Design of Piston

The following points to be considered in the design

of pistons for I.C. engines:
• Strength to resist the gas and inertia forces
• Dispersion of the heat of combustion
• Gas and oil sealing of the cylinder
• Bearing area sufficient to prevent undue wear
• Minimum weight
• Noiseless operation
• Resistance to mechanical and thermal dispersion
• Adequate support for a piston pin

1
 Design of Piston

The design of piston and its dimension are

determined by the
• Mechanical and thermal loads,
• Shape and arrangement of combustion branch
• The number of piston rings
• The presence of reinforcing ribs
• The thickness of piston crown

2
 Design of Piston

The thickness of piston head :

The thickness of piston head or top is calculated by
considering the strength criteria by using the equation

3pD2 p
t= = 0.43D
16 ft1 f t1

3
 Design of Piston

Where p = gas pressure, N/mm²

ft1 = permissible tensile stress, N/mm²

D = diameter of cylinder, mm

4
 Design of Piston
Piston rings:
Piston rings are provided at the head of the piston

The radial thickness of the piston rings is

3p w
tr  D
f t2

Where , pw = radial wall pressure, N/mm²

ft2 = permissible stress for the piston ring

5
 Design of Piston
The minimum radial thickness is given by

D
tr =
10  n
Where n = number of rings

= 3 to 4 for automobile and aircraft pistons

= 5 to 7 for stationary C.I. engine pistons

6
 Design of Piston

And axial thickness

ta = 0.7 tr to tr

Empirically, radial thickness t r = 0.029 to 0.33D

7
 Design of Piston

Piston barrel (skirt):

The maximum thickness of the piston barrel is given as

t1 = 0.03D + b + 4.72mm

where b = depth of ring groove on two sides

b = 2 ta + 0.4 mm

8
 Design of Piston

Length of the piston skirt

L = L1 + 2 n. ta + t
F
L1 = .
pb  D
where

F = bearing force between piston and cylinder

pb = bearing pressure

Empirically, length of piston barrel, L = D to 1.5D

9
 Design of Piston
Piston pin:
• Piston pin is designed for maximum gas pressure
• It is usually made hollow to reduce its weight
 D2
Maximum force on piston, F max  xp
4
Also F max = pb . l .do

Where, do = outside dia of pin, mm, l = length of pin

= 1.5 do for petrol engines
= 2 do for oil engines

10
 Design of Piston

Max B.M at the centre of the pin

Fmax .D
B.M Max = (i)
8
π  d 04 -di4 
Resisting B.M = f t .   (ii)
32  d 0 

Equating equation (i) & (ii) inner diameter of the pin may

be calculated for given valves of do , di. The induced stress

may be checked

11
 Design of Piston

Problem :
1. Design a piston for I.C. engine using the following data.

The diameter of cylinder bore is 300 mm and maximum

explosion pressure is 5 N/mm². The piston may have 4

compression rings and an oil ring

12
 Design of Piston
Permissible stress for piston = 27 N/mm²

Permissible stress for piston rings = 80 N/mm²

Radial wall pressure = 0.04N/mm²

Permissible bearing pressure for pin = 15 N/mm²

Permissible bending stress in pin = 85 N/mm²

Permissible pressure on piston barrel = 0.4 N/mm²

13
 Design of Piston

Solution :
Max. explosion pressure, p = 5 N/mm²
Diameter of cylinder bore, D = 300 mm
Max .force on piston, F max   D2
xp
4
  300 
2

 x5
4
= 353429 N

14
 Design of Piston

Piston head :
Thickness of piston head,
p
t = 0.43. D
f t1
5
= 0.43 × 300 x
27
= 55.5 mm = 56 mm

15
 Design of Piston
Piston rings : Radial thickness of piston rings

3Pw 3 x 0.04
tr = D x = 300 x
ft 2 80
= 11.62 mm
Axial thickness of piston rings
ta = 0.7 tr = 0.7 × 11.62 = 8.15 mm

Depth of ring groove on two sides ,

b = 2 ta + 0.4 mm

= (2×8.15) + 0.4 = 16.7 mm

16
 Design of Piston
Piston barrel :
Maximum thickness of barrel,
t1 = 0.03 D + b +4.72 mm
= 0.03 × 300 +16.7 + 4.72
= 30.42
= 30.45 mm
• Thickness of piston barrel may be reduced from top to
bottom
• The minimum thickness (t2) at the bottom (open end) is
0.25 times t1
t2 = 0.25 t1 = 0.25 × 30.45
= 7.62 mm
17
 Design of Piston
Effective side thrust on piston,
F = 0.1. F max = 0.1 ×353429
= 353429 N
Length of piston below the rings,
F 353429
L1 = =
pb  D (0.4 x 300)
= 294.5 mm
Length of piston,
L = L1 + 2n.ta + t
= 294.5 + 2×4× 8.15 + 56
= 415.7 mm
18
 Design of Piston
Piston pin :
Let l and do be the length and outside diameter of the pin
and l = 1.5do
Fmax = l.do.Pb
353429 = 1.5do x do x 15
Assume bearing pressure 10 to 15 N/mm2

353429
do2 =
1.5 x 15

19
 Design of Piston

353429
do =
1.5 x 15

= 125.33mm
= 125.5 mm (say)
l = 1.5do = 1.5 x 125.5
= 188.25 mm

20
 Design of Piston
Max B.M at the centre of pin
Fmax .D 353429 x 300
B.Mmax = =
8 8
= 13253588 N mm

π  d o 4 -d14 
Resisting B.M = f t .  
32  d o 

π 125.54 - d14 
32  125.5 
= 85 x

21
 Design of Piston
Resisting B.M = B.Mmax

π 125.54 - d14 
32   = 13253588
85 x
 125.5 
d14 = 18668524

d1 = 4 18668524= 65.73mm

Inside diameter d1 = 65.75 mm

22
 Quiz
3 pw
tr  D
f t2
1. The radial thickness of the piston ring is ____________

L= D to 1.5 D
2. Empirically length of piston barrel is ______________

23
 Connecting Rod

Function :
• Connecting rod is used to convert reciprocating motion
of the piston into rotary motion of the crank shaft

24
 Connecting Rod

Materials:
• It is made of drop forged steel or Aluminum alloy

25
Design of Connecting Rod

Fig 1

26
 Design of Connecting Rod

• Connecting rod is subjected to thrust load because

of gas pressure on the top of the piston

• The connecting rod can be treated as column with

pin ends

• Due to angular acceleration , the inertia force acts

transversely on connecting rod causing bending
moment on it

27
 Design of Connecting Rod
Let P = Force transmitted by piston
 2
= D p
4
Where, D = cylinder diameter, mm

p = maximum gas pressure N/mm²

Pc = Effective axial force (buckling load) derived

from gas Pressure

= (Factor of safety) ×P
Factor of safety may be taken as 4 for low speed
engines and 6 for high speed engines.

28
 Design of Connecting Rod

Rankine – Gordon formula can be used for design of cross

l
section since ( ) for connecting rod will not be large
k
f c .A c
Pc = 2
L
1+a  
K
Where L = Length of connecting rod
K = radius of gyration of Cross Section of
connection rod
a = constant
1
= for forged steel
7500
29
 Design of Connecting Rod

The dimensions of a long connecting rod may be obtained

by using the Euler’s formula
 2 EI
Pc = 2
l

Where l = Length of connecting rod

I = M.I. of given cross – section

E = Modulus of elasticity

30
 Quiz

1. The reciprocating motion of the Piston is converted to

connecting rod
rotary motion of crank shaft by _____________

2. Drop forging process is used for manufacturing of

__________
connecting rod

31
 Quiz

3. Connecting rods are usually of following cross section

a) Circular

b) I – section

c) H - section

d) All of the above

32
Design of Engine Valve

Fig 1 Parts of poppet valve

33
 Design of Engine Valve

Design calculations :
( a) diameter of valve,

d= D S
V

where D = Diameter of cylinder, mm

S = Mean speed of piston
= 90 to 225m/min.

34
 Design of Engine Valve
V = Velocity of gas/air through valve, m/min
= 7500 to 12000, m/min for gas valve

= 1500 to 1800, m/min for air valve

= 900 to 1350, m/min for exhaust valve

Taking average valves for S and V, the value of ‘d’ may be
obtained as :
d = 0.11D for gas valve
= 0.27D for air valve
= 0.34D for exhaust valve

35
 Design of Engine Valve

(b) Valve lift is calculated from the equation ,

d πd 2
( = πdh.cosα)
h = 4cosα 4

(c) Diameter of valve rod (stem)

d
+4mm
do = 8

36
 Design of Engine Valve
(d) Thickness of valve head

p mm
t = 0.5d
ft
where p = maximum gas pressure,N/mm2

ft = allowable stress in valve material, N/mm2

37
 Design of Engine Valve

Diameter of valve head ,

d1 = d+2b
where b = width of seating, mm
t
b=
tanα

Emperically,
b = 0.1 d + 4 mm

38
 Design of Engine Valve
Problem :
The valve of an I.C. engine is 60 mm in diameter and
is subjected to a maximum gas pressure of 4 N/mm2.
The safe bending stress in valve material is 45 N/mm2.
Determine
a) Thickness of valve head
b) Diameter of valve rod
c) Maximum lift of the valve
d) Width of seat
e) Diameter of valve head

39
 Design of Engine Valve

Solution :
a). Thickness of valve head
p 4
t = 0.5d = 0.5× 60
ft 45
= 8.95 mm

b). Diameter of valve rod,

d
do = + 4 = 60/8 + 4
8
= 11.5 mm

40
 Solution (contd..)

c). Maximum lift of the valve

d
h= Assume α = 30°
4cosα
= 17.32 mm
d). Width of seat,
t 8.95
b= =
tanα tan 30 o
= 15.5 mm
e). Diameter of valve head
d1 = d + 2b
= 60 + 2 × 15.5 = 91 mm
41
 Quiz

1. Formula of Diameter of valve ____________

2. Valve lift equation is ___________

3. Dia. Of valve rod equation is____________

4. Formula of thickness of valve head is_____________

42
 Design of Clutch

Torque transmitted by single plate clutch:

The axial thrust with which the contact surfaces are

held together is depends on the two conditions:

i) Uniform pressure

ii) Uniform wear

43
Uniform Pressure:
Consider a single friction surface as shown in figure.
Consider an elementary ring at radius r and having
radial thickness dr. If pressure is uniform, then axial
force on the ring
dw = p.2Пr.dr

44
 Uniform Pressure (contd..)
The frictional force caused by dw
dF = µ.p.2r. dr
Fictional torque ,dT = dF.r
= µp.2  r2. dr
r2

T = 2µp   dr
2
r
r1
T = 2µp  1  r 3
 r2
3

 3 
 
When pressure is uniformly distributed
W
P =  r2  r2 
1 2

2  r13  r23 
T  W  2 2 
3  r1  r2 
45
Uniform Wear:
To maintain uniform contact, the wear must be
uniform over the entire area, wear is proportional to the
product of pressure and rubbing velocity
wear α pv (V = ωr)
wear α p.r
wear = constant .pr
Since wear is uniform (CONSTANT) c = p. r
c
p=
r

46
 Uniform Wear (contd..)

Axial force on elementary ring

dw = p.2  r.dr
r2 r2

W=2  p.r.d
r1
r  2 c  d r
r1

= 2  c [r]r1r2 = 2  c (r1 – r2)

W
C=
2  r1  r2 
W
P=
2 r  r1  r2 
47
 Uniform Wear (contd..)
Frictional force on elemental ring
dF = µdw
= µ.p.2  rdr
Frictional torque on elemental ring
dT = µdw.r = 2  µp.r2.dr
r2
T=2µ

r1
p.r 2 dr


r2
T=
r1  r2
 r.dr
r1

T =(μ W/ r1-r2 )  r12  r22 

 2 
 r1  r2    
48
T= μw 2
 Uniform Wear (contd..)

The above equations can be summarized as

Frictional torque = T =μwrm

Where rm = mean radius

2  r13  r23 
rm =  for uniform pressure
3  r1  r2 

1
=  r1  r2  for uniform wear
2

49
 Design of Clutch

Torque transmitted by Multiplate clutch for uniform wear

T = nμw  r1  r2  
2
For Multiplate clutch, Let n – be number of Pair of contact
surfaces
Torque transmitted by Multiplate clutch For uniform
pressure
2  r13  r23 
n.   2 2 
T= 3  r1  r2 
If n1 = number of plates on driving shaft
n2 = number of plates on driven shaft
Then number of effective surfaces
50
n = n 1+n 2 -1
 Design of Clutch

Problem 1
For transmitting 15 kW power at 4000 RPM a single
plate clutch with both sides effective is to be designed
such that the outer radius is 1.5 times the inner radius.
Find the required dimensions of the friction lining.
Assume uniform wear conditions. The coefficient of
friction may be taken as 0.35 ; and intensity of
pressure as 0.25 N/mm²

51
 Design of Clutch
Solution :
Power, P = 15 KW

Speed, N=4000 RPM

2 NT
We know that P =
60

Friction torque, T = 15 × 10³ × 60 /2. π.4000 = 35.81 Nm

= 35810 Nmm

52
 Solution (contd..)

Let rı = outer radius

r2 = inner radius

For uniform wear, p.r = C

and the intensity of pressure is maximum at inner radius, r2

C = 0.25 r2

53
 Solution (contd..)

Load, W = 2 π C (r1 - r2)

= 2 π × 0.25 r2 (r1 – r2)

= 2 π × 0.25 r2²(1.5 – 1)

W = 0.786 r2²

54
 Solution (contd..)
Frictional torque,
  r1  r2  
T = n.μW  
 2 
1.5r2  r2 
= 2 x 0.35 x 0.786r22  
 2
35810 = 0.688 r2³

or r2 = 37.33 mm

and r1= 56 mm

55
 Quiz

1. Torque transmitted by single plate clutch (Uniform pressure)

2  r13  r23 
T    2 2 
 r1  r2 
is given by ____________
3

• Torque transmitted by single plate clutch (Uniform wear) is

  r1  r2  
T  W  
given by _____________
 2 

56
 Universal Joint – Function

• The two shafts having intersecting axes may be

connected by a universal joint or coupling

• Advantage in the use of this coupling is the angle

between the axes of the shafts may be altered while the
shafts are in motion

57
 Universal Joint – Function

• In the mechanism of a motor car universal joint or

couplings must be introduced between the gear box and
propeller shaft and in between propeller shaft and
differential

58
Design of Universal Joint

59
 Design of Universal Joint

• The proportions of the coupling are shown in the figure

• The shafts A and B are forked at the ends

• The joint is made by two pins of equal size

• These allows the forked ends to turn freely about

• Then the pin is in double shear

60
 Design of Universal Joint

The diameter ‘d’ can be calculated from

T= π/16 x f s x d3

T= 2 x π/4 x dp2 x f sp x d

where d = diameter of shaft

fsp = Allowable shear stress the pin

fs = Allowable shear stress the shaft

61
 Design of Universal Joint

Problem 1
In a universal joint a driving shaft transmits a torque of
5000 Nm to the driven shaft. Determine the suitable
diameter for the shaft and the pins.
Assume :
safe shear stress for shaft = 50 N/mm²
safe shear stress for shaft for pin = 25 N/mm²

62
 Design of Universal Joint
Solution :
Torque, T = 5000 × 10 ³ N/mm
Safe shear stress for shaft, fs = 50 N/mm²
 D3
T=( ).fs
16
or Diameter of shaft,

16 x 5000 x 103
D3
π x 50
= 79.86 mm
= 80 mm
63
 Solution (contd..)

Diameter of pins :
Resisting moment offered by pin,
d2 
 2   fs  D
 4 
or Diameter of pin,
5000 x 103 x 4
D
2. x 25 x 80
= 39.89 mm
= 40 mm

64
 Quiz

1. When two shafts have inter section axes they may be

Universal coupling
connected by a ___________________

2. The angles between the axes of the shafts may be

altered while the shafts are in motion
_________

65