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(tH) =
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
t1 = D
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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
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CONNECTING ROD
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.
r = crank length, = 00
Fb = FI
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