Ganpat University

U. V. Patel College of Engineering

Department of Mechanical Engineering
VII- Sem. Mechanical Engineering
2ME702 - Design of Mechanical Systems
Design of I.C. Engine Components
Tutorial: 3 Date:

Exa.1
Determine the diameter of cylinder, thickness of cylinder with re-boring allowance and
length of cylinder for a vertical four-stroke compression ignition engine from the
following data:
Brake power = 4.5 KW, speed = 1200 rpm, indicated mean effective pressure = 700
KN/m2, mechanical efficiency = 80 %, assume length of stroke is 1.1 times the diameter
of cylinder, the maximum explosion pressure is 8 times the indicated mean effective
pressure, For cast iron cylinder allowable strength is 60 MPa and Poisson’s ratio is 0.21,
Take and , the tensile strength
of the cast iron is 130 MPa, the maximum side thrust is 10 % of the gas force, length of
cylinder is 1.25 times the stroke length. Calculate: (i) hoop stress produced in the cylinder
(ii) thermal stress (iii) Longitudinal tensile stress and (iv) maximum side thrust in the
cylinder.

Exa.2
Determine the thickness of the crown of an aluminium alloy piston for single acting four-
stroke engine on the basis of heat dissipation from the following data:
Piston diameter = 90 mm, Speed = 1500 rpm, Length of the stroke = 99 mm, Mean
effective pressure = 0.7 N/mm2, bsfc = 0.26 Kg/KWh, L/r ratio = 4, Heat conducted
through the piston crown = 10 % of heat generated during combustion, Calorific value of
the fuel = 42 MJ/Kg, Assume mechanical efficiency of engine as 80 %, Max. explosion
pressure is 8 times the mean effective pressure, allowable stress for aluminium alloy = 55
N/ mm2, Heat conductivity of the piston material = 1600 J/s m2 °C/ mm, take Tc – Te =
110 °C. Also calculates: (i) Indicated power (ii) Break power (iii) Fuel consumption (iv)
Heat supplied (v) heat flow rate.

Exa.3
Determine the thickness of the crown of an aluminium alloy piston for single acting four-
stroke engine on the basis of heat dissipation from the following data:
Piston diameter = 90 mm, Speed = 1500 rpm, Length of the stroke = 99 mm, Mean
effective pressure = 0.7 N/mm2, bsfc = 0.26 Kg/KWh, L/r ratio = 4, Heat conducted
through the piston crown = 10 % of heat generated during combustion, Calorific value of
the fuel = 42 MJ/kg, Assume mechanical efficiency of engine as 80 %, Max. explosion
pressure is 8 times the mean effective pressure, allowable stress for aluminium alloy = 55
N/ mm2, Heat conductivity of the piston material = 1600 J/s m2 °C/ mm, take Tc – Te =
110 °C. Also calculate: (i) Indicated power (ii) Break power (iii) Fuel consumption (iv)
Heat supplied (v) heat flow rate.
Exa.4
Design a connecting rod for a petrol engine from the following data:
Diameter of piston = 110 mm, mass of reciprocating parts = 2 kg, length of connecting
rod = 325 mm, stroke = 150 mm, speed = 1500 rpm with possible over speed upto 2500
rpm, compression ratio = 4:1, maximum explosion pressure, pc = 2.5 MPa. Take I section
for connecting rod. Consider width of flange B = 4t, height of I section H = 5t, web
thickness = t, factor of safety = 5, σcr = 460 N/mm2, Rankine constant for both ends
hinged, a = 1/6250, allowable bearing pressure = 15 N/mm2. Calculate: (i) the outer
diameter of the piston pin, (ii) length of the small end, (iii) inner diameter of the small
end, (iv) outer diameter of the small end, (v) diameter of the crank pin, (vi) length of the
crank pin, and (vii) thickness of bush. Assume suitable data wherever necessary. Here
given notations are as per usual practices.

Exa.5
Design a cast-iron piston for a single-cylinder, four stroke, with the following data:
Cylinder bore = 105 mm, stroke = 1.4 cylinder bore, maximum gas pressure = 5.2 MPa,
indicated mean effective pressure = 0.78 MPa, mechanical efficiency = 80%, fuel
consumption = 0.16 kg per brake power in KW per hour, high calorific value of fuel =
46300 KJ/kg, speed = 400 rpm, temperature at piston center = 425 , temperature at
piston edge = 225 , heat conductivity factor = 46.6 W/m/ for CI, heat dispersed
through top = 5.5% of heat produced, permissible tensile stress for piston = 30 MPa for
CI, pressure between rings and piston = 1.04 MPa, permissible tensile stress in rings = 80
MPa, permissible pressure on piston barrel = 0.4 MPa, permissible pressure on piston pin
= 18 MPa, permissible tensile stress in piston pin = 90 MPa.

Exa.6
Design a connecting rod for a petrol engine with the following data.
Piston diameter = 106 mm, weight of reciprocating parts = 22 N, length of the rod center
to center = 340 mm, stroke = 140 mm, RPM = 1600 with 50% overdrive, compression
ration = 7:1, estimated maximum explosion pressure = 2.5 MPa. Assume suitable data if
required.

Exa.7
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 gray cast
iron FG 200 ( ) and the factor of safety is 5. Determine the thickness of
the cylinder head.
Studs are used to fix the cylinder head to the cylinder and obtained a leak proof joint.
They are made of steel FeE 250 ( ) and the factor of safety is 5. Calculate:
(i) Number of studs
(ii) Nominal diameter of studs
(iii) Pitch of studs
Exa.8
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.

Exa.9
Design a connecting rod for a high-speed IC engine using the following data:
Cylinder bore = 125 mm, length of connecting rod = 300 mm, maximum gas pressure =
3.5 MPa, length of stroke = 125 mm, mass of reciprocating parts = 1.6 kg, engine speed =
2200 rpm. Assume suitable data and state the assumptions you made.

Subject Incharge:

Dr. B. P. Patel