Design of IC Engine Components

1. DESIGN OF IC ENGINE COMPONENTS
DR.MAHALINGAM COLLEGE OF ENGINEERING AND TECHNOLOGY, POLLACHI.
P.KARUPPUSAMY AP / AUTO
R.VISHNURAMESHKUMAR AP / AUTO
DEPARTMENT OF AUTOMOBILE ENGINEERING
Reference:
1. A text book of MACHINE DESIGN – R.S. KHURMI
2. Design of MACHINE ELEMENTS – V.B. BHANDARI
Year / Sem : III / VI
AY : 2018 – 19

2. UNIT – II
DESIGN OF PISTON
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3.  The piston is a disc which reciprocates within a cylinder.
 It is either moved by the fluid or it moves the fluid which enters the cylinder.
Function of a Piston:
 To receive the impulse from the expanding gas
 To transmit the energy to the crankshaft through the connecting rod.
 To disperse a large amount of heat from combustion chamber to cylinder walls.
ENGINE PISTON
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4. Piston Nomenclature (Trunk type)
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5.  The piston of internal combustion engines are usually of trunk type.
 Such pistons are open at one end.
A piston consists of the following parts :
1. Head or crown.
The piston head or crown may be flat, convex or concave depending upon the
design of combustion chamber.
To withstand the pressure of gas in the cylinder.
2. Piston rings.
To seal the cylinder in order to prevent leakage of the gas past the piston.
3. Skirt.
To acts as a bearing for the side thrust of the connecting rod on the walls of
cylinder.
4. Piston pin (gudgeon pin or wrist pin).
To connect the piston to the connecting rod.
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6. Materials Requirements for a Piston:
 To withstand the high gas pressure and inertia forces.
 To minimize the inertia forces.
 To disperse the heat of combustion.
 To withstand thermal and mechanical distortion.
 To possess good wearing qualities
 To have little or no tendency towards corrosion
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7. Cast iron Pistons vs. Aluminum Alloy Pistons
 The cast iron pistons are used for moderately rated engines with piston speeds below
6 m/s and aluminum alloy pistons are used for highly rated engines running at higher
piston speeds.
 Since the coefficient of thermal expansion for Al is about 2.5 times that of CI,
therefore, a greater clearance must be provided between the piston and the cylinder
wall (than with cast iron piston) in order to prevent seizing of the piston when engine
runs continuously under heavy loads.
 Since the Al alloys used for pistons have high heat conductivity (nearly four times
that of cast iron), therefore, these pistons ensure high rate of heat transfer and thus
keeps down the maximum temperature difference between the center and edges of the
piston head or crown.
 Since the Al alloys are about three times lighter than cast iron, therefore, its
mechanical strength is good at low temperatures, but they lose their strength (about
50%) at temperatures above 325°C.
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8. Material for Pistons:
The most commonly used materials for pistons of I.C. engines are
 cast iron
 cast aluminum
 forged aluminum
 cast steel
 forged steel
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9. Design Considerations for a Piston:
 Should have enormous strength to withstand the high gas pressure and inertia
forces.
 Should have minimum mass to minimize the inertia forces.
 Should form an effective gas and oil sealing of the cylinder.
 Should provide sufficient bearing area to prevent undue wear.
 Should disperse the heat of combustion quickly to the cylinder walls.
 Should have high speed reciprocation without noise.
 Should be of sufficient rigid construction to withstand thermal and mechanical
distortion.
 Should have sufficient support for the piston pin.
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10. Design of Piston
Design of piston consists of
1) Thickness of the Piston Head or Crown
2) Radial thickness & Axial thickness of Piston Rings
3) Thickness of Piston Barrel
4) Length of the Piston Skirt
5) Thickness of the Radial Ribs
6) Diameter of Piston Pin
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11. Piston for I.C. engines (Trunk type).
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12. Piston Head or Crown
Considerations:
1) It should have adequate strength to withstand the straining action due to pressure of
explosion inside the engine cylinder
2) It should dissipate the heat of combustion to the cylinder walls as quick as possible.
Assumptions:
1) Treat head as a flat circular plate of uniform thickness
2) Fixed at the outer edges
3) The head is subjected to a uniformly distributed load due to the gas pressure over the
entire cross-section
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13. Thickness of Piston: Strength Criterion
Grashoff’s Formula
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14. Thickness of Piston: Heat Dissipation Criterion
Heat absorbed by the piston due combustion =
Heat flow through head from center to cylinder wall
𝜋𝑟2
∗ 𝑞 =
𝑑𝑇
𝑑𝑟
∗ 𝑘 ∗ 2𝜋r * 𝑡 𝐻
Where, r – radius of piston (m)
q – heat flux flow from gases (W/m2)
T – temperature at the circumference with radius r, oC
𝑑𝑇
𝑑𝑟
- temperature gradient
k – heat conductivity, W/m oC
𝑑𝑇 =
𝑞
2𝑘 ∗ 𝑡 𝐻
𝑟 𝑑𝑟
Integrating from r =0 (@ piston center) & temperature Tc to r = D/2 & Temperature Te
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15. 𝑇𝑐 − 𝑇𝑒 =
𝐷2 𝑞
16 𝑘 𝑡 𝐻
𝑡 𝐻 =
𝐷2 𝑞
16 𝑘 (𝑇𝑐 − 𝑇𝑒)
If H = Heat flowing through the piston head in kJ/s or watts
𝑞 =
𝐻
𝜋
4 𝐷2
𝑡 𝐻 =
𝐻
4𝜋𝑘 𝑇𝑐 − 𝑇𝑒
k = Heat conductivity factor in W/m/°C. Its value is 46.6 W/m/°C for grey cast iron,
51.25 W/m/°C for steel and 174.75 W/m/°C for Al alloys.
(TC – TE) may be taken as 220°C for CI and 75°C for Al 15

16. The heat flowing through the positon head (H) may be determined by the following
expression, i.e.,
H = C × HCV × m × B.P.
Where, C = Constant representing that portion of the heat supplied to the engine
which is absorbed by the piston. Its value is usually taken as 0.05.
HCV = Higher calorific value of the fuel in kJ/kg.
It may be taken as 45 MJ/kg for diesel and
47 MJ/ kg for petrol,
m = Mass of the fuel used in kg per brake power per second, and
B.P. = Brake power of the engine per cylinder
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17. Notes :
1. The thickness of the piston head (tH) is calculated by using equations (i) and (ii) and larger
of the two values obtained should be adopted.
2. When tH is 6 mm or less, then no ribs are required to strengthen the piston head against
gas loads. But when tH is greater then 6 mm, then a suitable number of ribs at the center
line of the boss extending around the skirt should be provided to distribute the side thrust
from the connecting rod and thus to prevent distortion of the skirt. The thickness of the
ribs may be takes as tH / 3 to tH / 2.
3. For engines having length of stroke to cylinder bore (L / D) ratio upto 1.5, a cup is
provided in the top of the piston head with a radius equal to 0.7 D. This is done to
provide a space for combustion chamber
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18. Piston Rings
Function:
 To impart the necessary radial pressure to maintain the seal between the piston and
the cylinder bore.
Material Requirements:
 grey cast iron or alloy cast iron
 To good wearing properties
 To retain spring characteristics even at high temperatures
Material:
Types:
1) Compression rings or pressure rings
2) Oil control rings or oil scraper
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19. Compression Rings or Pressure Rings
 inserted in the grooves at the top portion of the piston
 may be three to seven in number
 transfer heat from the piston to the cylinder liner
 absorb some part of the piston fluctuation due to the side thrust.
Oil Control Rings or Oil Scrapers
 provided below the compression rings.
 These rings provide proper lubrication to the liner by allowing sufficient oil to move
up during upward stroke
 at the same time scraps the lubricating oil from the surface of the liner in order to
minimize the flow of the oil to the combustion chamber.
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20.  The compression rings are usually made of rectangular cross-section and the diameter
of the ring is slightly larger than the cylinder bore.
 A part of the ring is cut- off in order to permit it to go into the cylinder against the liner
wall.
 The diagonal cut or step cut ends, as shown in Fig.
 The gap between the ends should be sufficiently large when the ring is put cold so that
even at the highest temperature, the ends do not touch each other when the ring expands,
otherwise there might be buckling of the ring.
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21. 1) The radial thickness (t1) – considering radial pressure between cylinder wall and ring.
From bending stress consideration in the ring, the radial thickness is given by
2) The axial thickness (t2 ) of the rings may be taken as 0.7 t1 to t1
Piston Ring Design Calculation
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22. 3) The width of the top land (i.e. the distance from the top of the piston to the first ring groove)
is made larger than other ring lands to protect the top ring from high temperature conditions
existing at the top of the piston,
4) The width of other ring lands (i.e. the distance between the ring grooves) in the piston may
be made equal to or slightly less than the axial thickness of the ring (t2).
5) The depth of the ring grooves should be more than the depth of the ring so that the ring
does not take any piston side thrust.
6) The gap between the free ends of the ring is given by 3.5 t1 to 4 t1.
The gap, when the ring is in the cylinder, should be 0.002 D to 0.004 D.
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23. Piston Barrel
It is a cylindrical portion of the piston.
The maximum thickness (t3) of the piston barrel may be obtained from the following
empirical relation
t3 = 0.03 D + b + 4.5 mm
b = Radial depth of piston ring groove which is taken as 0.4 mm larger than the radial
thickness of the piston ring (t1)
b = t1 + 0.4 mm
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24. Piston Skirt
 The portion of the piston below the ring section is known as piston skirt.
 In acts as a bearing for the side thrust of the connecting rod.
 The length of the piston skirt should be such that the bearing pressure on the piston
barrel due to the side thrust does not exceed 0.25 N/mm2 of the projected area for low
speed engines and 0.5 N/mm2 for high speed engines.
 It may be noted that the maximum thrust will be during the expansion stroke.
 The side thrust (R) on the cylinder liner is usually taken as 1/10 of the maximum gas
load on the piston.
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25. Maximum gas load on the piston,
𝑃 = 𝑝 𝑚𝑎𝑥 ∗ 𝐴𝑟𝑒𝑎
Maximum side thrust on the cylinder
R = P/10
pmax = Maximum gas pressure in N/mm2, and
The side thrust (R) is also given by
R = Bearing pressure × Projected bearing area of the piston skirt
= pb × D × l
l = Length of the piston skirt
D = Cylinder bore
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26. In actual practice,
the length of the piston skirt (l) is taken as 0.65 to 0.8 times the cylinder bore (D).
Total length of the piston (L)
= Length of skirt + Length of ring section + Top land
The length of the piston (L) usually = D to 1.5 D.
 Longer piston - better bearing surface for quiet running of the engine,
 But it should not be made unnecessarily long as it will increase its own mass and thus the
inertia forces.
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PISTON PIN
 The piston pin (also called gudgeon pin or wrist pin) is used to connect the piston and
the connecting rod.
 It is usually made hollow and tapered on the inside, the smallest inside diameter being
at the centre of the pin, as shown.
Material used for the Piston Pin
 case hardened steel alloy containing nickel, chromium, molybdenum or vanadium
 Tensile strength – 710 MPa to 910 MPa.

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1. Full floating type piston pin
2. Semi Full floating type piston pin
 The connection between the piston pin and the small end of the connecting rod
PISTON PIN TYPES

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The piston pin should be designed for
 The maximum gas load or
 The inertia force of the piston
whichever is larger.
PISTON PIN DESIGN
CRITERIA FOR PISTON PIN DESIGN
1. Bearing Consideration
2. Bending Consideration

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1. Bearing Consideration
Length of the piston pin in the bush of the small
end of the connecting rod in mm
l1 = 0.45 D
load on the piston due
to gas pressure or gas
load
= load on the piston pin due
to bearing pressure or
bearing load
gas load =
=bearing load Bearing pressure × Bearing area
= pb1 × d0 × l1
d0 = outside diameter of the piston pin
Assuming, di = 0.6 do

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2. Bending Consideration
Checked in bending by assuming the gas load to be
uniformly distributed over the length l1 with supports at
the centre of the bosses at the two ends.

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33. Problem:
The following data is given for a four-stroke diesel engine:
Cylinder bore = 250 mm
Length of stroke = 300 mm
Speed = 600 rpm
Indicated mean effective pressure = 0.6 MPa
Mechanical efficiency = 80%
Maximum gas pressure = 4 MPa
Fuel consumption = 0.25 kg per BP per h
Higher calorific value of fuel = 44 000 kJ/kg
Assume that 5% of the total heat developed in the cylinder is transmitted by the piston.
The piston is made of grey cast iron (Sut = 200 N/mm2 and k = 46.6 W/m/°C) and
The factor of safety is 5.
The temperature difference between the center and the edge of the piston head is 220°C.
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34. (i) Calculate the thickness of piston head by strength consideration.
(ii) Calculate the thickness of piston head by thermal consideration
(iii) Which criterion decides the thickness of piston head?
(iv) State whether the ribs are required
(v) If so, calculate the number and thickness of piston rips.
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35. Given Data:
D = 250 mm = 0.25 m
l = 300 mm = 0.3
m = 600 rpm
pm= 0.6 MPa = 0.6 N/mm2
pmax = 4 MPa = 4 N/mm2
Ƞ = 80% = 0.8
Sut = 200 N/mm2
fs = 5
C = 0.05
m= 0.25 kg per BP per h
HCV = 44 000 kJ/kg
k = 46.6 W/m/°C (Tc - Te) = 220°C
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36. Design Procedure: Piston
(i) Calculate the thickness of piston head by strength consideration.
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37. (ii) Calculate the thickness of piston head by thermal consideration
(iii) Which criterion decides the thickness of piston head?
The criteria which has higher thickness
𝑡 𝐻 =
𝐻
4𝜋𝑘 𝑇𝑐 − 𝑇𝑒
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38. (iv) State whether the ribs are required
If
The ribs are required.
(v) If so, calculate the number and thickness of piston rips.
Assume, the no. of ribs = 4 to 6
Thickness of ribs
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39. 39

40. 40
Tutorial :
The Following data is given for the piston of a four-stroke diesel engine:
Cylinder bore = 250 mm
Material of piston rings = Grey cast iron
Allowable tensile stress = 100 N/mm2
Allowable radial pressure on cylinder wall = 0.03 MPa
Thickness of piston head = 42 mm
Number of piston rings = 4
Calculate:
(i) radial width of the piston rings;
(ii) axial thickness of the piston rings;
(iii) gap between the free ends of the piston ring before assembly;
(iv) gap between the free ends of the piston ring after assembly;
(v) width of the top land;
(vi) width of the ring grooves;
(vii) thickness of the piston barrel; and
(viii)thickness of the barrel at open end.

41. 41
Given Data:
D = 250 mm
σt = 100 N/mm2
pw = 0.03 MPa = 0.03 N/mm2
tH = 42 mm
z = 4

42. 1) The radial thickness (t1)
2) The axial thickness (t2 ) of the rings may be taken as 0.7 t1 to t1
Piston Ring Design Calculation
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t 2min = D / 10z

43. 5)
6)
3) The gap between the free ends = 3.5 t1 to 4 t1.
4) The gap, when the ring is in the cylinder(after assembly) = 0.002 D to 0.004 D.
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7) The thickness (t3) of the piston barrel t3 = 0.03 D + b + 4.5 mm
b = Radial depth of piston ring groove = t1 + 0.4 mm
8) The thickness (t4) of the piston barrel at open end
t4 = 0.35 t3 to 0.45 t3

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45. 45
The following data is given for the piston of a four-stroke diesel engine:
Cylinder bore = 250 mm
Maximum gas pressure = 4 MPa
Allowable bearing pressure for skirt = 0.4 MPa
Ratio of side thrust on liner to Maximum gas load on piston = 0.1
Width of top land = 45 mm
Width of ring grooves = 6 mm
Total number of piston rings = 4
Axial thickness of piston rings = 7 mm
Calculate:
(i) length of the skirt and
(ii) length of the piston

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47. 47
The following data is given for the piston of a four-stroke diesel engine:
Cylinder bore = 250 min
Maximum gas pressure = 4 MPa
Bearing pressure at small end of connecting rod = 15 Mpa
Length of piston pin in bush of small end = 0.45D
Ratio of inner to outer diameter of piston pin = 0.6
Mean diameter of piston boss = 1.4 x outer diameter of piston pin
Allowable bending stress for piston pin = 84 N/mm2
Calculate:
(i) outer diameter of the piston pin
(ii) inner diameter of the piston pin;
(iii) mean diameter of the piston boss;
(iv) check the design for bending stresses.

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Design a cast iron piston for a single acting four-stroke diesel engine with the following data:
Cylinder bore = 300 mm
Length of stroke = 450 mm
Speed = 300 rpm
Indicated mean effective pressure = 0.85 MPa
Maximum gas pressure = 5 MPa
Fuel consumption = 0.30 kg per BP per h
Higher calorific value of fuel = 44 000 kJ/kg
Assume suitable data if required and state the assumptions you make

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