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Designand Assembly of Piston (Atb-237) Design Project Report

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DESIGNAND ASSEMBLY OF PISTON

(ATB-237) DESIGN PROJECT REPORT

SUBMITTED By
LOGARAJ.G
In partial fulfilment for the award of the degree of
BACHELOR OF TECHNOLOGY
IN
AUTOMOBILE MOTORSPORTS ENGINEERING

SCHOOL OF MECHANICAL SCIENCES


DEPARTMENT OF AUTOMOBILE ENGINEERING
HINDUSTAN INSTITUTE OF TECHNOLOGY AND SCIENCE
PADUR, CHENNAI-603103

MAY 2018

BONAFIDE CERTIFICATE
Certified that this design project report DESIGN AND ASSEMBLY OF
PISTON is the bonafide work of ''LOGARAJ.G(16105003)'' Who carried out
this design project work under my supervision. Certified further that to the best
of my knowledge the work reported here does not part of any other
project/research work on the basis of which a degree or award was conferred on
an earlier occasion othe rcandidate.

HEAD OF THE DEPARTMENT PROJECT GUIDE/MENTOR


DR. K. KAMALAKKANNAN MR. SASI KUMAR
PROFESSOR AND HEAD (AUTO) ASSISTANT PROFESSOR
DEPARTMENT OF DEPARTMENT OF
AUTOMOBILE ENGINEERING AUTOMOBILE ENGINEERING
HINDUSTAN INSTITUTE OF HINDUSTAN INSTITUTE OF
TECHNOLOGY AND SCIENCE TECHOLOGY AND SCIENCE
PADUR PADUR

THE DESIGN PROJECT EXAMINATION HELD ON –

INTERNAL EXAMINER EXTERNAL EXAMINER


NAME: NAME:
SIGNATURE: SIGNATURE:
ACKNOWLEDGEMENT

First and foremost I would like to thank the Lord Almighty for his presence and
immense blessings throughout the project work.

It’s a matter of pride and privilege for me to express my deep gratitude to the
management of HITS for providing me the necessary facilities and support.

I wish to express my heartfelt gratitude to Dr K.KAMALAKKANNAN,


PROFESSOR, HEAD OF THE DEPARTMENT OF AUTOMOBILE
ENGINEERING for much of his valuable support encouragement in carrying
out this work.
I would like to thank my internal guide MR.SASI KUMAR for continually
guiding and actively participating in my project, giving valuable suggestions to
complete the project work.

I would like to thank all the technical and teaching staff of the Automobile
Engineering department, who extended directly or indirectly all support

LOGARAJ.G(16105003)
CHAPTER-I
INTRODUCTION
1.1GENERAL INTRODUCTION
PISTON
A piston is a component of reciprocating engines, reciprocating pumps, gas
compressors and pneumatic cylinders, among other similar mechanisms .It is the moving
the component that is contained by a cylinder and is made by gas tight by piston rings.
In an engine its purpose is to transfer case from expanding gas in the cylinder to the
crankshaft via a piston rod and or connecting rod . In a pump the function is reversed and
force is transferred from the crankshaft to the piston for the purpose of compressing or
ejecting the fluid in the cylinder
CONNECTING ROD
A Connecting rod is a shaft which connects a piston to a crank or crankshaft
in a engine. Together with the crank it forms a simple mechanism that converts reciprocating
movement into rotating motion. A connecting rod may also convert rotating motion into
reciprocating motion its original use. Earlier mechanism such as the chain could only import
pulling motion. Being rigid a connecting rod may transmit either push or pull allowing the
rod to rotate the crankshaft through the two halves of revolution . In the few two stroke
engines the connecting rod is only required to push. Today the connecting rod is best known
through its use internal combustion piston engines such as automobile engines.

Fig 1.1 Piston & Connecting Rod

1.4CONSTRUCTION
A piston is a cylindrical engine component that slides back and forth in the cylinder
bore by forces produced during the combustion process. The piston acts as a movable
end of the combustion chamber.The stationary end of the combustion chamber is the
cylinder head. Pistons are commonly made of a cast aluminium alloy for excellent and
lightweight thermal conductivity. Thermal conductivity is the ability of a material to
conduct and transfer heat. Aluminium expands when heated, and proper clearance
must be provided to maintain free piston movement in the cylinder bore. Insufficient
clearance can cause the piston to seize in the cylinder. Excessive clearance can cause
a loss of compression and an increase in piston noise.Piston features include the
piston head, piston pin bore, piston pin, skirt, ring grooves, ring lands, and piston
rings. The piston head is the top surface (closest to the cylinder head) of the piston
which is subjected to tremendous forces and heat during normal engine
operation.A piston pin bore is a through hole in the side of the piston perpendicular to
piston travel that receives the piston pin.A piston pin is a hollow shaft that connects
the small end of the connecting rod to the piston. The skirt of a piston is the portion of
the piston closest to the crankshaft that helps align the piston as it moves in the
cylinder bore. Some skirts have profiles cut into them to reduce piston mass and to
provide clearance for the rotating crankshaft counterweightsA ring groove is a
recessed area located around the perimeter of the piston that is used to retain a piston
ring. Ring lands are the two parallel surfaces of the ring groove which function.Piston
rings commonly used on small engines include the compression ring, wiper ring, and
oil ring. A compression ring is the piston ring located in the ring groove closest to the
piston head. The compression ring seals the combustion chamber from any leakage
during the combustion process. When the air-fuel mixture is ignited, pressure from
combustion gases is applied to the piston head, forcing the piston toward the
crankshaft

1.5 WORKING PRINCIPLE


Piston rings seal the combustion chamber, transferring heat to the cylinder wall and
controlling oil consumption. A piston ring seals the combustion chamber through
inherent and applied pressure. Inherent pressure is the internal spring force that
expands a piston ring based on the design and properties of the material used. Inherent
pressure requires a significant force needed to compress a piston ring to a smaller
diameter. Inherent pressure is determined by the uncompressed or free piston ring gap.
Free piston ring gap is the distance between the two ends of a piston ring in an
uncompressed state. Typically, the greater the free piston ring gap, the more force the
piston ring applies when compressed in the cylinder bore.A piston ring must provide a
predictable and positive radial fit between the cylinder wall and the running surface of
the piston ring for an efficient seal.The radial fit is achieved by the inherent pressure
of the piston ring. The piston ring must also maintain a seal on the piston ring lands.In
addition to inherent pressure, a piston ring seals the combustion chamber through
applied pressure. Applied pressure is pressure applied from combustion gases to the
piston ring, causing it to expand. Some piston rings have a chamfered edge opposite
the running surface. This chamfered edge causes the piston ring to twist when not
affected by combustion gas pressures.Another piston ring design consideration is
cylinder wall contact pressure. This pressure is usually dependent on the elasticity of
the piston ring material, free piston ring gap, and exposure to combustion gases. All
piston rings used by Briggs & Stratton engines are made of cast iron. Cast iron easily
conforms to the cylinder wall. In addition, cast iron is easily coated with other
materials to enhance its durability.Care must be exercised when handling piston .

LIST OF CONTENTS
CHAPTER NO TITLE PAGE NO
I INTRODUCTION 1
1.1 GENERAL INTRODUCTION 1
1.2 CONSTRUCTION 2
1.3 WORKING 3
1.4 OUTLINE OF PROJECT 4
1.5 OBJECTIVE OF THE PROJECT 4
II LITERATURE REVIEW 5
III RESEARCH METHODOLOGY 6
3.1 CALCULATIONS 6
3.2 MEASUREMENTS 8
3.3 MANUFACTURER 9
IV RESULTS 10
4.1 2D DESIGN 10
4.2 DESIGN CONSIDERATIONS 11
V CONCLUSION 12
REFRENCES 13

LIST OF THE FIGURES


FIG NO TITLE OF THE COMPONENTS PAGE NO
1.1 GENERAL INTRODUCTION 1
4.1 2D SKETCH OF PISTON & CONNECTING ROD 10
4.2DESIGN CONSIDERATIONS
PISTON
In designing a piston for I c engine the following points should be taken into
considerations:
 It should have enormous strength to withstand the high gas pressure andinteria forces.
 It should have minimum mass to minimise the inertia forces.
 It should form an effective gas and oil sealing of the cylinder.
 It should provide sufficient bearing area to prevent un due wear.
 It should disperse the heat of combustion quickly to the cylinder walls.
 It should have high speed reciprocation without noise.
 It should be of sufficient rigid construction to withstand thermal and mechanical
distortion.
 It should have sufficient support for the piston pin.
CONNECTING ROD
In designing a connecting rod the following dimensions are required to be
determined:
 Dimensions of cross-section of the connecting rod
 Dimensions of the crankpin at the big end and the piston pin at the small end
 Size of bolts for securing the big end cap and
 Thickness of the big end gap

11
CHAPTER-IV
4.1 RESULT
4.1.1CONNECTINGROD

Fig 4.1 Connecting Rod


4.1.2PISTON

Fig 4.2 Piston


3.3MANUFACTURER
CASTING
An object made by pouring molten metal or other material into a mould.
FORGING
Forging is the operation where the metal is heated and then a force is applied to
manipulates the metals in such a way that the required final shape is obtained.
CUTTING OF MATERIAL
Cut the material a little greater than the required due to further process.
HEATING BILLETS
Billet is heated in the furnace at 500-600
HOT FORGING
Hot forging is defined as working a metal above its re- crystallization temperature.

9
ABSTRACT
The paper deals with study of the assembly of piston and connecting rod of a four wheeler
diesel engine. The components of the assembly have to be rigid and assembly has to be
moved as a mechanism. Hence the analysis to be involved a rigid body analysis. So the forces
in the components as the engine reciprocates have to be calculated and these forces are used
to calculate the dynamic stresses in the component of interest of connecting rod. It is
proposed to replace with two sets of materials for the components of the assembly and check
the parameters by performing the static,dynamic and thermal analysis.In this project the main
parts of the assembly engine piston,connecting rod are modeled and assembled as per the
given design.And the finite element analysis done. The meshing is done in HyperMesh.
CHAPTER –III
RESEARCH METHEDOLOGY
3.1 CALCULATIONS
PISTON
STEP-1
S=
STEP-2
Cylinder volume when piston at TC (s=/+a)defined as the clearance volume Vc .
The cylinder volume at any crank angle is:

STEP-3
Maximum displacement or swept volume:

STEP-4
Compression ratio:

3.2 MEASUREMENTS
PISTON
 DIAMETER = 67.5mm
 OVERALL LENGTH = 55.8mm
 PIN HOLE = 16mm
 WEIGHT- = 74g
CONNECTING ROD
 OVERALL LENGTH = 112mm
 INNER DIA BIG END BEARING = 40mm
 OUTER DIA BIG END BEARING = 50mm
 INNER DIA SMALL END BEARING = 10.6mm
 OUTER DIA SMALL END BEARING = 25mm
 GERNAL BEARING = 0.2mm
 NUT LENGTH = 47.1mm
 BOLT = 0.86mm

8
1.2 OUTLINE OF THE PROJECT
The project deals with the design of piston and connecting rod . The components are
dismantled. The piston and connecting rod are designed in 2D with measured measurements
using the software AUTOCAD.The function of the component is studied . The mechanical
properties of the materials is studied.

1.3 OBJECTIVE
 To dismantle the piston and connecting rod ,study the different component and model
of the using AUTO CAD.
 To measure the dimensions of the component using measuring instruments such as
vernier calliper and measuring tape.
 To study the function of piston and connecting rod and its components
 The piston and connecting rod is the one of the most important component in the
engine.
 They are required to run the engine and vehicle by converting chemical energy into
mechanical energy.
 The piston plays the conversion of the rotary into linear.
4
CONNECTING ROD
STEP 1
Length of the connecting rod l=112mm so for both ends hinged L=l=112mm
Rankins formula,

STEP 2
For connec ting rod equally strong in buckling about the both axes
Ws(X axis)=Ws(Y axis)
=
STEP 3
 In actual practice Ixx is kept slightly lower than 4Iyy
 3<
 for calculating WB=max.gas force x factor of safety .

7
CHAPTER V
5.1CONCLUSION
Piston features include the piston head, piston pin bore, piston pin, skirt, ring grooves, ring
lands, and piston rings. Today, the connecting rod is best known through its use in internal
combustion piston engines, such as automobile engines. These are of a distinctly different
design from earlier forms of connecting rod used in stream engines and stream locomotives.
CHAPTER-II
LITERATURE REVIEW
NEWTONS LAW
‘If a body is in motion then it will remain in motion until and unless an external force is
applied to bring the body in rest’ as said by Newton.

PASCAL’S LAW
It states that when pressure is applied on a part of a liquid it is equally transmitted in the full
liquid in all direction.
PISTON AND CONNECTING ROD
 This paper reviews piston and ring friction which can account for 65% of the mechanical
friction in an internal combustion engine.
 It shows the cylinder linear lubrication is predominantly hydrodynamic with localized
contact between ring and linear at TDC firing.
 The degree of the contact may increase during transition conditions.
 The piston secondary motion is an important phenomenon in the internal combustion
engine.
 It occurs due to the piston transfer and rotational motion during piston reciprocating
motion.
 The piston secondary motion results in the engine friction and engine noise.there has been
lot of research activities going on in the piston secondary motion using both analytical
models and experimental studies.
 These studies are aimed at reducing the engine friction as well as the noise generated due
to piston secondary motion.

REFERENCES
[1] Mr. Sudarshan Martandel , Mr. Y . N . Jangale, Mr . N.S. Motgi (Mech) design and
analysis of shock absorber . INDIA Volume 2, Issue 3, March 2013
[2] Hero Honda Splendor service manual 2010. Hero motocop pvt. Itd
[3] http://www.cycleworld.com.com/2015/03/23/history-simplicity-and-effectiveness-of-
motorcycle-telescopic-fork-tech-editor-kevin-cameron
[4] Burt D, Formula SAE piston and connecting rod design BE thesis,2004,University of
queensland

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