPa =36

x For heat transfer

tH = mm
. ( )
Where H = heat flowing through piston head in watt
k = heat conductivity factor in W/m (For grey CI = 46.6 W/m , For Al alloy =
174.75 W/m , For steel = 51.25 W/m )
TC = temp. at center of the piston head , TE = temp. at edges of the piston head
TC TE = 220 for CI and 75 for Al

x Heat flowing through piston head


H = C X HCV X m X B.P. (in kW)
Where C = 0.05, HCV = 45 X 103 kJ/kg for diesel and 47 X 103 kJ/kg for petrol
m = mass of fuel in kg/kJ/s=3600
Note
x When tH < 6 mm no ribs are required
x for greater than 6 mm thickness of ribs may be taken as tH /3 to tH /2=0.4 tH
x For engines having L/D < 1.5 cup is provided on the piston head with a radius equal
to 0.7D
x
PISTON RINGS
x Radial thickness of the piston ring by considering the radial pressure between cyl.
wall and ring

t1 = D

Where D = cylinder bore in mm, pw = gas


pressure on cylinder wall in N/mm2 = 0.025 mm2
to 0.042 N/mm2, = allowable bending (tensile)
stress in MPa or N/mm2 =100

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x Axial thickness, t2 = 0.7t1 to 1t1 or D/(10nR) where nR = number of rings
x Width of top land, b1 = tH to 1.2tH
x Width of other ring lands, b2 = 0.75t2 to 1t2
x Gap between free ends of the ring, G1 = 3.5t1 to 4t1
x Gap when the ring is in the cylinder, G2 = 0.002D to 0.004D

PISTON BARREL
x Max thickness of piston, t3 = 0.03D+b+4.5 mm
Where b = t1+0.04 mm (radial depth)
x Piston wall thickness towards open end, t4 = 0.25t3 to 0.35t3

PISTON SKIRT
x Max side thrust on cylinder due to gas pressure, R = X Xp N
Where = 0.1 (coefficient of friction)
x Length of the piston skirt, l =
Where R = max side thrust in N, pb = bearing pressure = 0.45 N/mm2
x Total length of piston, L = Length of skirt (l) + Length of ring section (4t2+3b2) + Top
land (b1)

PISTON PIN
x Outside diameter of pin, d0 = (mm)
Where pb1 = 25 N/mm2 (Bearing pressure at small
end of connecting rod bushing)
l1 = length of pin in bush of the small end of
connecting rod = 0.45D mm
x Inside diameter of pin, di = 0.6d0

x Check = M/Z < 140


( )
Where M = N mm and Z =

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CONNECTING ROD

DIMENSION OF I SECTION OF THE CONNECTING ROD


x Flange and web thickness = t
x Width, B = 4t, Height, H = 5t
x IXX = 4Iyy , where Ixx = (419/12)t4 , Iyy =
(131/12)t4
x Force on the connecting rod or piston,

FC or FL = (N)
x Buckling load, WB = FC X FOS (Assume FOS = 4 to 6)
x Radius of gyration of the section about X axis, kxx2 = Ixx/A = 3.18t2
where A = 11t2 (L=l)
x Length of crank, r = Stroke of piston/2
x Rankines formula, WB =

Where a = 1/7500 for steel =1/1600 for CI =1/9000 for wrought iron, = 320 MPa
x Depth near big end, H1 = 1.1H to 1.25H
x Depth near piston end, H2 = 0.75H to 0.9H

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DIMENSIONS OF CRANKPIN OR BIG END BEARING AND
PISTON PIN OR SMALL END BEARING
Big end
x Load on the crankpin, Wc = dclcpbc
Where dc = dia of crankpin, lc = length of crankpin = 1.3dc, pbc = bearing pressure = 10
N/mm2 (if the value is not given)
FL = Wc
The big end has removable precision bearing shells of brass or bronze or steel with thin
lining (1 mm or less) of bearing metal such as babbit.

Small end
x Load on the piston pin, Wp = dplppbp
Where dp = dia of piston pin, lP = length of piston pin = 2dp, pbp = bearing pressure = 15
N/mm2 (if the value is not given)
FL = Wp
The small end bearing is usually a phosphor bronze bush of 3 mm thickness.

SIZE OF BOLTS FOR SECURING THE BIG END CAP


x Force on bolts, Fb =
Where dcb = core diameter of the bolts, = allowable tensile stress of bolts = 120 N/mm2
nb = number of bolts = 2; db= dcb /0.84
x Inertia force of the reciprocating parts, FI = ( + )
where mR = mass of reciprocating parts in kg, = Angular acceleration in rad/s2=2 N/60

r = crank length, = 00
Fb = FI

THICKNESS OF BIG END CAP


x Maximum bending moment on cap, Mc = FI . x/6
Where x = distance between bolt centre = dia of crank pin + 2 X Thickness of bearing liner
+ Nominal dia of bolt + clearance
= dc + 2 X 3 + db + 3 mm (dc= lP)
x Section modulus of cap, Zc = bctc2/6
x = Mc/Zc

x Check:
Mass of connecting rod per metre length, m1 = Al
(assume = 8000 kg/m3) ( l is in m)(A=11t2)
Max bending moment, Mmax = m1 r ( r is in m)

Zxx = 2Ixx/5t
= Mmax/Zxx

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CYLINDER BLOCK
x Thickness of cylinder wall, t = 0.045D + 1.6 mm
x Thickness of dry liner = 0.03D to 0.035D
x Thickness of water jacket wall = t/3 for big cylinder = 3t/4 for small cylinder
x Water space between outer cylinder wall and inner jacket wall = 0.08D + 6.5 mm

BORE AND LENGTH OF THE CYLINDER


x l = 60000 X I.P./pmAn
where l = length of stroke, pm = indicated mep, A = cylinder bore area
x Length of cylinder, L = 1.15l
The max gas pressure may be taken as 9 to 10 times the mep.

CYLINDER FLANGE AND STUDS


x Flange thickness, tf = 1.2t to 1.4t
x Core dia of the stud, dc = 0.84d
Where d = nominal dia of stud
x dc2 = D2p/ns
where ns = number of studs = 0.01D + 4 to 0.02D + 4 mm
p = max pressure, = 35 to 70 MPa
x Pitch of the stud = , Dp = pitch circle diameter = D + 3d

Pitch of the studs lie between 19 to 28


Note: The major dia of the stud (d) lies between 0.75tf to tf . In no case bolt less than 16 mm
should be used. Distance of flange from the centre of the hole of the bolt or stud should lie
between d+6 and 1.5d.
CYLINDER HEAD
x Thickness of head, tH =

Where C = 0.1, = 30 to 50 MPa

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