sy mmbols The diamel (steam engine) Steam Engine Cylinder: Cylinders and Pistons of Steam and Internal Combustion Engines Description and Units the maximum load on the piston, N (kgf) the depth of the piston ring, mm number of studs or bolts length of the piston, mm Iength of cylinder, mm length of the gudgeon pin bearing, mm speed of the engine, rev/s working pressure, MN/m? (kgf/mm?) actual mean effective pressure, MN/m? (kgf/mm?) thickness of the cylinder, mm thickness of the cylinder flange, mm thickness of the piston head, mm the radial thickness of the piston ring, mm ean speed of the piston, m/s (Table 18. 1) weight ofthe reciprocating parts, N (kg) allowable stress, MN/m? (kgf/mm?) ___| Equation Eqn. No. 1000¢P) J? : acting - (P) ]? ter of a double acting eninge D= Jom | SLunits 18.1(a) 4 | p= |]? | P= [arpa Metric units 18.1(b) 403404 Cylinders and Pistons of Steam and Internal Combustion Engines “Particular Equation Eqn. No, where P = indicative power, kw (Mhp): L, vy = 2L,n mean speed of the pistons. mys: 1 = speed of the engine. rev/s ‘Pm is mean effective pressure. MN/m? (kgf/mm-) pD length of the storke, m ‘An empirical rule to determine the thickness = 5 + 7.6 mm 18.2) of ordinary grey C.1. cylinder without liner * where D = inside diameter of cylinder. mm @, = 10 to 40 MN/m? (1.02 to 4.08 kgf/mm*) for ordinary grey C.1 The thickness of the cylinder (Lame’s 18.2¢b) equation) for brittle material, mm The thickness of the cylinder according to IS. Grashof’s equation, mm. IS. Clavarino’s equation for the cylinder wall thickness, mm where D, is the inside diameter of the cylinder, mm 7, is the permissible working stress, MN/m? (kgf/mm?) P. is the pressure inside the cylinder, MN/m? (kgf/mm?) 111s the poisson’s ratio of lateral cc ig. 18.24 Fig. 18.1: Cylinder with liner Fig. 18.2(b): Cylinder coverane ine af a 405 q ir —— ticular ee | Equation > _ hickess of the cylinder flange b= 1antola Ean_No, sfeylinder 18.3(a) as L. = stroke + : 1s ol eX pte ml pees Over piston rings 18, 3¢p) em the cylinder (Fig. 18.4) = PNP Ibo, 18.3¢c) « se P= pressure of steam, MN/m? (kgf/mm?): 7, Howable stress on the cover plate, = 20.6 MN/m* (2.10 kgf/mm? n O10 kgtimm?) for Cs, = 55, 0 MN/m? (5.60 kgf/mm?) for cast steel re oot diameter of the stud | 4, = D\ pln, a li; 18.4( where i = number of studs used, It should be in multiples of 4 ‘ o, = working tensile stress in studs = 1.08d, MN/m? (0.1 1d, kgf/mm?) d 2 20 mm, major diameter of stud i the maximum pitch of studs | P. = 17 VP 18.4(b ) Imernal Combustion Engine Cylinder: ‘The diameter of a4 stroke internal | = | 1000 4P 1 i = sr units Pi combustion engine, mm | units(P inkw) — 18.5(a) 1 | (15x 4P)]? D= Metric units (P in Mhp)18.5(b) aa eaees The thickness of the inner walls of 0.045D + 1.5 mm 18.6(a) automobile engine cylinder | The Jacket wall thickness 1) = 0.032D + 1.5 mm 18.6(b) The water space, i.e. the distance between the outside of the cylinder and inside of the jacket: (a) For natural circulation cooling ty = 8to 11 mm 18.6(c) te =6t08 mm 18.6) _(b) For pump circulation Shoulder on liner (») sec tgine esta linear Fig, 18.4: Cylinder coverOo” 406 Cylinders and Pistons of Steam and Tnternal Combustion Haine, Particular | Equation Fan. Ny Circular flat eylinder heads fe 4 The mininauny thickness of an unstayeet Ma |= (J! ba head or cover phate, mm : Hay whore By asthe diameter of shortest span, aim (reer Fig, 18.5) A is an empirical eoetficient (Table 18.1) prise maim inside pressure, MNin! Ct fn ory isthe alle sig stress, MNfn! yeni?) (Table 1.2) The thickness of a plate uniformly loaded: 1 kD play i With a diameter of Dy supported a the circumference, mm where ky is the coetlicient (refer Table 18.3) “The maximum deflection of the cover plate y noe ft’ where ky is the coef ‘Table 18.3) : _ p Wh Tm; | a r | | we) G) wn Types of cylinder heads and covers4ersand Pistons of Steam and Internal Combustion f : ingines i" i 407 jculal . partic ; _ Equation 5 — When a flat east iron plate qn. No. load F distrib Mte with a diameter Dy and sujected to a ad F distributed uniformly over an area op supported freely at the circumference | uy the thickness, I" ro I. ~ 061D D, doy 18.7(c) {ii the deflection 18.7(d) ip) Fixed rigidly around the circumference (i) the thickness 1- E (Diy = 0.65 ./— log, (=! a loz, ( D ) 18.7(e) (ii) the deflection O.0SSDEF Ee 18.7(f) The thickness of a flat cylinder head, mm 1=0.31D yplou 18.7(g) where p = maximum pressure inside the cylinder, MN/m? (kgf/mm?) 4 = allowable working stress; 74 = 82.40 MN/m? (8.40 kgf/mm?) low carbon cast steel = 34.32 MN/m? (3.50 kgf/mm?) for C.L = 42.00 MN/m? (4.28 kgf/mm?) for Aluminum alloys = 55.00 MN/m? (5.60 kgf/mm?) for Nickel Cast Iron The number of studs 0015 D+4 18.8 The flange thickness 1 = 125d 10 1.5d;f) > 1.10rt0 1.251 18.9(@) where d is the diameter of bolt, mm = 125d to 1.50d 18.9(b) Length from the inside edge of cylinder to | the centre of bolt, mm ‘The depth (1) of tapped hole for studs inside the eylinder, mm Dr.— | el to = 1.25d in steel castings |" = tsodto 1-154 in cast iron 18.90) | =1.75d to 2.00d in aluminium Flange diameter ~ (3 to 6) mm 18.9(d)- an tons of Stam an Infernal Combustion Engines 409 inte y tlt Equation Eqn. No. eter of piston Rod: la - cer of piston rod d=D ploy Is. sbatance pressure or difference between the steam inlet and pedal un whet the exhaust pressure, MN/m? (kg/mm?) cry = allowable stress in the piston rod, (in calculating oy, take the factor of safety 10 for double acting engines and 8 for single acting engines on the ultimate strength) cos 26" ee ) 18.12 a force of the reciprocating parts on | F = o.g0sze a coss m The inert ihe piston, N (ket) -ank radius, mm: We is the weight of reciprocating parts, N¢kg?) where r= et 1 = length of the connecting rod, mm; m = Hr «i centre, positive sign is to be taken from inner 6 = crank angle from the dea o sign from outer dead centre isa) | 4 = 043D yplou 18.13¢a) | Dis the diameter of pision, mm dead centre while the negativ Trunk Pis The thickness of piston head (Table where p is the uid pressure, MNJan? ¢ket/mn = allowable tensile stress. im?) for good close grained cast iron or aluminium = 38 Nim? 3.90 ket alloys, with ultimate tensile strength of 137.0 MN/m? (14 kgf/mm?) Nickel Cast iron, semi-steel or special aluminium 55M 5.6 kgf/mm?) for sioy having ultimate tensile strength of 206 MN/mn? (21 kgf/mm?) 32.5 MNinv 84 kgf/mm’) for forged steel Anempirical formule te determine the 1, = 0.0320 + 1.5mm 18.13(b) Trrckneas ofthe cas ron aurarnobile P72 piston head, 10 | yf the Crown from the {heat flow, mm | 18.13) The thickness © consideration ¢!os Minders and Pistons of Steam * ae Cutinders am eam and Internal Combustion kn me Particular Kquation Ke : AN. No, yore w= heat fe from gases. /s mm? (kg m/s mW?) depends upon the rst material, mean effective pressure and stroke-bore ratio 1.25, F oe Bolts tend to dish the plate: Kis found by the relation Gor O0E RD LAWig/ HD). where W = total bolt load in N: H = total pressure on area bounded by the outside diameter the gasket, in pounds; and fig and d are as shown in Fig. 1s ¢ “Maximum Minimum of Speci ss Temperature Flange Material at Room Temperature (Deg C) | 0 |S SE alesis 370) 74(7.55) | 82(8.36) | 90(9.18) | 115(11.73) | 98(10.00) 200 65(6.63) | 72(7.34) | 8018.16) | 8718.87) 101(10.30) 425 56(5.71) | 62(6.32) 68(6.93) | 75(7.65) | 87(8.87) 450 47(4.80) | 52(5.30) | 57(5.81) | 626.32) -73(7.44) 480 313.77) | 42(4.28) | 46(4.70) 5065.10) $85.91) 510 28(2.86) | 32(3.26) | 34.47) | 373.77) 444.50) Table 18.3 Coefficients in Formulas for Cover Plates Material Method of | Circular | Rectangular — Elliptical of Cover Plate | Holding Edges Plate Plate Plate _|k Te ks a Supported, free | 0.54 | 0.038 [0.75 | 1.73 (15 Fixed O44 | 0.010 | 0.62 | 1.4: 1.6" 2 Mild stel | Suppo, free | 0.42 0.60 1.38 2 ixed 5 3: 1.28 “Wi pals 0.35 O49 LAL 09 : Table 18.4 Thickness of Piston Head ‘Type of Engine Pist = Sirokt Compression-ignition oil engines on Material Four Stroke Two St 0 do. Cast iron O.1ID-0.13D 0.160 oT Spark ignition gas engines Aluminium — Q.13p—o.16D 0170-2 Cast iron OD—o.14D 0.20D-8*“= stinders and Pistons of steam and Internal co au vi | Combustion engin es Iuble 18.8 Weights of Reciprocating Parts Weight W/A, MN/m’* of Piston Area Types of Engine Spark Ignition Compression I om, Single Acting Engine _— ; raft 150% 107? 2.75 x 10 2.06 x 10" 3.19 2.06 x 10° - 340 10 109 otomobil : : Trock and tractor 2.40 x 1078 = 5.15 x 10 240% 105.15 = . 3 3 3 Sx 19 Mesium speed stationary 1030 10° = 27.50% 10° _1030% 10° 3050. 195 ‘ein Metric unts kgm of piston area) canbe obtained by dividing the given yah les with 9.8067 Table 18.9 Magnitude of Radial Pressure ofthe Piston Rings on the Cy Barrel (according to Unwin) linder ne __Seam Engines Type of engine Tp. LP. LP. engines a ees PMN 002746 002060 0.01372 0.02402-0.03090 0.0 aE-on ketimm?) (0.0028) (0.0021) _(@.0014) _(0.00245-0,00315) (00am —_thetimm!) (0.0028) (007) EEE _ COSA) _(0.0028-0.0035) References (1) Bhattacharya, S.C, Basu Malik, J. R., “Machine Design”, Besu Mallik & Co., Caluta, 1965 (2] Vallance, A., Doughtle, V. L., “Design of Machine Members”, ae ign of Machine Members”, 3rd edition, McGraw Hill Bok