Problems of Practices

Of
Machine Design
I.C. Engine Parts
Prepared By

Brij Bhooshan
Asst. Professor
B. S. A. College of Engg. And Technology
Mathura, Uttar Pradesh, (India)

Supported By:
Purvi Bhooshan

Please welcome for any correction or misprint in the entire manuscript and your
valuable suggestions kindly mail us brijrbedu@gmail.com.

1. An automobile engine has a bore of 150 mm and stroke of 150 mm. It is expected
that the engine would develop a maximum pressure of 32.0 kg/cm2 and the engine
would run at a speed of 1100 r.p.m. The connecting rod length to crank radius ratio
is 5.0. Find the dimensions of the I-section connecting rod to be used for a safety
factor of 8 and made of medium carbon steel. The I-section cross-section be taken
as 6t x 4t, where t = flange and wed thickness. Assume that the yield strength of
steel is 3500 kg/cm2 and E = 2.0 x 106 kg/cm2.
Weight of the reciprocating parts of the engine = 0.03 kg/cm2 of piston area. Any
data not given-can be assumed suitably.
2. An equal angle section 100 mm × 100 mm × 8 mm is welded to a gusset plate to
serve as a tension member. Calculate the minimum amount of overlapping by the
angle section on the gusset plate with a view to limit the induced stress to 100
mega pascal in the angle section when only the side welds are used. The effective
area of angle may be taken as the area of the connected leg plus half the area of the
unconnected leg. The safe stress in the weld is 90 mega pascal and the shock factor
is 1.5.
3. Data given below refer to a single cylinder 4-stroke I.C. engine.
Find the suitable dimensions of cross-section of the connecting rod under gas load
and check the design under inertia load due to the self-weight of the connecting rod
OR find the suitable dimensions of crank web of a centre crank for the engine.

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2 Problems of Practices on I. C. Engine Parts

Cylinder diameter = 110 mm

Stroke = 160 mm
Power = 10 kW at 800 rpm
Max. explosion pressure = 2.2 MPa (22 kgf/cm2) at TDC
Length of connecting rod = 360 mm
At max. torque position gas pressure = 1.2 MPa (12 kgf/cm2) at  = 40°
Mass of reciprocating parts = 2 kg
Density of connecting rod material = 7.2 kg per 1000 cm3.
Draw neat sketch, wherever necessary.
4. A connecting rod is required to be designed for a high speed, four stroke I.C.
engine. The following data are available.
Diameter of piston = 88 mm.
Mass of reciprocating parts = 1.6 kg
Length of connecting rod (centre to centre) = 300mm
Stroke = 125 mm
R.P.M. = 2200 (when developing 50kw)
Compressing ratio = 6.8:1 (approximately)
Probable maximum explosion pressure (assumed shortly after dead centre, say
at about 3°) = 3.5 N/mm2.
5. Design a cast iron piston for a single acting four stroke engine for the following:
Cylinder bore = 100 mm
Stroke = 120 mm
Max. gas pressure = 5 N/ mm2
Brake mean effective pressure = 0.65 N/mm2
Fuel consumption = 0.227 kg/kW/hr
Speed =2200 rpm
Assume suitable data if required.
6. Design a connecting rod for four stroke petrol engine with the following data:
Piston diameter = 0.10 m
Stroke = 0.14 m
Length of connecting rod, centre to centre = 0.315m
Weight of reciprocating parts = 18.2 N
Speed = 1500 rpm with possible over speed of 2500
Compressor ratio = 4:1,
Probable Max explosion pressure = 2.45 MPa.
7. Determine the thickness of a cast iron cylinder wall and the stresses for a 250 mm
petrol engine with a maximum gas pressure of 3.0 N/mm2. Take the reboring factor
for the cylinder wall as 7.5 mm and Poisson ratio as 0.25 for cylinder material.
Take maximum hoop stress as 45 MPa for the material.
8. Find the thickness of a piston crown for a four stroke engine developing power at
1500 rpm. Other relevant data for the engine are given as:
(1) piston diameter = 87 mm
(2) length of the stroke = 96 mm
(3) mean effective pressure = 0.7 N/mm2
(4) bsfc = 0.26 kg/kW/h
(5) L/r ratio = 4
(6) heat conducted through the crown = 10% of heat generated during

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 Problems of Practices of Machine Design By Brij Bhooshan 3

combustion.
(7) Calorific value of fuel = 42 MJ/kg
Assume that the piston is made of aluminum alloy with thermal conductivity 1600
J/sm2 ° c/mm and allowed temperature difference is 111 °C.
9. Design a connecting rod for a four stroke petrol engine with the following data:
Piston dia = 0.10 m;
stroke = 0.14 m;
Length of connecting rod (centre to centre) = 0.315 m.
Wt. of reciprocating parts = 18.2 N
speed = 1500 rpm
Compression ratio = 4:1
Max. explosion pressure = 2.45 Mpa.
10. Design a centre crank for a double acting steam engine running at 150 rpm with a
stroke of 0.35 m. The overhung flywheel weights 22.70 kN and the connecting rod
force 'F' at dead centre is 45.40 kN. The engine is vertical.
11. Determine the diameter of the piston rod for a steam cylinder 1.50 m in diameter,
in which the greatest difference of pressure on the two sides of the piston is 0.2 M
Pa. Length of the rod is 2.8 m. Factor of safety is 8.
12. Determine the cross section of I section connecting rod for a single cylinder IC
engine.
Following data are provided for the engine:
(1) Piston diameter = 100 mm
(2) mass of reciprocating parts = 2.25 kg
(3) length of connecting rod = 300 mm
(4) stroke length = 125 mm
(5) speed = 1500 rpm
(6) maximum explosion pressure = 3.5N/mm2
(7) factor of safety =7
(8) density of rod material = 8000 kg/m3
(9) yield stress in compression = 330 MPa
Assume width of section as 4t and depth as 5t, where t is the web thickness of I
section.
13. A cast iron piston tor single acting tour stroke engine for the following
applications:
(1) Cyliner bore = 100 mm
(2) Stroke = 120 mm
(3) maximum gas pressure = 5 N/mm2
(4) break mean effective pressure = 0.65 N/mm2
(5) fuel consumption = 0.227 kg/k W/h
(6) Speed = 2200 rpm
Find the suitable thickness of the piston head. Thermal conductivity for cast Iron is
460 J/s m2 °c/m and allowable temperature difference is 222°C.
14. Design a connecting road for 4 stroke petrol engine, with the following data:
Piston diameter = 0.10 m
stroke length = 0.15 m
Length of connecting rod (centre to centre) = 0.30 m
Weight of reciprocating parts = 20 N

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4 Problems of Practices on I. C. Engine Parts

Speed is 1500 rpm with possible overspeed of 2500 rpm

Compression ratio = 4:1
Maximum Explosion pressure = 2.5 MPa.
15. Design a piston for a single acting four stroke engine for the following
specifications:
Cylinder bore = 0.30 m
Stroke length = 0.375 m
Maximum gas pressure = 8 MPa
Brake mean effective pressure = 1.15 MPa
Fuel consumption = 0.22 kg/kW/hr.
Speed = 500 rpm
Assume suitable data.
16. A 4 stroke diesel engine has the following specifications:
Brake power = 5 kW
Speed = 1200 rpm
Indicated mean effective = 0.35 N/mm2 Pressure
Mechanical efficiency = 80%
Determine the bore and length of the cylinder and thickness of cylinder head.
17. A four stroke IC engine is developing 50 kW power at 2200 rpm for which a
connecting rod is required to be designed for the following data:
Piston diameter = 90 mm
Mass of reciprocating parts = 1.5 kg
Length of connecting rod between the two centres = 300 mm
Stroke length = 125 mm
Approximate compression ratio = 6.8:1
Maximum explosion pressure shortly after dead centre = 3.5 N/mm2.
18. Design an aluminium alloy piston for a single acting four stroke engine for the
following specifications:
Cylinder bore = 0.30 m
Stroke = 0.375 m
Maximum gas pressure = 8 MPa
Brake mean effective pressure = 1.15 MPa
Fuel consumption = 0.22kg/kW/hr
Speed = 500 rpm
19. A four stroke petrol engine has following data:
Piston diameter = 100 mm
Stroke = 150 mm
Length of connecting rod = 315 nun
Weight of reciprocating parts = 18.2 N
Speed = 1500 rpm
Compression ratio = 4:1
Maximum explosion pressure = 2.40 MPa
Determine the size of rod cross section, dimensions of big and small ends of the
connecting rod and size of bolts for big end cap.
20. The cylinder of a slow speed steam engine is 250 mm diameter and the steam
pressure 1 N/mm2. The piston rod length is 1000 mm and the connecting rod is 1.2
m long. The engine stroke is 550 mm. Determine the dimensions of the cross
section of the connecting rod assuming the depth to be twice as thickness and a
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 Problems of Practices of Machine Design By Brij Bhooshan 5

suitable diameter for the piston rod.

21. A four stroke diesel engine has the following specifications:
Brake power : 12 kW
Speed : 1500 rpm
Indicated MEP : 0.35 N/mm2
Mechanical efficiency : 80%
Determine :
(i) bore and length of the cylinder,
(ii) thickness of the cylinder head, and
(iii) size of stud for the cylinder head
22. Design a connecting rod for a Petrol Engine from the following data:
Diameter of piston =110 mm
Mass of reciprocating parts, m = 2 kg
Length of connecting rod, l = 325 mm
Stroke =150 mm
Compression ratio = 4:1
Speed = 1500 rpm with possible over speed of 2500 rpm
Maximum explosion pressure = 2.5 MPA.
23. Design a Cast Iron Piston for a single acting four stroke engine for following data:
Cylinder bore = 90 mm
Stroke = 120 mm
Maximum gas pressure = 5 N/mm2
Mean effective pressure = 0.75 N/mm2
Mechanical efficiency = 80%
Fuel consumption = 0.2 Kg per Brake power per hour
Higher Calorific value of fuel= 43 × 103 kJ/Kg
Speed = 2000 RPM
Any other data required for the design may be assumed.
24. Design an aluminium alloy piston for a single acting four stroke engine, for the
following specification:
Cylinder bore = 0.40 m;
Break mean effective pressure = 2.5MPa
Stroke = 0.480 m;
Fuel consumption = 0.36 kg/ kW/hr
Maximum gas pressure = 10 MPa;
Speed = 900 r.p.m
25. Design a connecting rod for 4 stroke petrol engine with the following data:
Piston diameter = 0.20 m
Stroke length = 0.30 m
Length of connecting rod (centre to centre) = 50 m
Weight of reciprocating parts = 50 N
Speed is 1440 r.p.m with possible overspeed of 3000 r.p.m
Compression ratio = 3:1
Maximum explosion pressure = 3 MPa.
26. A four stroke diesel engine has the following specifications:
Brake power = 5 kW; Speed = 1200 rpm; Indicated mean effective pressure = 0.35
N/mm2; Mechanical efficiency = 80 %.
Determine: 1. Bore and length of the cylinder; 2 thickness of the cylinder head; and
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6 Problems of Practices on I. C. Engine Parts

3. Size of studs for the cylinder head.

27. Design a cast iron for a single acting four stroke engine for the following data:
Cylinder bore = 100 mm; Stroke = 125 mm; Maximum gas pressure = 5 N/mm2;
Indicated mean effective pressure = 0.75 N/mm2; Mechanical efficiency = 80%; Fuel
consumption = 0.15 kg per brake power per hour; Higher calorific value if fuel = 42
 103 kJ/kg; Speed=2250 rpm.
28. The bore of a cylinder of the four stroke diesel engine is 150 mm. The maximum
gas pressure inside the cylinder is limited to 3.5 Mpa. The cylinder head is made of
grey cast iron FG 200 (ut = 200 N/mm2) and the FOS is 5. Determine the thickness
of the cylinder head. Studs is made of steel FeE 250 (yt = 250 N/mm2) and the FOS
is 5. Calculate:
(i) Number of studs
(ii) Nominal diameter of studs
(iii) Pitch of studs
29. Determine the dimensions of cross-sections of the connecting rod (I-section), for a
diesel engine with the following data:
(i) Cylinder bore = 100 mm
(ii) Length of connecting rod = 320 mm
(iii) Maximum gas pressure = 2.45 Mpa
(iv) FOS against buckling failure = 5.
30. A four stroke diesel engine has the following specifications:
Brake power = 5 kW; Speed = 1200 r.p.m.; Indicated mean effective pressure = 0.35
N/mm2; Mechanical efficiency = 80 %.
Determine: 1. bore and length of the cylinder; 2. thickness of the cylinder head; and
3. size of studs for the cylinder head.
31. Design a cast iron piston for a single acting four stroke engine for the following
data:
Cylinder bore = 100 mm; Stroke = 125 mm; Maximum gas pressure = 5 N/mm 2;
Indicated mean effective pressure = 0.75 N/mm2; Mechanical efficiency = 80%; Fuel
consumption = 0.15 kg per brake power per hour; Higher calorific value of fuel = 42
× 103 kJ/kg ; Speed = 2000 r.p.m. Any other data required for the design may be
assumed.

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