SNS COLLEGE OF TECHNOLOGY

(An Autonomous Institution)

COIMBATORE-35

DEPARTMENT OF AUTOMOBILE
ENGINEERING

B.E. – AUTOMOBILE ENGINEERING

16AU302 – AUTOMOTIVE ENGINE COMPONENT DESIGN

DESIGN DATABOOK
DESIG\i OF PISTON

PISTON HEAD (OR) CROWN:

On the basis of first considera1io11 of strajning action,

Thickness of the piston head (tH) = ✓ 3pD /l 6cr 1

2
(in mm)

Where,

p = Maximum gas pressure or Explosion pressure in N/mm 2

D = cylinder bore or Outside Diameter of the piston in mm

cr 1 = Permissible bending stress for the material of the Piston in N/mm2 or Mpa

For,

Grey cast iron = 35 to 40 Mpa

Nickel Cast iron & Aluminum Alloy = 50 to 90Mpa 0

Forged alloy l = 60 to l 00 Mpa

on· the basis of second consideration of heat transfer,

-----�H�---- (in mm)

I 2. 5 6 k (Tc-TE)

Where,

H=Heat flowing through the Piston Head in Klis or Watts

k= Heat conductivity factor in W/m/ ° C

For-,

Grey Cast iron = 46.6 W/m/ ° C

Aluminum alloy =174.75 W/m/ ° C
Steel =51.25 W/m/ ° C

Tc= Temp at the centre of the Piston Head jn ° C

0 1
;.

T E = Temp at the edges of the Piston Head in °C

The temperature difference (Tc-T E) may be taken as,

Cast iron = 220 °C

Aluminum = 75 °C
The heat flowing through the Piston head (H) may be determined by the
following expression,

H = C*HCV*m*B.P in Kw

Where,

C= constant. Its Value is taken as 0.05

0

HCV=Higher calorific value of the fuel in KJ/Kg

For,

Diesel= ➔5 "' l 0 :: KJ, Kg.

Petrol = 47" 10 3 KJ!Kg.

m = Mass of the fuel used in Kg per Brake Power per second.

B.P = Brake power of the Engine.

B.P=I.P*ll m

Where,

I.P = {pm.L.A.n)/60000 (Watts)

P m =Indicated mean effective pressure

(The max .gas pressure (p) may be taken as 9 to 10 times the Indicated
mean effecti\·e pressure (pm).

L= Stroke length in mm.

A= Cross sectional area of the cylinder in mm2 =( n/4)*D 2

D = cylinder bore in mm

�-----
okes per min
n = Number of working str

= N, for two stroke engine

r.p.m)
(N=speed of the engine in
oer
thi ckness of the pis ton hea d (tH ) is c,1 icuiated by using two basis and lar:=
The
adopted.
of the values should be
9mm no ribs are required.
When ttt is greater than
are p r ovided to
than, then a suitable number of ribs
When tH is 9mm or less
ad.
strengthen the piston he

e th ick ne ss of th e rib s may be taken as tH/3 to ttt/2.

Th

DESIGN OF PI TON RINGS

PISTON RINGS
ring (t1) - D ✓ 3 pj cr 1
I . Radial thickness of the

D= Cylinder bore in mm, 2

re of ga s on the,cylin de r wa ll in N/mm
pw= Pressu
N/mm to 0.042 N/mn/
2
a Its value is limited from 0.025 0

ile) stress in Mpa.

Cit= Allowable bending (tens
pa to 110 Mpa for Cast iron Rings.
Its value may be tak�n from 85M

ial thickness (t ) of the rin gs may be taken as 0.7 t 1 to t1.

2. The ax 2
following
he mi nim um axi al thi ckness (t2 ) may also be obtained from the
T
Empirical relation.

Where,
nR =Number of rings
3. Width of th e top land,

d,
Width of the other ring lan

nds of the ring i s ,

The gap b etween the free e

the cylinde r,
The gap when the ring is in

G 2 =0.002D to 0.004D

PlSTON BARREL:

) of the pi ston barrel may be obtained from the

The maximum thickness (t 3
n.
following empirical relatio

t 3 =0.03D +t1 +4.9 mm

4 ) towards the open en
d,
The piston wall thickness (t
t4 =0.25 t3 to 0.35 t3

PISTON SKIRT:

the cylinder due to gas pressure,

The maximum side thrust on
2
R=µ*(n:/4)*D *p
Where,
µ=0.1
ma xim u m side thrust on the cyli
nder due to be.aring press-uce
we also kno w the
on the piston barrel (pb),
R = Pb *D*l
Where,

D= cylinder bore in mm
P = maximum gas pressure (or) explosion pressure in N/mn/
P b= Bearing pressure= 0.45 N/mm 2
l= le ngth of the piston skirt in 111111.

Total l ength of the piston,

L= l + (-1 t2 +3b 2 ) +b1

DESlGN OF PISTON PIN

Let,

do= outside diameter of the pin in mm

1 1 = Length of pin in the bush of the small end of the connecting rod in
mm
/= 0.-15D

P b1 = Bearing pressure at the small end of the connecting rod bu shino in

1 b
N/mm . Its value for bronze bushin g is taken as 25 N/mm-
2 0

We know that load on the pin due to bearing pressure

( Pb1 *do* 11 ,

We also know that max. Load on the piston due to gas pressure or max. Gas
load
= (11:/4)*D 2 *p

From the two equations we can find outer dia of the piston pin.

Inside diameter of the piston pin = 0.6·do

Let do and d i be the outside and inside dia of the piston pin. We know that the
section modulus,
4
/2=(n/32)* {(do) -( di )"; •do;

We know that maximum bending moment,

(We calculate allowable bending stress (cr b) for the material)

Where,
o b = allow'able bending stress for the material of the piston pin. Its
usually taken as 84 Mpa for Case hardened carbon steel and 140 Mpa for heat
treated alloy steel.

/M=P*D/8

Where,

P= (n/4)*D 2 *p
�

DESIGN OF CYLINDER HEAD

THICKNESS OF THE CYLINDER WALL

Let,
Do= Outside dia of the cylinder in mm
D = Inside dia of the cyl�nder in mm
p = maximum pressure inside the engine cylinder in N/ mn, 2
t = thickness of the cylinder wall in mm
1/m=Poisson's ratio. Its value is taken as 0.25
The apparent longitudinal stress is given by
o 1 =D 2 *p/ {(Do) 2 -(D) 2 }

The apparent circumferential stress is given by

oc=D*p*/2t

Net longitudinal stress = 01- crc (1/m)

Net circumferential stress = crc - 01 (1/m)

The thickness of the cylinder wall (t) usually taken from cylindrical
formula,

(i.e.) t= (p*D/2* Oc) +C

Where,

p= Maximum gas pressure inside the cylinder in N/mm 2

D = lnside dia of the cylinder or cylinder bore in mm

cr c= Permi�sible circum ferential or hoop stress for the cylinder material

in Mioa or N 1 111111-

Its value may be taken from 35 Mpa to 100 Mpa.

Depending upon the size and material of the cylinder.
C=Allowance for reboring.
Allowance for reboring for LC.Engine Cylinder

I
0

D
75 JOO ' 150 200 250 300 350 400 450 500
(mm)

I
I
2.4 4.0 6.3 8.0 9.5 11.0
(mm)
1.5
I 12.S 12.5 12.S

Thickness of the cyl�nder wall (t) may be obtained from the folla:.wing empirical
relation,

t= 0.0-l5 D-1.6 (in mm)

BORE AND LENGTH OF THE CYLINDER

Let,
P m= Indicated mean effective p1 �:-sure.
(The maximum gas pressure (p) may be taken as 9 to 10 times the
indicated mean effective pressure (P m)) ,

I= stroke length in mm

A=Cross sectional area of the cylinder in mm 2 =(n/4)*D 2

D= cylinder bore in mm

n=number of working strokes per min.

for two stroke engine

=): _
=N·2. for four stroke engine
(N=speed of the engine in r.p.m)

We know that the power produced inside the Engine cylinder,

�
I .P = (p 111 .L.A.n)/60 (Watts)

From thi::; expression, the bore (D) and the length of stroke (1) are determined.
. '

The leng1h of the stroke is generally as 1.25D to 2D.

Since there is a clearance on both sides of the cylinder, therefore length of the
cylinder is taken as 15% greater than the length of stroke.

Length of the cylinder (L) = 1.15 * length of stroke = 1. 15 * I

SfZE OF STUDS FOR THE CYLINDER HEAD

Let,
d= nominal dia of the stud in mm
dc= core dia of the stud in mm.Ir is usually taken as 0.84d.
cr 1 = Tensile stress for the material of the stud which is usually nickel
steel. It may be taken as 35 J\lpa ro 70 Mpa.
n 5 Number of studs
=

We know that the force acting on the cylinder head (or on the studs)
=(n/4)*D 2 *p

The number of studs (n 5 ) are usually taken between 0.010+4 and 0.02D+4

We know that the resisting force offered by all the studs

= n5 * (rr/4)*(dc) 2 * cr1 �

From the above equations we calculate the nominal dia of the stud

The pitch circle dia of the studs (D p ) is taken as D+3d

We know that Pitch of the studs,

=n* D pf n s

CYLINDER HEAD THICKNESS

The cylinder head may be approximately taken as a tlat circular plate whose
thickness (th ) may be determined from the following relation

t h=D* ✓ C*p/a c
Where,

________,
p= Maximum gas pressure (or) Explosion pressure in N/mm 2
D=cylinder bore (or) Outside diam eter of the Piston pin in mm

cr c= Allowable circumferential s tress in Mpa or N/mm 2

It may be taken as 30 Mpa to 50 Mpa

C = constant whose value is taken as 0.1

DESIGN OF CONNECTING ROD

The ":arious forces acting on the connecting rod are as follows,

I) Fore e on the piston due to gas pressure & inertia of the reciproca ting pans.
2) Foree due to inertia of the connecting rod or inertia bending forces.
'3) Fore e due to friction of the piston rings & of the piston.
4) Fore e due to friction of the piston bearings and the crankpin bearing.

DI1'1ENSIONS OF CROSS SECTION OF THE CONNECTING ROD

Let us consider an I - section of the connecting rod as shown in fig. with the
follo-\.'>·ing propornons.

Flange & \Veb thickness of the section = t

Width of the section = B = 4t

Depth or Height of the section =H=St

Fi r:--1 or al I icr us find whether the section chosen is sa6sfactor.y or not.

lxx = 4lvy

Where,

Ixx = Moment of inenia of the section about X-axis

I yy = Moment of inenia of the section about Y-axis

In actual practice, lxx is kept slightly less than 4 Ivv. It is usually taken be1,,·ee 11 3
and 3 .5 and the connecting rod is designed for buckling about X-axis.

Now for the section as shown in fig,

Area of the section= A=2(4t*t)-,- (J t*t) = 11t2

3
lxx = ( l/12) {4t*(5t) -3t*(3t) 3 l = (-ll9/!2)'"t -1

Ivv = 2*(l/12)*t*4t 3 + (l/12)*3t*t3 = (1.31. 12f' t.j

Since I xx/ In = 3.2, therefore the :-;ection chosen is quiet satisfactor y.

Now Jet us find the dimensions of this I-section. Since the coi:nectinl! rod i,-
,. -
designe d by taking the force on the connecting rod (Fe) equal to the max. On the
piston (F L ) due to gas pressure. Therefore,

Buckling load (W 8) may 'be calculated by using the following relation.

W 8 = Fc*Factor of safe ty

Where,
p= max. gas pressure (or) explosion pressure in N/mm 2

Factor of safety may be taken as 5 to 6

Now according to Rau)cjne's formula, we know.Buckling load ( \\' 8 ),

W 8= ____-=-cr,.._*�A,...._______

l + a (L/kxx/

Where,
a= constant

= 1/7500 for mild steel

= 1/9000 for \nought iro n

= 1/1600 for cast iron

nnecting rod = l
L= equivalent length of the co

crc= compressi\ e yield str ess

kxx� ✓ IxxfA
tion (t)
ations \\ e can fin d thickness of the sec
From the above two equ
end (or piston he ad) is taken as,
The dep_th near the small
.)

H 1 =0.75H to 0.9H
d (or crank end) is taken as,
The depth near the big en
0

H 2= 1.1 H to 1.25H
near the small end,
Dimensions of the section
= H 1 *B •

near the big end,

Dimensions of the section

K PIN OR BIG END BEARJNG

DIMENSIONS OF THE CRAN

Let,
or big end beari ng
de= Diameter of the crank pin '
big end bearing.
le= length of the crank pin or

= l .25dc to l .5dc
re
Pbc= Bearing pressu
1
= 7 N/mm to 12.5 N/mm
2

crank pin or big end bearing,

We know that load on the

--�--------
= dc*lc* Pbc

Since the crank pin or big end bearing is designed for the max. Gas force (F L ).
therefore equating the load on the crank pin or big end bearing to the max. Gas
force.

\Ve can find the Diameter & Length of the crank pin or big end bearing .
..
DIMENSIONS OF THE PISTON PIN OR SMALL END BEARING

Let,
dp= Diameter of the piston pin or small end bearing

Ip= Length of the piston pin or small end bearing.

= l .Sdp to 2dp

Pbp= Bearing pressure

=10.5 N/mm2 to 15 N/mm 2
\Ve know that load on the piston pin or small end bearing

=dp*lp* Pbp

Since the piston pin or small end bearing is designed for the Max. gas force
(F L )· therefore equating the load on the crank pin or small end bearing to the Max.
ps force

\Ve can find diameter and length of the piston pin or small end bearing.

SIZE OF BOLTS FOR SECURJNG THE BIG END CAP

.
Let,

d eb =Core diameter of the bolts

cr 1 = Allowable tensile stress for the material of the bolts
0

nb = Number of Bolts. Generally t,,·o bolls are L:scc.

We kn ow that force on the bolts

The bolts and the big end cap are subjected to tensile force which corresponds
10 the inertia force of the reciprocating parts at the top dead centre on the
cxhau-st stroke. We know that inertia force of the reciprocating pnrts,

Where,
m R= Mass of the reciprocating parts in Kg

co= Angular speed of the Engine in rad/s.

r = Rad ius of the crank in meters =stroke/2

l=length of the connecting rod in meters

Equaling the two equations we get core dia of the bolt.

The nominal or major dia (db ) of the bolt is given by,

>

THICKNESS OF THE BIG END CAP

Let,

tc=Thickness of the big end cap

bc= Width of the big end cap. Its valµe is equal to the length of the Crank"
pin or big end bearing (d b )
cr c=Allowable bending stress for the material of the cap.

Max. bending moment is taken as,

Where,

----� ----
centers
x= Distancc between the bolt
= Dia of crank pin or big end
bearing (dJ..,.. (2*thickness of r.carinl!� liner
Clearance (3mm)
(�111111)) + Nominal dia (db)+

�cction modulus for cap

(crb),
\\'c know that Bending stress

tc is obtained
I· rorn this equation the value

DESIGN OF SHAFTS
ng loads
Shi1 ns subjected to Fluctuati
bending and torsion,
\ ,haft subjected to combined

nt,
I he equivalent twisting mome
2 2
Tc== ✓ (Km*M) + (K,*T)
3
T e= (1t/l 6)*t*d
•
\\'hcrl!,

-c = Allowable sheer stress

we can find the diameter of the shaft
1-rom the above two equations

Casc-2
nt,
rh,: cqui valent bending mome
2 2
✓ (Km*M) + (K/T)
Mc= (l/2) ((Km*t-.1) -r

3
M c= (n/32)* crb * d

\\'here,
e stress
01,=Max.tensile or compressiv
we can find the diameter of the shaft
l·rnm the above two equations

-
e factor for Bci1ding
K 111 =combined shock&:. F ;,t:gu
e factor for torsion
K,::::; combined shock & Fatigu

--
Km K1
Nature of loads

llotat ing shafts,

ady load 1.5 1.0
l .Gr,ulu,1ly applied or Ste
with minor shocks 1.5 to 2.0 1.5 to 2.0
2.S uddenly applied load
major Shocks 2.0 to 3.0 1.5 to 3.0
3.So<Jdcnly applied with
I
I

ined torsional twist in and bend in moments

Sha ft£ sub· ected to comb

Case- I
ment.
The equivalent twisting mo
j

\\'IH;fC,

1 = Allowable shear stress

.
shaft
ions we can find the diameter of the
From the above two equat

ment,
The t;quivalent bending mo
Me = (l/2) {M+ sJ M2+T2
,
3
M .:= (n/32)* crb *d

>
ressive stress.
01,=Maximum tensile or comp
- •·----- ------------------------�-------
.1
.

.�
\L\TERI.-\LS FOR CYLINDER HEAD

A cylinder liner which does not have any direct contact with the engine
(\ioling \\'3tcr in known as dry liner. Cylinder liner \Vhich have its outer surface
i11 Jircct -:-0ntact \\·ith the engine cooling water it is knO\\·n as wet liner.
The cylinder liners are made from good quality close grained Cast iron
1.Pcarlitic Cast iron), Ni cast iron and Ni-Cr Cast iron. In some cases Ni-Cr Cast
s1ccl with Mo may be used. The liner surface of the liner should be properly
heat-treated in order to obtain a hard surface to reduce wear.

�-IA TERIA LS FOR PISTON

The most commonly used materials for pisron of LC.Engine are Cast
iron, Cast Al, Forged Al, Cast steel & Forged steel. The cast i ron Pistons are
used for moderately rated engines with Piston speeds below 6m/s and Al alloy
pistons are used for highly rated engines ru'nning at higher piston speeds.
'
· The co-efficient of thermal expans10n for A1 1s 0.24* 10· 6 m/ °C and for Cast
�
�! iron it is 0.1*10- 6 m/° C
The he.at conductivity for Al Pistons 174.75 W/m,·�c and for Cast iro n it is 46.6
\V/111/° C

The Density of Al is 2700 kg/111 3 and for Cast iron it is 1 200 kg/m3

�-1/\ TERIALS FOR PISTON'RINGS

These are usually made of grey cast-iron or alloy cast iron because of
their good wearing properties and also they retain spring characteristics even at
high temp.

\1ATERIALS FOR CONNECTING ROD

The connecting rods are usually manufaciured b� drop forging process

:ind it has adequate strength, stiffness and minimum ,,·eight. The material
mostly used for connecting rod varies from mild carbon steels (Having 0.35%
I\> 0.45% carbon) to alloy steels (Cr-Ni or Cr-Mo steels).
• ·.
K .,HAFTS
\1 :\Tl:RIALS FOR CRAN
stresses art? induced in the crank shaft
The following t1vo t) pes of
l . Bending stress
al moment on the shaft
2. Shear stress due to Torsion
only made from carbon steel, special steel or
The crank shafts are comm monly made from
rial engine the crankshaft� are com
'.)p�c1al Cast iron. In indust eng ines Mg Steels such
8) 55C8 and 60C4.In trnn�port
0
�arhnn steel such as 40C are generally used. In aero engines Ni-Cr steels
) 27M n2 and 37l\ !n2
as 20Mn2
Cr 1 Mo28 are generally used.
:,-u\,,'.:h ;1s 35Ni 1 Cr60,40Ni 2

DESIGN OF FLY\VHEEL
of speed
C,i �1 licicnt of Fluctuation
dif fer enc e betwe en the max and min speed during a cycle is called
rhc ed 10 the
1:c Flu ctu ati on of spe ed . The ratio o& the max Fluctuation of spe
tlH: n1:
ficient of Fluctuati on of speed.
1111.:.111 �.;)ccd is called Co-ef

of energy:
C ,H: llicicnt of Fluctuation
the max fluctuation of energy to the work
It is defined as the ratio of
d u m: per cycle.
y - Min.energy
�1.1:-.. Fluctuation
of energy (�E)= Max.energ

:--.ktlH)i.L:.l
E)= m*R"'l *co *C 5
2
ctuation of en erg y (
0 �
\I.,.._. Flu

Mass of the Flyv, heel in kg

1
Ill

volume*density = 2*1t*R* A*p 3

& fo � ¥·1 ·i�---
as 7260 kg /m
be taken
{ Density of cast iron may
111:1> IH.: taken as 78
00 kg/m )

t\ b*t

b- \vidth of the rim

i
t

3
t = thickness of the rim

( the ratio between which is usually taken as 2 )

I
R= Radius of Fly,,·heel.

ro = 2n*N/60 (N=speed)

Cs= Co-efficicnr of Fluctuation of speed = ro 1 -ro i/ro

Method -2

Max. Fluctuation of energy (6E) = C E * work done per cycle

Where,
C E= the Co-efficient of Fluctuation of energy
>
Work done per cycle (N/m) =P*60/N

P= engine power

�= speed in r.p.m

Method -3

Max. Fluctuation of energy (6E) = I*ro 2 *Cs

Tensile st1ess (0 1 J = p*v�1

Where,

v 2= Peripheral velocity
0

v = n*D*:--; 60 (we can find dia of the Flywheel)

Energy of the Fl),,·heel rim (E nm) = (J/2)*m* v 2

m = b*t*2 "' n "' R*p (find b & t)

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