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MD Piston Numerical

DESIGN CALCULATIONS (Gujarat Technological University)

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Design of Piston

Design a cast iron piston for a single acting four stroke diesel
engine with the following data:
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 per BP per h
Higher calorific value of fuel = 44000 kJ/kg
Assume Suitable Data if required and state the assumptions
you make.
Given Data:
D = 300 mm, l = 450 mm=0.45 m, N = 300 rpm, 𝑝𝑚 = 0.85
Mpa, 𝑝𝑚𝑎𝑥 = 5 𝑀𝑝𝑎, m = 0.3 kg per BP per h, HCV = 44000 kJ/kg

Step I: Piston Head or crown (Thickness)

Find thickness using strength and Heat dissipation (Thermal
consideration) criteria.

 The thickness of piston head by strength consideration is

given by,

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3 𝑝𝑚𝑎𝑥
𝑡ℎ = 𝐷√ BDDB = 29.15
16 𝜎𝑏

Here 𝜎𝑏 is not specified in given data so,

Assumption No 1: The permissible tensile stress for the cast
iron piston is 40𝑁⁄𝑚𝑚2 .
BDDB = 29.16
2
𝝈𝒃 = 𝝈𝒕 = 40𝑁⁄𝑚𝑚
So,
3 𝑝𝑚𝑎𝑥 3(5)
𝒕𝒉 = 𝐷 √ = 300 √16(40) = 𝟒𝟓. 𝟗𝟑 𝒎𝒎 …………..(a)
16 𝜎𝑏

 The thickness of piston head by Thermal consideration is

given by,
𝐻
𝑡ℎ = [12.56𝑘(𝑇 −𝑇 )] × 103 BDDB = 29.16
𝑐 𝑒

For calculation of 𝑡ℎ , first find the value of H (amount of heat

conducted through piston head)
𝐻 = [𝑐 × 𝐻𝐶𝑉 × 𝑚 × 𝐵𝑃] × 103 BDDB = 29.16

For a four stroke engine, n = N/2 = 300/2 = 150 strokes/min

BDDB = 29.8
𝒑𝒎 𝒍 𝑨 𝒏 (0.85)(0.45 𝜋(300)2
IP = = [ ] (150)
𝟔𝟎 60 4
BDDB = 29.10
𝐈𝐏 = 67593.33 W = 67.59 kW
Assumption No 2:
The mechanical efficiency is 80% or 0.8 BDDB = 29.7

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Now, BP = η IP = 0.8(67.59) = 54.07 kW

BDDB = 29.7

m = 0.3 kg per BP per h

0.3
= (60×60) 𝑘𝑔 𝑝𝑒𝑟 𝐵𝑃 𝑝𝑒𝑟 𝑠𝑒𝑐𝑜𝑛𝑑 BDDB = 29.16

𝑚 = (83.33 × 10−6 )𝑘𝑔 𝑝𝑒𝑟 𝐵𝑃 𝑝𝑒𝑟 𝑠𝑒𝑐𝑜𝑛𝑑

Assumption No 3:
The ratio of heat absorbed by the piston to the total heat
developed in the cylinder is 5 % or 0.05. BDDB = 29.16
C = 0.05
Now,
𝐻 = [𝑐 × 𝐻𝐶𝑉 × 𝑚 × 𝐵𝑃] × 103
= [0.05 × 44000 × (83.33 × 10−6 ) × 54.07] × 103
𝐻 = 9912.44 W

Assumption No 4:
The thermal conductivity factor (k) for cast iron piston is 46.6
W/m/̊C. BDDB = 29.16
Assumption No 5:
The temperature difference (𝑇𝑐 − 𝑇𝑒 ) between the centre and
the edge of the piston head is 220̊C.
BDDB = 29.16
So Now,
𝐻
𝑡ℎ = [12.56𝑘(𝑇 −𝑇 )] × 103
𝑐 𝑒

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9912.44
= [12.56×46.6×(220)] × 103

𝒕𝒉 = 𝟕𝟔. 𝟗𝟖 𝒎𝒎 …………………………………………(b)
From (a) and (b) , thickness based on thermal consideration is
more , so
𝒕𝒉 = 𝟕𝟔. 𝟗𝟖 𝒎𝒎 or 77 mm

Step II: Piston ribs

Since t h = 77 mm , t h > 6
BDDB = 29.17
So, ribs are required.

Assumption No 6:
The number of piston ribs is 4. BDDB = 29.17
Thickness of piston rib is given by,
𝑡ℎ 𝑡ℎ 77 77
𝑡𝑟 = 𝑡𝑜 = 𝑡𝑜
3 2 3 2 BDDB = 29.17

𝑡𝑟 = 25.67 𝑡𝑜 38.5
𝒕𝒓 = 𝟑𝟎 𝒎𝒎 (Assume any number between25.67 𝑡𝑜 38.5)

Step III: Requirement of Piston cup

Check l/D ratio.
𝑙 450
Here, 𝐷 = 300 = 1.5 BDDB = 29.17

Therefore, a cup is required (∵l/D = 1.5)

BDDB = 29.17
Radius of cup = 0.7 D = 0.7 (300) = 210 mm

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Step IV: Piston rings

Radial width of piston ring is given by,

3𝑝𝑤
𝑏 = 𝐷√ BDDB = 29.23
𝜎𝑡

Assumption No 7:
The allowable radial pressure (𝑝𝑤 ) on the cylinder wall is
0.035 Mpa. BDDB = 29.23

Assumption No 8:
The piston rings is made up of cast iron and the permissible
tensile stress is 90𝑁⁄𝑚𝑚2 . BDDB = 29.23
Assumption No 9:
The number of compression ring is 3 and there is 1 oil scraper
ring. So total number of rings z = 4 BDDB = 29.22
Now,

3𝑝𝑤 3 (0.035)
𝑏 = 𝐷√ = 300√ = 𝟏𝟎. 𝟐𝟓 𝒎𝒎
𝜎𝑡 90

 Axial thickness(width) of piston ring is given by,

h = (0.7b) to b = (0.7)(10.25) to 10.25 BDDB = 29.23
h = 7.17 to 10.25
h = 8 mm
Also check, ℎ𝑚𝑖𝑛

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𝐷 300
ℎ𝑚𝑖𝑛 = = = 7.5 𝑚𝑚 ∴ 𝒉 > 𝒉𝒎𝒊𝒏 BDDB = 29.23
10𝑧 10(4)
 The gap between free ends of ring before assembly is given by,
𝐺1 = 3.5𝑏 𝑡𝑜 4𝑏 = 3.5(10.25)𝑡𝑜 4(10.25)
BDDB = 29.23
𝐺1 = 35.87 𝑡𝑜 41𝑚𝑚
𝑮𝟏 = 𝟒𝟎 𝒎𝒎

 The gap between free ends of ring after assembly is given by,
𝐺2 = 0.002𝐷 𝑡𝑜 0.004𝐷 = 0.002(300)𝑡𝑜 0.004(300)
𝐺2 = 0.6 𝑡𝑜 1.2 𝑚𝑚 BDDB = 29.23
𝑮𝟐 = 𝟎. 𝟖 𝒎𝒎

 The width of the top land is given by,

BDDB = 29.23
ℎ1 = 𝑡ℎ 𝑡𝑜 1.2 𝑡ℎ = 77 𝑡𝑜 (1.2)(77)𝑚𝑚
ℎ1 = 77 𝑡𝑜 92.4 𝑚𝑚
𝒉𝟏 = 𝟖𝟓 𝒎𝒎

 Distance between two consecutive ring grooves is given by,

ℎ2 = 0.75 ℎ 𝑡𝑜 ℎ = 0.75 (8) 𝑡𝑜 8 𝑚𝑚 BDDB = 29.23
ℎ2 = 6 𝑡𝑜 8 𝑚𝑚
𝒉𝟐 = 𝟕 𝒎𝒎

Step V: Piston Barrel

 The thickness of piston barrel at the top end is given by,
𝑡3 = (0.03𝐷 + 𝑏 + 4.9) = 0.03(300) + 10.25 + 4.9
𝒕𝟑 = 𝟐𝟒. 𝟏𝟓 𝒎𝒎 𝒐𝒓 𝟐𝟓 𝒎𝒎 BDDB = 29.24

 The thickness of piston barrel at the open end is given by,

𝑡4 = (0.25𝑡3 ) 𝑡𝑜 (0.35𝑡3 ) = (0.25 × 25) 𝑡𝑜 (0.35 × 25)
𝑡4 = 6.55 𝑡𝑜 8.75 𝑚𝑚 BDDB = 29.24
𝒕𝟒 = 𝟕 𝒎𝒎

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Step VI: Piston Skirt (remember all steps of skirt design)

The length of skirt is given by,
𝜋𝐷2
𝜇( ) 𝑝𝑚𝑎𝑥 = 𝑝𝑏 𝐷𝑙𝑠
4
Assumption No 10:
The allowable bearing pressure (𝑝𝑏 ) for the skirt portion of the
piston is 0.45 Mpa.
Assumption No 11:
The ratio of side thrust on liner to maximum gas load on piston
(Coefficient of friction 𝜇) 𝑖𝑠 0.1
𝜇 = 0.1
 Now for length skirt,
𝜋𝐷2
𝜇( ) 𝑝𝑚𝑎𝑥 = 𝑝𝑏 𝐷𝑙𝑠
4
𝜋 × 3002
0.1 × (5) = (0.45)(300)𝑙𝑠
4
∴ 𝒍𝒔 = 𝟐𝟔𝟏. 𝟖𝒎𝒎 𝒐𝒓 𝟐𝟔𝟐 𝒎𝒎

Step VII: Piston length (remember all step for piston

length)
Length of Piston = Top Land + length of ring section + length
of skirt
Length of ring section = 4h + 3ℎ2 = 4(8) + 3(7) ( ∵ 𝑧 = 4)

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Length of ring section = 53 mm

∴ Length of Piston(L) = 85+53+262 = 400 mm
 According to empirical relationship,
L = D to 1.5D = 300 to 1.5(300) = 300 to 450 mm
∴ 𝑫 < 𝑳 > 𝟏. 𝟓𝑫

Step VIII: Piston Pin

First calculate outside diameter of the piston pin using eqn.,
𝜋𝐷2
( ) 𝑝𝑚𝑎𝑥 = (𝑝𝑏 )1 × 𝑑0 × 𝑙1
4 BDDB = 29.25

Assumption No 12:
The bearing pressure(𝑝𝑏 )1 at the bush of the small end of
connecting road is 30 Mpa. (take 25 Mpa) BDDB = 29.25
Assumption No 13:
The length of piston pin in the bush of the small end of
connecting road is (0.45)D.
𝑙1 = 0.45𝐷 BDDB = 29.24

𝜋𝐷2
( ) 𝑝𝑚𝑎𝑥 = (𝑝𝑏 )1 × 𝑑0 × 𝑙1
4
𝜋 × 3002
× 5 = 30 × 𝑑0 × (0.45)(300)
4
𝒅𝟎 = 𝟖𝟕. 𝟐𝟏 𝒎𝒎 𝒐𝒓 𝟗𝟎 𝒎𝒎
In order to make shaft hollow, we will increase diameter to 120
mm.

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𝒅𝟎 = 𝟏𝟐𝟎 𝒎𝒎
 Inner Diameter (𝒅𝒊 ) = 0.6(𝑑0 ) = 𝟕𝟐 𝒎𝒎
BDDB = 29.24
Assumption No 14:
The piston pin is made of case hardened alloy still and
permissible tensile stress is 140 Mpa.
BDDB = 29.25

 Bending Moment, BDDB = 29.25

𝑃𝐷 353429.17×300 𝜋𝐷2
𝑀𝑏 = = (∵ 𝑃 = ( ) 𝑝𝑚𝑎𝑥 )
4
8 8

𝑀𝑏 = 13253.59 × 103 𝑁 − 𝑚𝑚
𝜋(𝑑𝑜 4 −𝑑𝑖 4 ) 𝜋[(120)4 −(72)4 ]
𝐼= = BDDB = 29.25
64 64

𝐼 = 8855101.44𝑚𝑚2
𝑑0 120
𝑦= = = 60 𝑚𝑚 BDDB = 29.25
2 2

𝑀𝑏 𝑦 13253.59 × 103 × 60
𝜎𝑏 = =
𝐼 8855101.44 BDDB = 29.25

𝝈𝒃 =89.80 Mpa (𝝈𝒃 < 𝟏𝟒𝟎 𝑴𝒑𝒂)

 The mean diameter of the piston boss is given by,

mean diameter of the piston boss = 1.4𝑑0 =1.4(120)= 168mm

……………………………………………………………….

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