Example 1. A four stroke diesel engine has the following specifications : Brake power = 5 kW ; Speed= 1200 rp.m. ; Indicated mean effective pressure = 0.35 N! mm? : 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. Solution. Given: B.2 = SkW = 5000 W; N= 1200 r.p.m. or n = N/2 = 600: P= 0.38 Nimm?: 1, = 80% = 0.8 1, Bore and length of cylinder Let D = Bore of the cylinder in mm, A = Cross-sectional area of the cylinder = ax Pont J =Length of the stroke in m. = 1.5 Dmm=1.5 D/1000m (Assume) ‘We know thatthe indicated power, LP = BP /n,, = $000 / 0.86250 W “We also know thatthe indicated power (IP), Ppl An _ 0.35X15Dx "Dx 600 250 = = 4.12103 ease 0 60x 1000%4 412s 108 (+ For four stroke engine, = 2) D = 6250 / 4.12 = 109 = 1517 « 10° or D= 115 mm Ans, and D=15 «15 =172.5 mm ‘Taking a clearance on both sides of the eylinder equal to 15% of the stroke, therefore length of the eylinder, L= 118 = 1.15 « 172) = 198 say 200 mm Ans. 2. Thickness of the cylinder head Since the maximum pressure ( p) in the engine cylinder is taken as 9 to 10 times the mean sfiective pressure ( p,,). therefore Iet us take P=9p,=9* 0.3 ‘We know that thickness of the eyelinder head, Cp _ 445 foax Dre 71s a BAS Taking 15 Nimm? 4, = 9.96 say 10 mm Ans. \1 and ¢, = 42 MPa = 42 Nima)3. Size of studs for the cylinder head Let d = Nominal diameter of the stud in mm, d, = Core diameter of the stud in mm. Itis usually taken as 0.84 d. G, = Tensile siress for the material of the stud which is usually nickel steel n, = Number of studs, ‘We know that the force acting on the cylinder head (or on the stds) = 4x Dex p= 4% a15)'3.15 = 32 702 N a ‘The number of studs (a,) are usually taken between 0.01 D+ 4 (Le, 0.01 « 15 +4=5.15) and 0.02 D+ 4 (4e. 0.02 « 154 = 63), Letus take m,=6. ‘We know that resisting forse offered by all the studs = nx Fd, yx 6, = 6x70 84d)? 65 = 216 °N iy (Taking 0, = 65 MPa= 65 Nimm) From equations (i) and (i), d? = 32 702/216= 151 d= 2.3 say 14mm, The pitch circle diameter of the studs (D,) is taken D + 3d, D, = 8 +3%14= 157 mm “We know that pitch of the studs _ mx Dy _ mx 157 = 822mm a, 6 ‘We know that for a leak-proof joint. the pitch of the studs should lic between 19Vd to 28.5. where dis the nominal diameter of the stud. . Minimum pitch of the studs = Nd = 19014 =71.1mm and maximum piteh of the studs 28.50 d = 28.5Vi4 = 106.6mm Since the pitch of the studs obtained above ({.¢. 82.2 mm) lies within 71.1 mm and 106.6 mm, therefore, size of the stud (d1) calculated above is satisfactory. d= 14mm Ans.Example 2. 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 ; Indicated mean effective pressure = 0.75 Nim ; Mechantcal effictency = 80% ; Fuel consumption = 0.15 kg per brake power per hour ; Higher calorific value of fuel = 42 x 10° k/kg ; Speed = 2000 p.m. Any other data required for the design may be assumed. Solution. Given : D= 100 mm ; = 125 mm = 0.125 m ; p=$ N/mm? ; p, = 0.75 Nimm?; My = 80% = 0.8 ; m= 0.15 kg /BP/h=41.7 x 10% kg /BP/s; HCV= 42 x 10° kJ Ske: N= 2000 rp.m. The dimensions for various components of the piston are determined as follows = 1. Piston head or crown The thickness of the piston head or crown is determined on the basis of strength as well as on the basis of heat dissipation and the larger of the two values is adopted. ‘We know that the thickness of piston head on the basis of strength, Bp. [3x $100)? 186, 16x38 (Taking G, for cast iron = 38 MPa = 38 N/mm?) 15.7 say 16mm Since the engine is a four stroke engine, therefore, the number of working strokes per minute, 2000 /2= 1000 n=N/2 and cross-sectional area of the cylinder, A= We know that indicated power, _ PmelsAsn Pe 60 = 12.27kW 2 Brake power, BP = IPx ty =‘We know that the heat flowing through the piston head, H=CxHCVxmx BP 05 = 42 = 108 » 41,7 « 10% = 9.8 = 0.86 kW = 860 W (aking C = 0.05) +. Thickness of the piston head on the basis of heat dissipation, H 860 2.56K(Te— Te) 12.56 46.6 x 220 Gz For east iron , k= 46.6 Win°C, and Te ~T; = 220°) ‘Taking the larger of the two values, we shall adopt f= 16mm Ans. Since the ratio of L./Dis 1.25, therefore a cup in the top of the piston head with a radius equal 10.0.7 D (te. 70 mm) is provided, ly = 0.0067m = 6.7mm 2. Radial ribs The radial ribs may be four in number, The thickness of the ribs varies from Gy/ 3 t0 &y/ 2. ©. Thickness of the ribs, f= 16/3 to 16 /2=5.33 to 8 mm. Let us adopt f ~ 7mm Ans. 3. Piston rings Lotus assume that there are total four rings (.¢. , = 4) out of which thiee are compression rings and one is an oil ring. ‘We know that the radial thickness of the piston rings, Spe x 0.035 DAF Ee ~ 100) (Taking p, = 0035 Nimm?, and c= 90 MPa) 4 4mm and axial thickness of the piston rings = 07 ttt, Let us adopt 6 =3mm‘We also know that the minimum axial thickness of the pistion ring, D 100 10m, 10x4 Thus the axial thickness of the piston ring as already caleulated (Le, ,= 3 mm)is satisfactory. Aus. The distance from the top of the piston to the first ring groove. ie. the width of the top land, = 2.5mm Dy = fegt0 1.2 f= 16 to 1.2 ¥ 16 mm = 16 to 19.2 mm and width of other ring lands, by = 0.75 fy to t, = 0.75 x 3 to 3mm=2.25 to 3mm Letus adopt b, = 18 mm; and b= 2.5 mm Ans. ‘We know that the gap between the fice ends of the ring, G, = 35 tod 423.5% 34 tod 34mm=119 to 13.6 mm and the gap when the ring is in the eylinder, G, = 0.002 Dto 0.004 D= 0.002 « 100 to 0.004 » 100 mm 2100.4 mm Let us adopt G,=12.8 mm: and G,= 0.3 mm Ans. 4. Piston barrel Since the radial depth of the piston ring grooves (6) is about 0.4 mm more than the radial thickness of the piston sings (4). therefore, b=1,+04=34+04=38 mm ‘We know thot the maximum thickness of barrel. 1, = 0.03 D+ +45 mm=0.03 x 100+3.8+45=113 mm and piston wall thickness towards the open end, f= 0.25 f 100.35 f= 0.25 «11.3 10 0.35» 11.3 =2.8 to 3.9mm Let us adopt t, 5. Piston skirt Let 1 = Length of the skict in mm. ‘We know that the maximum side thrust on the eylinder due to gas pressure ( p). Ba ee pane BOO cea seas x «(Taking w= 0.1) ‘We also know that the side thrust dute to bearing pressure on the piston barrel (7), R= p,* Dx 1= 0.45 «100 « 1= 45 1N (Taking p,= 0.45 Niu?) From above, we find that 45 [= 3928 or [= 3928 / 45 = 87.3 say 90 mm Aus. + Total length of the piston . L sength of the skirt + Length of the ring section + Top land = 1-4 G43b) +b, 0+ (4x 3 +3 x 3) + 18= 129 say 130 mm Ans,6, Piston pin Let dy = Outside diameter of the pin in mm, 1, = Length of pin in the bush of the small end of the connecting rod in sum, and Pp, = Bearing pressure at the small end of the connecting rod bushing in. ‘Nanm2, It value for bronze bushing is taken as 25 N/mm, ‘We know that load on the pin due to bearing pressure caring pressure x Bearing area = py * dy * I, 5 dy x OAS x 100 = 1125 dy N (Taking 0.45 D) ‘We also know that maximum load on the piston due to gas pressure or maximum gas load aD (100)? a MPO x5 =39275N From above, we find that 1125 d, = 39275 or d,=39275/ 1125=34.9 say 35 mm Ans. The inside diameter of the pin (d) is usually taken as 0.6 dy. d, = 0.6 x 35 = 21 mm Ans. Let the piston pin be made of heat treated alloy steel for which the bending stress (o,, Jmay be taken as 140 MPa. Now let us check the induced bending stress in the pin. ‘We know that maximum bending moment at the centre of the pin, a= PD. _ 392782100 _ 494 169 ‘We also know that maximum bending moment (IM), “eg yt cap 2 {@Y-@' |, o 6, — 491 x 108 / 3664 ~ 134 N/mm? or MPa, Since the induced bending stress in the pin is less than the permissible value of 140 MPa (ie. 140'N’mm’), therefore, the dimensions for the pin as calculated above (Le. dy = 35mm and d,=21 mm) are satisfactory. [=| op= 36640,