THERMAL ENGINEERING

MINI PROJECT

TEAM: Group 7
NAYAN JOMI 20518061
NIKHIL ROSHAN KALATHIL 20518062
NISHANT GAURAV 20518063
PRATYUSH 20518064
RAHUL N S 20518065
RAMAKRISHNAN A S 20518066
RITHIK SHAJAN 20518068
ROSHAN SHAJU 20518069
DESIGN REPORT

SINGLE CYLINDER 15 kW
AIR COOLED DIESEL ENGINE

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 CONTENTS
Pg. No

1) Basic calculations and Assumptions………………….. 4

2) Designing of Cylinder………………………………… 5 - 7
a) Material Selection
b) Basic Calculations
c) Cylinder Design
3) Designing of Piston…………………………………… 8 - 10
a) Material Selection
b) Basic Calculations
c) Piston Design
4) Designing of Connecting Rod………………………… 11 - 14
a) Material Selection
b) Basic Calculations
c) Connecting Rod Design
5) Designing of Crank Shaft……………………………... 15 - 19
a) Material Selection
b) Basic Calculations
c) Crank shaft Design
6) Designing of Air cooling system……………………… 20 - 21
a) Material Selection
b) Basic Calculations
c) Air cooling System Design
6) Final Assembly………………………………………... 22 - 26

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BASIC CALCULATIONS AND ASSUPMTIONS

Brake Power (B.P) = 15 kW

Bore Diameter (D) = 78 mm
Stroke length (L) = 1.25D to 1.5D = 97.5 mm
Speed was taken to be 4500 rpm
Mechanical efficiency(ηm) was assumed to be 80%
Indicated power (I.P) = B.P/ ηm

∴ I.P = 0.8/15 = 18.75 kW

𝜋𝐷2
Area of cross section of Bore (A) = = 47.78 cm2
4

𝐼.𝑃×60
Pm = = 10.73 bar
𝐿𝐴𝑁

𝐵.𝑃×60
Break mean effective pressure (pmb) = = 4.29 bar
𝐿𝐴𝑁

Length of the Cylinder(Lc) = 1.15L = 112.12 mm

Clearance Length = Lc – L = 14.52 mm

𝜋𝐷2 𝐿
Swept Volume(Vs) = = 465.89 cc
4

𝜋𝐷2 Lc
Clearance Volume(Vc) = = 69.88 cc
4

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 DESIGNING OF CYLINDER
a) Material Selection

Gray Iron ASTM A48 Class 30 was selected as it has great vibration and sound
dampening properties. For this reason, it is still one of the best materials for
machine bases. It also has great thermal conductivity and excellent
machinability because of its network of graphite flakes.
UTS Hardness Density Thermal Specific Heat Coefficient of Thermal Compressive
(ultimate (g/cm3) Conductivity at Expansion Ɛ/F(Ɛ/C)X106 Strength (MPa)
tensile (W/m·K) 294K (J/Kg·k) average between 293K-
strength) 373K

207MPa 174 – 210 7.15 53 at (100°C) 0.14 (586) 5.8 (10.5) 752
BHN

b) Basic Calculations

1. Cylinder Wall
Cylinder walls are subjected to gas pressure and piston side thrust. As gas
pressure is more prominent, we consider 2 types of stresses:
a) Longitudinal Stress b) Circumferential Stress
𝑈𝑙𝑡𝑖𝑚𝑎𝑡𝑒 𝑇𝑒𝑛𝑠𝑖𝑙𝑒 𝑆𝑡𝑟𝑒𝑛𝑔𝑡ℎ 207 𝑀𝑝𝑎
Maximum Allowable Stress, 𝜎𝑎𝑙𝑙 = = =
𝑓𝑎𝑐𝑡𝑜𝑟 𝑜𝑓 𝑆𝑎𝑓𝑒𝑡𝑦 6
34.5 𝑀𝑝𝑎
𝑃𝑚𝑎𝑥∗𝐷 8.59∗78
Thickness of Cylinder wall, t= +𝐶 = + 1.5 = 11.21 𝑚𝑚
2∗𝜎𝑎𝑙𝑙 2∗34.5

Pmax = Maximum pressure inside the cylinder in N/mm2,

D = Inside diameter of the cylinder or cylinder bore in mm,
C = Allowance for reboring.
Taking stress analysis into consideration,
𝑃𝑚𝑎𝑥∗𝐷 8.59∗78
Longitudinal stress, 𝜎𝑙 = = = 29.44 𝑀𝑝𝑎
2∗𝑡 2∗11.21

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 𝑃𝑚𝑎𝑥∗𝐷 8.59∗78
Circumferential stress, 𝜎𝑐 = = = 14.94 𝑀𝑝𝑎
4∗𝑡 4∗11.21

As the stresses are under the maximum allowable stress, the dimensions of the
cylinder wall is adequate.
Length of Cylinder = 1.15 × stroke length = 1.15×97.5=112 mm

2. Cylinder Head
Cylinder head or cover is provided in most of the engines. It is made of a cylinder
box type section with considerable thickness which consists of an atomiser in the
centre of the cover, in case of diesel engines.
𝐶∗𝑝𝑚𝑎𝑥
The thickness of cylinder head is given by, 𝑡ℎ = 𝐷 √
𝜎𝑎𝑙𝑙

0.1∗8.59
= 78√ = 12.3mm
34.5

Where C is a constant taken as 0.1

3.Cylinder Flange and Studs

Cylinder Flange with studs or bolts are used to attach the cylinder wall and the
upper part of crank case. The cylinder flange is integral with the cylinder and
should be made thicker than the cylinder wall.
Flange thickness is taken as = 1.4 × t = 1.4 × 11.2 = 15.68 mm
The studs or bolts are screwed up tightly along with a metal gasket or asbestos
packing to provide a leak proof joint between the cylinder and cylinder head
Stud bolts used are made of ASTM A307 Grade A Carbon steel with allowable
tensile strength of 410 Mpa.
Number of studs is given by, 0.01×D + 4 < N < 0.02×D + 4
4.78 < N < 5.6 where Bore diameter, D = 78 mm
Hence the number of studs is taken as N=5.
𝑃𝑚𝑎𝑥 8.59
The diameter of studs,𝑑𝑐 = 𝐷 ∗ √ = 78 × √ = 5.04𝑚𝑚
𝑁∗𝜎𝑎𝑙𝑙 5∗410

Where D = Cylinder bore in mm,

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 Pmax = Maximum Allowable pressure in Mpa
𝑑𝑐 5.04
Nominal or Major diameter of stud, 𝑑𝑏 = = = 6𝑚𝑚
0.84 0.84

The stud pitch circle diameter, 𝐷𝑝 = 𝐷 + 3𝑑𝑏 = 78 + 3 ∗ 6 = 96𝑚𝑚

𝜋∗𝐷𝑝 3.14∗96
Pitch of stud pitch, 𝑃𝑏𝑜 = = = 60𝑚𝑚
𝑁 5

The outer diameter of flange, 𝐷𝑜 = (𝐷𝑝 + 2 ∗ 𝑑𝑏 + 12 )𝑚𝑚

= 96+2×6+12 = 120mm

c) Design of Cylinder

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 DESIGNING OF PISTON
a) Material Selection

An aluminium alloy AA2618 was chosen which have high ductility and
corrosion resistance. At sub-zero temperatures, their strength can be
increased. Aluminium 2618 alloy is an age hardenable alloy containing
magnesium and copper.

Density Tensile Yield Thermal Hardness

*1000 kg / Strength (Mpa) Strength (Mpa) Conductivity(W/mK) (HB)
m3
2.6-2.8 440 370 146 115

b) Basic Calculations
Thickness of Piston Head
Strength consideration
3𝑃𝑚𝑎𝑥
Maximum Thickness of head (th) = 𝐷√
16σb

D = cylinder bore (mm)

Pmax = maximum gas pressure (4 to 5 MPa)
σb = permissible bending stress 370 MPa (taking σb = 250)
th= 6.99 mm
Heat Dissipation Consideration
𝐻
th =
12.56𝐾(𝑇𝑐−𝑇𝑒)

H = amount of heat conducted through piston head (W)

k = thermal conductivity factor (175 W/m◦C )
Tc = Temperature at the Centre of the Piston
Te = Temperature at the edge of the piston
Tc - Te = 75̊C for Al
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th = 15.16 mm
Hence, Max thickness = 15.16 mm
Thickness of rib = 1/3 to ½ of piston head
Therefore, it is 5.053 mm to 7.56 mm
Piston Rings
3𝑃𝑤
Radial thickness of piston rings (tl) = 𝑑√
𝜎𝑡

d = diameter of the cylinder bore (mm)

pw = allowable pressure (0.025 to 0.042 MPa)
σt = permissible tensile stress (110 MPa with factor of safety = 4)

∴t 1 = 2.1 mm

Axial thickness t2 = 0.7 to 1.0 t1

∴t 2 = 1.56 mm

Width of top land (b1) = 1.0 to 1.2 th

∴ b = 15.20 mm
1

Width of other ring lands (b2) = 14 mm

Gap between free ends of the rings (G1) = 9.8mm

Gap when ring is in cylinder (G2) = 0.2mm

Piston Barrel
Thickness of piston barrel at the top end t3 = 0.03 d + a1 + 4.9

∴t 3 = 9.8mm

Thickness of piston barrel at open end t4 = 0.25 to 0.35t3

∴t 4 = 3mm

Piston Skirt

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Length of piston skirt ls = 0.65 to 0.8 D
∴l = 51mm
s

Total length of piston L = 1.0 to 1.5 D

∴L = 79.60mm
Piston Pin
Outside diameter do = 58.40mm
Inside diameter di = 35.04mm
Maximum Bending moment at the centre of the pin σb = 29.3715 MPa
c) Design of Piston

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 DESIGNING OF CONNECTING ROD

a) Material Selection
Carbon Steel was selected as the material for Connecting rod because of ability
to absorb high impact at the expense of durability and also for lightness of steel.

Type AISI/ASTM Tensile Yield Ductility Thermal

Carbon
name strength strength (% Conductivity
content
(MPa) (MPa) elongation (Metric)
(wt.%)
in 50 mm)
Medium 1040 0.37 – 620 415 49.8 W/mK
25
0.44

b) Basic Calculations
1.Dimensions of Cross-section of Connecting Rod
A connecting rod is a machine member which is subjected to alternating direct
compressive and tensile forces. Since the compressive forces are much higher
than the tensile forces, therefore, the cross-section of the connecting rod is
designed as an I-section of the connecting rod which has proportions of Flange
and web thickness t, Width of section, B=4t, and depth or height of section,
H=5t
Connecting rod should be equally strong in buckling about both axes. For
buckling about X-axis, both ends are hinged and about y-axis, both ends are
fixed. For connecting rod to be equally strong in both axes, 𝐼𝑥𝑥 = 4 ∗ 𝐼𝑦𝑦
where 𝐼𝑥𝑥 is moment of inertia in X-axis and 𝐼𝑦𝑦 is moment of inertia in Y-axis.
Area of section, A = 2 (4 t × t) + 3t × t = 11 t²
1 419 4
𝐼𝑥𝑥 = ( 4𝑡(5𝑡)3 − 3 ∗ 𝑡 ∗ (3𝑡)3 ) = 𝑡
12 12
1 1 131 4
𝐼𝑦𝑦 = ∗ 𝑡 ∗ (4𝑡)3 + ∗ 3𝑡 ∗ 𝑡 3 = 𝑡
6 12 12
𝐼𝑥𝑥
= 3.2, which is satisfactory for section chosen
𝐼𝑦𝑦

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Length of connecting rod, L=2×stroke length= 2×97.5= 195mm
782
Buckling Load, 𝑊𝐵 = 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝐺𝑎𝑠 𝑓𝑜𝑟𝑐𝑒 ∗ 𝐹𝑂𝑆 = 8.59 ∗ 3.14 ∗
4

= 41025.32 N
𝐼
Radius of Gyration, 𝐾𝑥𝑥 = √ 𝑥𝑥 = 1.78t²
𝐴

Using Rankine’s Formula,

𝜎𝑐 ∗𝐴 415∗11𝑡²
𝑊𝐵 = 𝐿 = 195
!+𝑎( ) 1+0.0002( )²
𝐾𝑥𝑥 1.78𝑡

Where 𝜎𝑐 is the compressive yield strength of material used,

which is carbon steel.
From the equation, Thickness of flange or web, t=2.54mm
Width of section, B=4t= 10.16mm Height of section, H= 5t=12.7mm
Area, A=11t²=70.96mm²
These dimensions are at the middle of the connecting rod. The width (B) is kept
constant through- out the length of the rod, but the depth (H) varies.
Depth near big end, 𝐻2 = 1.25 ∗ 𝐻 = 15.875𝑚𝑚
Depth near small end, 𝐻1 = 0.9 ∗ 𝐻 = 11.43𝑚𝑚
2.Dimensions of Crank pin and Piston pin
The Crankpin is designed for maximum gas force on crankpin.
That is, Maximum gas force=load on crankpin
41025.32= 𝑑𝑐 ∗ 𝑙𝑐 ∗ 𝑝𝑏𝑐 =𝑑𝑐 ∗ 3𝑑𝑐 ∗ 10
Where 𝑑𝑐 is the diameter of crankpin
𝑙𝑐 is the length of crankpin
𝑝𝑏𝑐 is the bearing pressure of crank pin
From the equation, 𝑑𝑐 = 56.17𝑚𝑚
𝑙𝑐 = 1.3 ∗ 𝑑𝑐 = 73.02𝑚𝑚

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For Piston pin,
Load on piston pin= 𝑑𝑝 ∗ 𝑙𝑝 ∗ 𝑝𝑏𝑝 = 𝑑𝑝 ∗ 2𝑑𝑝 ∗ 15 = 30𝑑𝑝 ²
Where 𝑑𝑝 is the diameter of piston pin
𝑙𝑝 is the length of piston pin
𝑝𝑏𝑝 is the bearing pressure of piston pin
Since load on piston pin is maximum gas force,
41025.32=30𝑑𝑝 ²
𝑑𝑝 = 37𝑚𝑚 𝑙𝑝 = 2𝑑𝑝 = 74𝑚𝑚

3. Size of Bolts on the Big End Cap

Bolts used are high carbon steel.
Given,
𝑑𝑐𝑏 = Core diameter of the bolts,
𝜎𝑡 = Allowable tensile stress for the material of the bolts
𝑛𝑏 = Number of bolts. Generally, two bolts are used
𝑚𝑟 = Mass of reciprocating parts
Knowing that size on the bolt depends on the inertia force on the bolts,
Force on the bolts = Inertia force of reciprocating parts
𝜋 𝑟
∗ (𝑑𝑐𝑏 )2 ∗ 𝜎𝑡 ∗ 𝑛𝑏 = 𝑚𝑟 ∗ 𝜔2 ∗ 𝑟(1 + )
4 𝑙
𝜋 2𝜋∗4500 2 0.039
∗ (𝑑𝑐𝑏 )2 ∗ 60 ∗ 2 = 2.25 ∗ ( ) ∗ 0.039(1 + )
4 60 0.195

From the equation, Diameter of bolts, 𝑑𝑐𝑏 = 15.74mm

𝑑𝑐𝑏
Nominal diameter, 𝑑𝑏 = =18.73mm
0.84

4.Thickness of Big End Cap

𝑡𝑐 = Thickness of the big end cap,
𝑏𝑐 = Width of the big end cap

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𝜎𝑏 = Allowable bending stress for the material of the cap = 80 N/mm2
x= Distance between bolt centres
= 𝑑𝑐 + 2 ∗ 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑙𝑖𝑛𝑒𝑟 + 𝑑𝑏 + 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒
=56.17+2×3+18.73+3= 84mm
Maximum bending moment on cap,
𝐼𝑛𝑡𝑒𝑟𝑡𝑖𝑎 𝑓𝑜𝑟𝑐𝑒∗𝑥 23359.85∗84
𝑀𝑐 = = = 32037.9𝑁𝑚𝑚
6 6

Section modulus,
𝑏𝑐 (𝑡𝑐 )² 73(𝑡𝑐 )²
𝑍𝑐 = = = 12.16(𝑡𝑐 )
6 6

𝑀𝑐
Knowing bearing stress, 𝜎𝑏 =
𝑍𝑐
32037.9
80=
12.16(𝑡𝑐 )²

From the equation, 𝑡𝑐 = 18.33mm

c) Connecting Rod Design

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 DESIGNING OF CRANKSHAFT

a)Material Selection
AISI 1045 Medium Carbon Steel was selected which is characterized by good
weldability, good machinability, and high strength and impact properties in
either the normalized or hot-rolled condition. It has a low through-hardening
capability with only sections of around 60 mm in size being recommended as
suitable for tempering and through-hardening.

Density Hardness Tensile Tensile Modulus of Shear Modulus

(Kg/m3) (Brinell) Strength(yield) Strength(Ultimate) (Elasticity) GPa
MPa MPa GPa
7861.093 163 310 565 200 80

b) Basic Calculations

1) When the crank is at dead centre. :At this position of the crank, the
maximum gas pressure on the piston will transmit maximum force on the
crankpin in the plane of the crank causing only bending of the shaft. The
crankpin as well as ends of the crankshaft will be only subjected to bending
moment. Thus, when the crank is at the dead center, the bending moment on the
shaft is maximum and the twisting moment is zero.
Consider a single throw three bearing crankshaft .
Let D = Piston diameter or cylinder bore in mm,
p = Maximum intensity of pressure on the piston in N/mm2,
W = Weight of the flywheel acting downwards in N, and
*T1 + T2 = Resultant belt tension or pull acting horizontally in N.
The thrust in the connecting rod will be equal to the gas load on the piston
(FP ). We know that gas load on the piston,

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FP = (p /4)´ D2 ´ p= (p /4)´ 78mm2 ´ 10.73Mpa=51271N

Due to this piston gas load (FP) acting horizontally, there will be two horizontal
reactions H1
and H2 at bearings 1 and 2 respectively, such that
Assuming (b1/ b)= (b2/ b)=b/2

H1 =Fp ´ (b1/ b) = 25635.5 N

and
H2 =Fp ´ (b2/ b)= 25635.5N

Due to the weight of the flywheel (W) acting downwards, there will be two
vertical reactions V2
and V3 at bearings 2 and 3 respectively, such that

V2 = W ´ (c1/C) = 1.25 * 10^3 N

and
V3 = W ´ (c2/c)= 1.25 * 10^3 N

Now due to the resultant belt tension (T1 + T2), acting horizontally, there will
be two horizontal reactions H2¢ and H3¢ at bearings 2 and 3 respectively, such
that
H2  = {(T1 + T2 ) c1 }/C=3.25* 10^ 3 N

And

H3 = {(T1 + T2 ) c2}/C=3.25* 10^ 3 N

The resultant force at bearing 2 is given by

R2 = root of {(H2 + H2¢ )2 + (V2 )2
=28.90KN

and the resultant force at bearing 3 is given by

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R3 = root of{ (H3 )2 + (V3 )2} = 3.48KN
Now the various parts of the centre crankshaft are designed for bending
only, as discussed below:

(a) Design of crankpin

Let dc = Diameter of the crankpin in mm=56.17 mm [from connecting rod]

lc = Length of the crankpin in mm = 73.02mm [from connecting rod]

sb = Allowable bending stress for the crankpin in N/mm2.=145.58MPa [

Plain carbon steel ]
(b) Design of left hand crank web.

The crank web is designed for eccentric loading. There will be two stresses
acting on the crank web, one is direct compressive stress and the other is
bending stress due to piston gas load (FP).
The thickness (t) of the crank web is given empirically as
t = 0.4 ds to 0.6 ds
= 0.22D to 0.32D
= 0.65 dc + 6.35 mm
Where; ds = Shaft diameter in mm,
D = Bore diameter in mm, and
dc = Crankpin diameter in mm,
The width of crank web (w) is taken as
w = 1.125 dc + 12.7 mm
We know that maximum bending moment on the crank web,
M = H, æb - (lc/2) -(t/2)) = 25*10^3 (78-(73.02/2)-(42.8605/2)) = 501493.7 5
KNmm
and section modulus,
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Z = (1/ σ) ´ w. t 2
=23235.27mm^3
\ Bending stress, σb= M/Z =501493.75/23235.27 = 21.58N/mm^2

and direct compressive stress on the crank web,

sc =H1/w . T= 25*10^3 / (75.89*42.8605)= 7.86 N/mm^2

\ Total stress on the crank web = Bending stress + Direct stress = sb + sc =
21.58+7.68 =29.26 N/mm^2

Since the total stress on the crank web is less than the allowable bending stress
of 145.58 MPa, therefore, the design of the left-hand crank web is safe.
(c) Design of right hand crank web

From the balancing point of view, the dimensions of the right-hand crank
web (i.e. thickness and width) are made equal to the dimensions of the left-hand
crank web.
(c) Design of shaft under the flywheel

We know ;
t=0.4ds to 0.6 ds
So, ds= t/0.4=107mm
Assume C/2=C1=C2 & assume the thickness of fly wheel to be 30mm
ie , C=l+30mm
We know that bending moment due to the weight of flywheel,
MW = V3 · c1
and bending moment due to the belt pull,
MT = H3¢ · c1
\ Resultant bending moment on the shaft
MS = root of (MW^2 + MT ^2) = p /32 (ds)3 s b

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ie;
[(l+30)/2]^2 (V3 + H3¢) ^2 = {p /32 (ds)3 s b}^2
On solving ;
l=25.64mm
So,
c=c+30=55.64mm
C1=C2=27.82mm

c)Design of Crankshaft

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 DESIGNING OF AIR COOLING SYSTEM

a) Material Selection

An aluminium alloy AA2618 was chosen which have high ductility and
corrosion resistance. At sub-zero temperatures, their strength can be
increased. Aluminium 2618 alloy is an age hardenable alloy containing
magnesium and copper.

Density Tensile Yield Thermal Hardness

*1000 kg / Strength (Mpa) Strength (Mpa) Conductivity(W/mK) (HB)
m3
2.6-2.8 440 370 146 115

b) Basic Calculation
Air cooling is a standard method of system cooling used to method of dissipate heat. The
object being cooled will have a flow of air moving over its surface. Most air-cooling systems
use a combination of fans and fins.
Here fins are made of Aluminium with number of fins N as 12, fin thickness t as 2mm, fin
length L as 35mm, with heat transfer coefficient, h as 20 W/m²k and thermal conductivity
237 20 W/m k. Aluminium is taken as they have high heat conductivity and ensures high
rate of transfer.
From Solidworks,
Area of the fins is found to be 0.203 m²
Heat transfer of the fins, 𝑄𝑓𝑖𝑛𝑛𝑒𝑑 = ℎ𝑎𝑙𝑢𝑚𝑖𝑛𝑖𝑢𝑚 x 𝐴𝑓𝑖𝑛𝑛𝑒𝑑 x (𝑇2 -𝑇1 )= 20 x 0.203 x (1000-298)

= 2850.12 W
Taking D as the outer diameter of cylinder,
Area unfinned = Total Area – Area covered by fins

= 𝜋 x D x L - 12 x π x D x t

= 3.14 x 100(112-12 x2) = 27632 mm²= 0.0276 m²

Heat transfer in unfinned region, 𝑄𝑢𝑛𝑓𝑖𝑛𝑛𝑒𝑑 = ℎ𝑐𝑎𝑠𝑡 𝑖𝑟𝑜𝑛 x 𝐴𝑢𝑛𝑓𝑖𝑛𝑛𝑒𝑑 x (𝑇2 -𝑇1 )

= 5.7 x 0.0276 x (1000-298)= 110.43 W

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Total Heat Transfer Q = 𝑄𝑓𝑖𝑛𝑛𝑒𝑑 + 𝑄𝑢𝑛𝑓𝑖𝑛𝑛𝑒𝑑 = 2850.12 + 110.43 = 2960.55 W

c) Design of Air Cooling System (Fins)

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FINAL ASSEMBLY

PISTON

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CYLINDER

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CRANKSHAFT

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CONNECTING ROD

25 | P a g e
FINAL ASSEMBLY

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