DESING CALCULATION OF ENGINE PARTS FOR 110- KENBO MOTORCYCLE
(PISTON, CRANKSHAFT, CAM SHAFT AND VALVE GEAR MECHANISM)
Mg Aung Myint Myat, Daw War War Min Swe
Abstract - This paper presents design calculation of engine
parts for 110 KENBO MOTORCYCLE. The type of 110
KENBO motorcycle engine is single cylinder, 4-storke
engine. The cooling system for this engine is provided by
using air-fin design. The air-fins are provided around the
cylinder. Some of the important engine parts are cylinder
head, inlet manifold, exhaust manifold, inlet valve, exhaust
valve, piston, piston rings, gudgeon pin, camshaft, crank
shaft and connecting rods etc. In this study the design and
calculation of piston, crankshaft, valve gear mechanism and
cam design are presented. The dimensions for various
components of the piston are determined in the first portion.
The induced bending stress in the piston pin is also
calculated. The second portion is the design calculation of
the crank shaft when the crank is at TDC and the crank is at
an angle of maximum twisting moment. The induced
bending stress on the crank pin is also calculated. The third
portion is the design calculation of the various component of
the value gear mechanism. The induced bending stress at the
fulcrum pin is also calculated. The position of exhaust valve
for open and close condition is expressed with displacement
diagram and the drawing profile of cam.
Keywords - 110Kenbo, Piston, Profile of Cam. Valve Gear
Mechanism
I. INTRODUCTION
T oday motorcycles are widely used in Myanmar for
transportation and other purposes. So, it is necessary to
know about the motorcycle engine in detail for mass
production in our country. There are various kinds of
motorcycle used in Myanmar such as: 110 (Kenbo), 110
(Loujia), 110 (Dream) and 125 (Kenbo) etc.
Ma Aung Myint Myat is with the Department of Mechanical Engineering,
Technological University, Magway (Phone: 95-063-23750; 95-063-23750).
Daw War War Min Swe was with Mandalay Technological University,
Mandalay. She is now with the Department of Mechanical Engineering,
Technological University, Magway ( Phone: 95-063-23750; 95-063-
23750).
Every motorcycle runs with single-cylinder four strokes
petrol. Among these motorcycles, 110 (Kenbo) motorcycle
will serve comfortably with its elegant design, up-to-date
structure and excellent engine performance. They are more
popular than the other because of luxurious appearance,
comfortable in riding and easy and safe in operation. In
general, there are two main types of engine (i) internal
combustion engine and (ii) external combustion engine. In
internal combustion engine, the burning of fuel and
conversion of energy takes place inside the engine. In
external combustion engine, the burning of fuel and
conversion of energy takes place outside the engine. The
operation of 110 (Kenbo) motorcycle engine is similar to
that of the internal combustion engine. As the name implies,
the internal combustion engine (briefly written as I.C
engine) are those engines in which the combustion of fuel
takes place inside the engine cylinder. The I.C engines use
their petrol or diesel as their fuel. In petrol engines (also
called spark ignition engines or SI. engines), the correct
proportion of air and petrol is mixed in the carburetor and
fed to engine cylinder where it is ignited by means of a
spark produced at the spark plug. The fuel used in 110
(Kenbo) motorcycle engine is petrol. The combustion takes
place in the combustion chamber.
II. OBJECTIVE
Main objectives of this study are as follows;
1. To analyze the force on the piston, the basis
dimensions of piston and bending stress on the
piston pin.
2. To analyze the force upon crankshaft and bending
stress on crankpin.
3. To calculate the dimensions of the valve gear
mechanism.
III. SCOPE
The scopes of the study are:
1. The induced bending stress in the piston pin is
calculated from the maximum gas load on the piston.
2. The bending stress on the crankpin is calculated
from the bending moment on the crank web. TABLE .I
3. The displacement diagram and profile of cam for . Tempearture at compression and power stroke
exhaust value’s position is described by using Auto CAD Temperature At the end of Max.temperature
inside of compression 2000°C, end
design.
cylinder about 400°C temperature
900°C
IV. Design Calculation Piston
- Data from Manual Book of 110 KENBO MOTORCYCLE
Cylinder Bore, D = 52.4 mm
Density of petrol ρ = 0.7 x 1000=700 kg/m3
Permissible bending (tensile), σ t = 50 to 90 MPa.
Stress for aluminium alloy
Temperature difference, ( TC - TE )=75°C (aluminium)
Heat Conductivity Factor,K = 174.75 W/m/°C
Figure 2. P-V Diagram and T-S Diagram
( for aluminium alloy )
From Otto cycle,
Higher Calorific value of fuel,
2-3 : Volume Constant Process
HCV= 47 x 103 KJ/Kg (for petrol)
- Calculation of maximum gas pressure (P3) in the
cylinder, P2 V2 P3 V3
∴ = --------------------------- (1)
On compression not only the gas pressure increases, T2 T3
but also, at the same time, the temperature; P2 P3
=
T2 T3
T3
∴ P3 = P2 ×
T2
Pressure
(kg/cm2) 2273
∴ P3 = 0.6082 × = 1.9121 MPa
723

(i) Thickness of piston head t H

By Grashoff 's Formula,

Figure 1. End pressure P2 and end temperature t2 as function 2

3 pD
of compression ratio tH = --------------------------------- (2)
16σ t

(ii) On the basic of second consideration of heat

From Figure[1] At compression ratio E = 9.1
transfer,
Compression end pressure,
tH = H --------------------------- (3)
P2 = 6.2 kg/cm2 x 9.8 m/sec2 = 60.822 N/cm2
12.56 × K(TC − TE )
∴P2 = 0.6082 MPa
H = Heat flow through the piston head
From Table ( I ),
= C x HCV x m x BP
Compression end temperature, t2 = 450°C+ 273 = 723 K
(iii) Thickness of the ribs, t R
Maximum temperature at power stroke, t3 = 2000°C + 273 =
t R = t H /3 to t H /2 ---------------------------------(4)
2273 K
(iv) The radial thickness of the ring,
 t1 = D 3 ρ w ---------------------- (5) (v) The induced bending stress on the piston pin σb ,
σt
4 4
π ⎡ (d 0 ) − (d i ) ⎤
(v) The width of the top land , M = ⎢ ⎥ σ b ------------------- (13)
32 ⎢ d0 ⎥
b1 = t H to 1.2 t H --------------------(6) ⎣ ⎦
(vi) The width of other ring lands, TABLE .III
b2 = 0.75 t 2 to 1.2 t 2 -------------- (7) Results of piston barrel calculation;
(vii) The gap between the free ends of the ring, t3 (mm) t4 (mm) l (mm) L σ b(N/mm2)
G1 = 3.5 t 1 to 4 t 1 ----------------- (8) eqn(10) eqn(11) eqn(12) (mm) eqn(13)
(viii) The gap when the ring is in the cylinder, 8.472 2.118 to 32.78 46.2 182.911
G2 = 0.002 D to 0.004 D ---------- (9) 2.9652

VI. Design Calculation of Crankshaft.

From the previous data;
Piston diameter or cylinder bore, D = 52.4 mm
Maximum intensity of pressure on piston,
P = 1.9121 M Pa(P =P3)
Weight of the flywheel acting, W = 1.3365 kg
Resultant belt tension or pull acting,
T1 + T2 = 0 (no belt).
Figure 3. Piston for I.C Engine (Trunk Type) (i) The piston gas load, FP,
TABLE .II π 2
FP = D ×p ----------------- (14)
Results of piston dimensions, 4
(ii) Bending stress on the crankpin σ b ,
tH(mm) by

G1(mm)

G2(mm)
tH (mm)

b1(mm)

b2(mm)
tH(mm)

t1(mm)

32M
eqn(2)

eqn(4)

eqn(5)

eqn(6)

eqn(7)

eqn(8)

eqn(9)

σb = --------------------- (15)
heat

3
πd c
- Results of calculation of crankshaft,
1.1024to

3.3072to

to0 2096

(i) Piston gas load FP = 4123.4817 N

1.5 to 2
3.3072

1 6536

3 9686

0.1048
7 to 8
3.75

(ii) Bending Stress on the crank pin

2

σ b = 10.7429 MPa
When the crank at an angle of maximum twisting

V. Design Calculation of Piston Barrel moment,

(i) The maximum thickness of the piston barrel. ( t 3 ) The maximum value of tangential force lines when the crank

t 3 = 0.03 D + t 1+4.9(mm) ----------------------- (10) is at angle of 25° to 30° from the dead centre for a constant

(ii) Piston wall thickness toward the open end, volume combustion engines (i.e. petrol engines)
t 4 = 0.25 t 3 to 0.35 t 3 ----------------------------- (11)
(iii) Length of the piston skirt l
l = R --------------------------- (12)
Pb × D
In actual practice, l = 0.65 D to 0.8 D

(iv) Total length of the piston L,

Figure 4. Crank shaft for single cylinder engine
L = Length of the skirt + Length of the ring section
Top Land
 θ = 25° to 30° VIII. Calculation of Valve Dimensions;

φ = sin θ /n ( n = l /ϒ) (i) Size of the valve port dp,

ap . vp = a. v
π 2
(i) Piston gas load FP = D × p' --------------- (16) π 2 π 2
4 (d p ) v p = D × v
4 4
(Assume, p' = 1 N/mm2 )
(ii) Maximum lift of the valve h,
(ii) Thrust on connecting rod FQ,
dp
FQ = FP ----------------------------- (17) h= ( α = 45°valve face
cos φ 4 cosα
(iii) Tangential Force FT, angle )

FT = FQ sin ( θ + φ ) ----------------- (18) (iii) Thickness of valve head t,

(iv) Radial Force FR , ρ

t = k.d p
FR = FQ cos ( θ + φ ) -------- -------- (19) σb
(v) Bending moment on the crank pin Mc (iv) Valve stem diameter d s ,
Mc = HR1 ×b2 d s = dp / 8 + 6.35 mm
(vi) Twisting moment on the crank pin Tc (v) Valve head diameter dv,
Tc = HT1 × r [ r = stroke/2 ] dv = dp + 2 × width of valve seat
(viii) Diameter of the crank pin dc, (vi) Total load on the valve, considering the weight of
3 the valve P = P1 + w
πd c
Te = × τ ----------------- (20)
16 P1=Gas load on valve
Te = Equivalent twisting moment on the crank w=Weight of valve
τ = Allowable shear stress (35 MPA for alloy cast iron) Results of valve dimensions:
Results of calculation of crankshaft (i) Size of the valve port d p = 15 mm
(i) Piston gas load FP = 2156.52 N (ii) Maximum lift of the valve h = 6 mm
(ii) Thrust on connecting rod FQ = 2164.7245 N (iii) Thickness of valve head t = 2 mm
(iii)Tangential Force FT = 1082.035 N
(iv) Valve stem diameter d s = 8 mm
(iv) Radial Force FR = 1874.8953 N
(v) Diameter of the crank pin, dc = 20 mm (v) Valve head diameter d v =18 mm

VII. Design Calculation of Valve Gear Mechanism and (vi) Total toad on the valve P = 102 N
Camshaft
The valves used in internal combustion engines are of the IX. Design of Cam.
following three types; (i) Diameter of camshaft D,
1. Poppet or mushroom valve; 2. Sleeve valve; 3. Rotary D' = 0.16 × Cylinder bore + 12.7 mm
valve. (ii) Base Circle diameter = D' +3 mm
In this engine, the poppet valves are used as inlet valve and (iii) Width of cam W',
exhaust valve. W' = 0.09 × Cylinder bore + 6 mm.

Results of cam design.

(i) Diameter of cam shaft D' = 21 mm
(ii) Base circle diameter = 24 mm
(iii) Width of cam W' = 11 mm

Figure 5. Valve Mechanisms


Figure 6. Displacement diagram
1. This paper consists of the design calculation of
main components of 110 KENBO motorcycle engine, but
the remaining engine parts such as connecting rod , fly
wheel and air-cooling system should be calculated.
2. The maximum gas pressure in the cylinder is
calculated according to compression ratio which is given
from the engine manual book. The maximum gas pressure
which obtains from the engine brake power is not satisfied
in calculating piston dimensions.
3. Although the air-cooling system for engine should
be calculated, it is difficult to open the engine into two
sections.

ACKNOWLEDGEMENTS
Figure 7. Profile of Cam (Full Scale) Mg Aung Myint Myat thanks Dr. Kyaw Aung, Daw War
War Min Swe and Dr. Aung Myo Lin for their supporting
X. DISCUSSIONS, CONCLUSIONS AND to the explanation of their experiences and essential
RECOMMENDATIONS suggestion for this paper.
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In this study, the conclusions are described as follows;
1. The calculated dimensions of the engine
components are relevant the practical dimensions.
2. The bending stresses are safe for the selected
materials.
The recommendations are described as follows;