Design of Cylinder and Cylinder Head

1. The single cylinder four stroke petrol engine has the following specifications :
• Brake Power = 7.35 kW
• Speed = 5000 rpm
• Brake mean effective pressure = 0.21 Mpa
• Bore to stroke ratio = 0.909
• Compression ratio =6
Determine the bore and length of the cylinder.
2. The cylinder of four stroke diesel engine has the following specifications :
• Cylinder bore = 145 mm
• Maximum gas pressure = 3.5 Mpa
• Reboaring allowance = 5 mm
• Cylinder material = FG200
• Poisson’s ratio = 0.25
• Factor of safety =5
Determine :
i. The thickness of cylinder wall
ii. The stress induced in the cylinder wall

3. Design a cylinder, cylinder head and cylinder head studs for four stroke engine with the
following specifications :
• Cylinder bore = 150 mm
• Maximum gas pressure = 3.2 N/mm2
• Reboaring allowance = 4.0 mm
• Cylinder head thickness constant = 0.35
• Allowable tensile stresses :

Name of Part Cylinder Liner Cylinder Head Studs

Material Alloy cast iron Alloy cast iron Alloy steel 40Ni3
Allowable Tensile
40 40 70
Stress, N/mm2

4. Design a cylinder, cylinder head and cylinder head studs for four stroke C. I. engine with the
following data :
• Brake power = 5 kW
• Engine speed = 1200 rpm
• Indicated mean effective pressure = 0.35 N/mm2
• Maximum gas pressure = 3.5 N/mm2
• Mechanical efficiency = 80 %
• Compression ratio = 12
• Reboaring allowance, c1 = 4.0 mm
• Cylinder head thickness constant, k1 = 0.35
• Allowable tensile stresses :

Name of Part Cylinder Liner Cylinder Head Studs

Material Alloy cast iron Alloy cast iron Alloy steel 40Ni3
 Allowable Tensile
40 40 70
Stress, N/mm2

5. The cylinder of four stroke diesel engine has the following specifications :
• Brake Power = 7.5 kW
• Speed = 1400 rpm
• Indicated mean effective pressure = 0.35 N/mm2
• Maximum gas pressure = 3.5 N/mm2
• Mechanical efficiency = 80 %
The liner and cylinder head are made of gray cast iron FG250 ( Sut = 250 Mpa and µ = 0.25 ).
The studs are made of plain carbon steel (Syt = 380 Mpa). If Factor of safety for all parts is 6,
calculate:
i. The bore and length of cylinder liner;
ii. The thickness of cylinder liner;
iii. The thickness of cylinder head;
iv. The size, number and pitch of studs.
6. A two stroke engine is to be designed for a brake power of 7 kW at a speed of 800 rpm. If the
indicated mean pressure is 05 Mpa, determine :
i. The bore and cylinder length;
ii. The thickness of cylinder liner;
iii. The thickness of cylinder head; and
iv. The size, number and pitch of studs.
Also calculate the apparent and net stresses in the liner, if the poisson’s ratio µ = 0.25

Design of Piston
7. Design a piston for a single cylinder four stroke diesel engine with the following specifications:
• Cylinder bore = 0.2 m
• Stroke length = 0.25 ma
• Speed = 600 rpm
• Brake mean effective pressure = 0.21 Mpa
• Maximum gas pressure = 3.5 N/mm2
• Brake specific fuel consumption = 0.25 kg/ Kw-h
Assume additional suitable data.

8. Design a cast iron piston for a single acting four stroke diesel engine with the following
specifications:
• Cylinder bore = 300 mm
• Length of stroke = 450 mm
• Speed = 300 rpm
• Indicated mean effective pressure = 0.85 Mpa
• Maximum gas pressure = 5 Mpa
• Fuel consumption = 0.3 kg/ Kw-h
• Higher calorific value of fuel = 42000 kJ/kg
• Thermal conductivity of cast iron piston = 46.5 W/ m ºC
• Allowable temperature difference for piston = 220 ºC
• Heat conducted through piston crown = 5 % of heat generated
during combustion
 • Radial pressure between piston ring and cylinder = 0.04 N/mm2
wall
• Permissible bearing pressure between = 0.4 N/mm2
piston skirt and cylinder wall
• Permissible bearing pressure between alloy steel = 25 N/mm2
piston pin and bronze bush in connecting rod
• Allowable tensile stress for C. I. piston = 37.5 N/mm2
• Allowable bending stress for alloy C. I. piston rings = 100 N/mm2
• Allowable shear stress for alloy steel piston pin = 80 N/mm2
• Allowable bending stress for alloy steel piston pin = 160 N/mm2

Design:
i. Piston head; ii Piston barrel; iii Piston rings;
iv Piston skirt; v Reinforcing ribs; vi piston pin
Assume additional suitable data, if required.

9. The following data is given for a four stroke diesel engine:

• Cylinder bore = 250 mm
• Length of stroke = 300 mm
• Speed = 600 rpm
• Indicated mean effective pressure = 0.6 Mpa
• Mechanical efficiency = 80 %
• Maximum gas pressure = 4 Mpa
• Fuel consumption = 0.25 kg/ BP/hr
• Higher calorific value of fuel = 44000 kJ/kg
Assume that 5% of total heat developed in the cylinder is transmitted by the piston. The piston is
made of gray cast iron FG200 (Sut = 200 N/mm2 and K = 46.6 W/m ºC ) and the factor of safety
is 5. The temperature difference between the centre and the edge of the piston head is 220 ºC.
Determine:
i. The thickness of piston head by strength consideration and thermal considerations.
ii. State whether the ribs are required, if so calculate the number and thickness of ribs.
iii. State whether a cup is required in the top of piston head, if so calculate the radius of the
cup.
10. Find the thickness of piston crown, based on thermal considerations for a four stroke engine with
the following specifications:
• Engine speed = 1500 rpm
• Piston diameter = 87 mm
• Length of stroke = 96 mm
• Brake mean effective pressure = 0.7 N/mm2
• Bsfc = 0.26 kg/kw-h
• l/r ratio =4
• Heat conducted through crown = 10 % of heat generated during combustion
• calorific value of fuel = 42 MJ/kg
• Reboaring allowance, c1 = 4.0 mm
Assume that the piston is made of aluminium alloy with thermal conductivity 175 W/m ºC
and allowable temperature difference of 111 ºC.
11. The following data is given for a four stroke diesel engine:
• Cylinder bore = 250 mm
• Maximum gas pressure = 4 N/mm2
Bearing pressure at small end of Connecting rod = 15 N/mm2
• Length of piston pin in bush of Small end = 0.45 * D
• Ratio of inner to outer diameter of piston pin = 0.6
• Mean diameter of piston boss = 1.4 * Outer diameter of piston pin
• Allowable bending stress of piston pin = 84 N/mm2
Calculate:
i. The outer diameter of piston pin;
ii. The inner diameter of piston pin;
iii. The mean diameter of piston boss;
iv. Check design for bending stress.

Design of Connecting Rod

12. A long thick steel tube of inner diameter 150 mm is subjected to an external pressure of 20
N/mm2. The allowable compressive and tensile stresses for the tube are 160 N/mm2and 100
N/mm2 respectively. Determine the outer diameter of the tube using:
i. The maximum principal stress theory;
ii. The maximum shear stress theory.
Derive the expression you use.
13. A thick cylindrical tube of size ɸ 100 * ɸ 150 is subjected to an internal pressure of 80 Mpa and
external pressure of 20Mpa. Plot the distribution of principal stresses across the wall thickness.
14. A high pressure compound cylinder consists of an inner steel cylinder with inner and outer
diameters of 50 mm and 75 mm respectively. It is reinforced by shrinking a steel jacket of outer
diameter 100 mm. The shrink fit is selected such that the interference pressure does not exceed
10 Mpa. The modulus of elasticity and poisson’s ratio for the cylinder material are 207000
N/mm2 and 0.29 respectively. Calculate:
i. The decrease in outer diameter of inner cylinder due to shrink fit;
ii. The increase in inner diameter of jacket due to shrink fit; and
iii. The original dimensions of inner cylinder and jacket.
15. A high pressure compound cylinder consists of an inner cylinder with inner and outer diameters
of 300 mm and 400 mm respectively. It is jacketed by an outer cylinder with an outer diameter of
500 mm. The tubes are assembled by a shrinking process in such a way that the maximum
principal stress induced in any tube is limited to 100 N/mm2. Calculate the interference pressure
and original dimensions of tubes. The modulus of elasticity of the steel used for tube is 210000
N/mm2.
16. A tube of inner and outer diameters of 50 mm and 75 mm respectively is reinforced by shrink
fitting another tube of 100 mm diameter. This assembly is to withstand an internal pressure of 35
Mpa. If the shrinkage pressure is such that the maximum tangential stress in both the tubes is the
same, calculate
i. The shrinkage pressure
ii. The original dimensions of the tube.
Also plot the distribution of tangential stresses. Assume E = 207 kN/m2.
17. A high pressure compound cylinder consists of an inner steel cylinder with inner and outer
diameters of 40 mm and 60 mm respectively. It is reinforced by shrinking a steel jacket of outer
diameter 80 mm. The compound cylinder is subjected to an internal pressure of 60 Mpa. If the
shrinkage allowance is such that the maximum circumferential stresses in inner tube and jacket
are same, calculate
 i. The interface pressure
ii. The original dimensions of inner tube and jacket.
Assume E = 207 kN/m2.
18. A high pressure vessel consists of steel tube with inner and outer diameters of 20 mm and 40 mm
respectively. It is jacketed by an outer diameter 60 mm. The tubes are assembled by shrinking
processes in such a way that the maximum principal stress is limited to 100 N/mm2. Assuming E
= 207 kN/m2, calculate :
i. The shrinkage pressure; and
ii. The original dimensions of tube.
19. A steel tube, with inner and outer diameters of 50mm and 75 mm respectively, is reinforced by
shrinking a steel jacket of outer diameter 100 mm. The outer diameter of the inner tube has the
tolerance of +0.059+0.043 mm, while the inner diameter of the jacket has the tolerance of +0.025
+0.000 mm.
i. Find the circumferential stress range of the tubes at the interface.
ii. The coefficient of thermal expansion is 1.15 * 10^-5 per C, calculate by what
temperature the outer jacket should be heated to achieve the shrink fit. Assume: E
= 207 kN/m2