DESIGN AND ANALYSIS OF IC ENGINE CYLINDER

21MEC301P – DESIGN OF MECHANICAL SYSTEMS

A PROJECT REPORT

Submitted by

S HARI VITTAL (RA2211002040003)

Under the guidance of

Dr. M. KAMATCHI HARIHARAN M.E., Ph.D.,

(Assistant Professor (S.G), Department of Mechanical Engineering)
in partial fulfillment for the award of the degree
of

BACHELOR OF TECHNOLOGY
in
MECHANICAL ENGINEERING
of
FACULTY OF ENGINEERING AND TECHNOLOGY

November 2024

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 SRM Institute of Science and Technology
(Deemed to be University Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that thisproject titled “DEISGN AND ANALYSIS OF IC ENGINE

CYLINDER” is the Bonafide work of “S HARI VITTAL RA2211002040003”,
who carried out the project work under my supervision. Certified further, that
to the best of my knowledge the work reported herein does not form any
other project report or dissertation on the basis of which a degree or award
was conferred on an earlier occasion on this or any other candidate.

SIGNATURE SIGNATURE

Dr. M. KAMATCHI HARIHARAN M.E., Ph. D Dr. R. RAJARAMAN, M.E., Ph.D.

GUIDE HEAD OF THE DEPARTMENT

ASSISTANT PROFESSOR (S.G) MECHANICAL

ENGINEERING DEPT. OF MECHANICAL ENGINEERING

Submitted for the Viva-Voce held on:

Signature of the Internal Examner-1 Signature of the Internal Examiner-2

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 ACKNOWLEDGEMENT

We express our humble gratitude to the management for the facilities

extended for the project work.

We extend our sincere thanks to the Dean Dr. C V Jayakumar, Vice Principal -
Academics Dr.C.Gomathy and Vice Principal- Examinations Dr.S.Karthikeyan
for their invaluable support.

We wish to thank Dr.R.Rajaraman, M.E., Ph.D., Professor & Head, Department

of Mechanical for his valuable suggestions and encouragement throughout the
period of the project work.

We are extremely grateful to our Project Coordinator Dr.Kamatchi Hariharan

M, M.E., Ph.D., Assistant Professor, Department of Mechanical for leading and
helping us to complete our course. He provided us the freedom and support
to explore the research topics of our interest.

We sincerely thank our management, all Mechanical faculty members, staff

and fellow students who have directly or indirectly helped our project.

Finally, we would like to thank our parents, our family members and friends
for their unconditional love, constant support and encouragement.

Regards

S HARI VITTAL

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 ABSTRACT
This project involves the design and fabrication of an internal combustion (IC) engine
cylinder using 3D printing technology. The objective is to understand and apply
mechanical engineering principles related to IC engines, while also exploring the
potential and limitations of additive manufacturing in creating complex engine
components. The project encompasses the design of a single-cylinder layout, focusing on
essential features such as intake and exhaust valves, piston clearance, and cooling fins.
Using CAD software, a detailed 3D model is created, emphasizing dimensions and
tolerances that align with the functional requirements of an IC engine.

Material selection, print resolution, and layer height are optimized to balance durability
with detail accuracy in the final print. This project provides a hands-on approach to
understanding engine mechanisms, assembly processes, and 3D printing technology,
offering insights into its application for rapid prototyping and educational purposes. The
outcome aims to demonstrate both the feasibility of using 3D printing for engine
modeling and the practical challenges that arise in translating theoretical design into a
functional, scaled-down prototype.

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 Index

1. What is an IC engine, what is the role of cylinder there.

2. What is a cylinder made of and how is it made
3. Advantages of making the cylinder with that material..
4. Model sum
5. Engineering drawing
6. 3d printing over casting.
7. 3d printing a cylinder
8. Why use Polylactic Acid
9. Difficulties I faced during making of the project .
10.Outcome of the project
11.Final product
12.Conclusion

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 CHAPTER 1
What is an IC engine, Types and applications. Role of
cylinder.
Introduction to IC Engines

An internal combustion (IC) engine is a widely used type of engine that

converts chemical energy from fuel into mechanical energy through
combustion. Unlike external combustion engines, where combustion
occurs outside the engine (like in steam engines), IC engines burn fuel
within the engine’s cylinders. This design allows IC engines to be compact,
efficient, and powerful, making them essential in automobiles, aircraft, and
various industrial applications.

In an IC engine, fuel, typically gasoline or diesel, is mixed with air and

ignited within a confined space called a cylinder. This combustion process
generates high-pressure gas, which forces a piston within the cylinder to
move. This linear motion of the piston is then converted into rotational
motion through a crankshaft, producing the mechanical energy needed to
power vehicles and machines.

Types of IC Engines

IC engines are typically classified into two main types based on their
combustion process: spark-ignition (SI) and compression-ignition (CI)
engines.

Spark-Ignition (SI) Engines use a spark plug to ignite a mixture of fuel and
air within the cylinder. This type of engine is common in gasoline-powered
vehicles.

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Compression-Ignition (CI) Engines, also known as diesel engines, rely on
high compression to raise the air temperature enough to ignite the diesel
fuel spontaneously. CI engines are often used in heavy-duty vehicles due to
their fuel efficiency and durability.

The Role of the Cylinder

The cylinder is one of the most crucial components of an IC engine, as it

forms the main chamber where combustion takes place. Its functions
include housing the piston, intake and exhaust valves, and occasionally the
spark plug or fuel injector. The cylinder allows fuel and air to mix,
compresses the mixture, and provides a confined space for combustion to
occur. This process involves several cycles in an engine, known as the four-
stroke cycle, consisting of intake, compression, power, and exhaust strokes.

1. Intake Stroke: The intake valve opens, allowing the air-fuel mixture to
enter the cylinder.

2. Compression Stroke: The intake valve closes, and the piston compresses
the mixture, increasing its temperature.

3. Power Stroke: The mixture is ignited (via a spark in SI engines or

compression in CI engines), causing a rapid expansion of gases that push
the piston down.

4. Exhaust Stroke: The exhaust valve opens, allowing the burnt gases to exit
the cylinder.

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The cylinder’s design and material are critical because they must withstand
high pressures, temperatures, and constant movement. It also needs
precise dimensional accuracy to ensure the proper fit and smooth
operation of the piston.

Cylinder Layouts and Configurations

Engine cylinders are arranged in various configurations depending on the

engine's design and intended application. Common layouts include inline
(all cylinders in a single row), V (cylinders in two angled rows), and flat
(cylinders in two opposite rows). These configurations affect the engine's
size, weight, balance, and power output, with the choice depending on
factors such as vehicle type and performance requirements.

In summary, the cylinder in an IC engine is a key component that facilitates

the controlled combustion of fuel to create motion. Its design must balance
strength, durability, and heat dissipation to withstand the demanding
conditions within an engine.

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 Chapter 2
Materials used for making an cylinder, how it is made

What is a Cylinder Made of, and How is it Made?

Materials Used in Cylinder Manufacturing

The material choice for an engine cylinder is crucial due to the high
temperatures, pressures, and stresses it must withstand. Traditional IC
engine cylinders are made of materials that combine strength, thermal
stability, and wear resistance, including:

1. Cast Iron: Known for its high wear resistance, cast iron has been a
popular choice for engine cylinders in heavy-duty and commercial vehicles.
Cast iron can endure high heat and pressure, has excellent damping
qualities to reduce vibration, and can hold lubrication well, which
minimizes wear.

2. Aluminum Alloys: Often used in high-performance engines, aluminum

alloys provide significant weight savings compared to cast iron. Although
not as wear-resistant as cast iron, aluminum has excellent thermal
conductivity, allowing it to dissipate heat more effectively. This
characteristic is beneficial for engines that need to manage high
temperatures effectively, as it reduces the risk of overheating.

3. Steel Alloys: While less common, steel alloys are occasionally used in
engines that require extreme durability. Steel cylinders can handle higher
pressures but are typically heavier than both aluminum and cast iron, so

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they’re reserved for applications where weight is less of a concern.

4. Composite Materials: Advanced materials, such as ceramics or fiber-

reinforced composites, are being researched for engine cylinders due to
their heat resistance and lightweight properties. However, they are still
limited to specialized applications due to cost and manufacturing
challenges.

Manufacturing Methods for Engine Cylinders

The manufacturing method chosen for engine cylinders depends on factors

like production volume, material, and precision requirements. Common
manufacturing processes include casting, forging, machining, and, more
recently, 3D printing.

1. Casting: For large-scale production, casting is a common and efficient

choice. This process involves pouring molten metal, usually cast iron or
aluminum, into a mold shaped like the cylinder. Casting allows for the mass
production of complex shapes with minimal material waste. Sand casting
and die casting are two popular methods. Sand casting is often used for
prototypes and small runs, while die casting, which uses metal molds, is
used for high-volume production.

2. Machining: After casting or forging, the cylinder typically requires

precise machining to achieve the required dimensions and surface finish.
CNC (Computer Numerical Control) machines are used to bore the inner
cylinder to an exact diameter and ensure a smooth surface for the piston to
move smoothly.

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3. Forging: In some cases, especially for high-performance engines, forging
is used. This process involves compressing metal under high pressure to
improve its strength and durability. While forging is more expensive than
casting, it results in a stronger cylinder that can handle higher stresses.

4. 3D Printing: With advances in 3D printing, prototyping a cylinder is

possible. This method is ideal for single or small-batch production,
especially for research and educational projects. Materials like PLA
(Polylactic Acid) can be used to create models quickly, though they lack the
durability for actual engine use.

Advantages of Common Cylinder Materials

Each material has unique benefits suited to specific engine needs:

Cast Iron: Durable and highly resistant to wear, it provides longevity for
commercial engines that must withstand continuous use. Cast iron’s ability
to retain lubricants also reduces internal friction.

Aluminum Alloys: Lightweight and great at dissipating heat, aluminum

reduces the overall engine weight, enhancing fuel efficiency and
performance. Its thermal properties make it an ideal choice for high-
performance engines, although aluminum requires proper surface
treatments to resist wear.

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Steel Alloys: Steel cylinders are highly durable and withstand high
pressure, making them suitable for specialized applications. However, their
weight limits their use to engines where durability is prioritized over
efficiency.

PLA for Prototyping: PLA is a biodegradable plastic commonly used in 3D

printing, offering a low-cost option for prototyping. While PLA cannot be
used in actual engine environments due to its low melting point, it provides
a simple way to produce scale models and test designs for educational or
preliminary design stages.

Cylinder Liners and Coatings

In engines where the primary cylinder material is not wear-resistant

enough, cylinder liners or coatings are added. Liners are thin-walled
cylindrical inserts made from materials with high wear resistance, such as
hardened steel or ceramics, and are fitted within the main cylinder block.
They provide a durable surface that can be easily replaced if worn down.

Some modern engines use coatings, like plasma-sprayed ceramics or

specialized nitrides, which enhance wear resistance, reduce friction, and
improve heat management. Coatings are increasingly common in
aluminum engines, as they enable lighter materials to perform reliably
under high stress.

In summary, engine cylinders are made from robust materials like cast
iron, aluminum alloys, and steel, chosen for their durability, heat
resistance, and wear properties. The production method, whether casting,
forging, or machining, is selected based on the application’s scale and
requirements. Recent advancements, such as 3D printing and material
coatings, continue to expand the possibilities for cylinder design,
improving durability, performance, and cost-effectiveness in various

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applications.

CHAPTER 3
Advantages of Making the Cylinder with Polylactic Acid

Why Choose Polylactic Acid (PLA) for Prototyping?

For this project, Polylactic Acid (PLA) was chosen as the primary material
for 3D printing a prototype of the IC engine cylinder. PLA, a biodegradable
thermoplastic derived from renewable resources, is popular for
educational and prototyping applications due to its cost-effectiveness, ease
of printing, and environmental benefits. Although not suited for real engine
conditions, PLA has several benefits that make it ideal for creating a model
cylinder:

1. Ease of Use: PLA’s low melting point and good layer adhesion allow for
smooth, accurate prints without issues like warping. This is crucial for
complex shapes like cylinders, where precision is essential.

2. Cost Efficiency: PLA is affordable, making it suitable for single-use or

low-volume projects. Its low cost allows for rapid iterations, making it ideal
for design and testing in educational environments.

3. Environmental Impact: As a biodegradable material, PLA is an eco-

friendly choice compared to metals, which require energy-intensive
processes to produce. This supports sustainable prototyping practices,

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especially valuable in education.

Benefits of PLA for Cylinder Prototyping

Rapid Prototyping: 3D printing with PLA enables quick production of

cylinder models, allowing for multiple iterations and easy design changes.
This supports efficient testing and learning.

Visualization and Fit Testing: PLA models provide a tangible, dimensionally

accurate representation of the cylinder, enabling designers to assess
assembly, fit, and other design aspects before moving to more durable
materials.

Accessibility: PLA is compatible with most 3D printers, making it widely

accessible for students and researchers. This facilitates hands-on learning
without the need for specialized manufacturing equipment.

Conclusion

Though limited to prototyping, PLA offers clear advantages in educational

settings. Its affordability, ease of use, and environmental benefits make PLA
a practical choice for learning and design validation. Through this project,
PLA has proven to be a valuable material for prototyping the IC engine
cylinder, balancing accessibility with the ability to test and improve
designs effectively.

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 Chapter 4

Model sum
Question:

A four-stroke diesel engine has the following specifications:

Brake power = 7 kW; Speed = 850 r.p.m.; Indicated mean effective
pressure = 0.3 N/mm²; Mechanical efficiency = 72%.
Determine:

1. The bore and length of the cylinder;

2. The thickness of the cylinder head; and

3. The size of studs for the cylinder head.

Note: The cylinder has an inner diameter of 10 mm, an outer diameter of

30 mm, and a length of 80 mm.

Let's solve the problem with the provided specifications.

Given Data

Brake Power (B.P.) = 7 kW = 7,000 W

Speed (N) = 850 r.p.m.

Indicated Mean Effective Pressure (IMEP) = 0.3 N/mm² = 0.3 × 10⁶ N/m²

Mechanical Efficiency (ηm) = 72% = 0.72

Inner Diameter (D) = 10 mm = 0.01 m

Outer Diameter = 30 mm = 0.03 m

Cylinder Length (L) = 80 mm = 0.08 m

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Step 1: Indicated Power (I.P.)

The indicated power (I.P.) is calculated using the mechanical efficiency

formula:

\eta_m = \frac{\text{Brake Power (B.P.)}}{\text{Indicated Power (I.P.)}}

I.P. = \frac{B.P.}{\eta_m} = \frac{7,000}{0.72} = 9,722.22 \, \text{W} =

9.722 \, \text{kW}

Step 2: Confirm Bore (Inner Diameter) Calculation

Since the inner diameter is already provided as 10 mm, let's ensure this
bore size fits with the required power output.

Using the formula for indicated power for a four-stroke engine:

I.P. = \frac{P_m \cdot L \cdot A \cdot N \cdot k}{60}

(Area of the cylinder bore)

(for a four-stroke engine)

Substituting these values:

9.722 \times 10^3 = \frac{0.3 \times 10^6 \cdot 0.08 \cdot \frac{\pi
(0.01)^2}{4} \cdot 425}{60}

9.722 \times 10^3 = \frac{0.3 \times 10^6 \cdot 0.08 \cdot \pi \cdot
0.0001 \cdot 425}{240}

9.722 \times 10^3 = 13.35 , \text{kW} \quad (\text{approximately}) ]

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The provided bore is adequate for the target indicated power.

Step 3: Thickness of the Cylinder Head

The thickness of the cylinder head can be estimated using the empirical
formula:

t = \frac{D}{6} + 3 \, \text{mm}

t = \frac{10}{6} + 3

t \approx 1.67 + 3 = 4.67 , \text{mm} ]

So, the thickness of the cylinder head is approximately 4.67 mm.

Step 4: Size of Studs for the Cylinder Head

To determine the size of studs for the cylinder head, calculate the force
acting on the cylinder head due to combustion pressure.

Force on Cylinder Head

The force on the cylinder head is:

F = \frac{\pi D^2}{4} \cdot P_m

(inner diameter)

Substitute these values:

F = \frac{\pi \times (0.01)^2}{4} \times 0.3 \times 10^6

F = \frac{\pi \times 0.0001}{4} \times 0.3 \times 10^6 ]

F = 23.56 \, \text{N}

Assuming four studs, the force per stud is:

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\text{Force per stud} = \frac{23.56}{4} \approx 5.89 \, \text{N}

Choosing Stud Size

Given a mild steel material with an allowable stress of around 150 MPa, an
M4 stud should be sufficient to handle the force.

Summary:

1. Bore (Inner Diameter) = 10 mm (as specified)

2. Cylinder Length = 80 mm (as specified)

3. Thickness of Cylinder Head = 4.67 mm

4. Size of Studs = M4

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Outcome of the Project: IC Engine Cylinder Prototype

The IC engine cylinder project successfully achieved its primary goals of

designing, prototyping, and analyzing a scaled-down model of an internal
combustion engine cylinder. Through this project, several outcomes were
accomplished, highlighting both technical and educational benefits:

1. Functional Prototype Creation: Using CAD software, an accurate 3D

model of the IC engine cylinder was designed with specified dimensions—
an outer diameter of 15 mm, inner diameter of 5 mm, and length of 80
mm. The prototype was successfully 3D printed in Polylactic Acid (PLA),
allowing for a tangible model that visually represents the design and
structure of a functional cylinder.

2. Understanding of 3D Printing Limitations and Material Properties:

Through the process of 3D printing the cylinder, the project demonstrated
the advantages and limitations of using PLA. PLA was easy to work with,
affordable, and environmentally friendly, but its mechanical properties
also showed it to be unsuitable for high-temperature or high-stress
applications, highlighting why it is best for prototyping rather than final
production parts in a real engine.

3. Insight into Cylinder Design and Fit: The project facilitated an

understanding of critical design aspects such as wall thickness, cylinder
bore, and the relationship between the cylinder and the piston, intake,
and exhaust components. The final printed model enabled visualization
and testing of these features, providing hands-on experience with key
engineering design principles.

4. Application of Engineering Theory in a Practical Setting: This project

bridged the gap between theoretical knowledge and practical application.
Concepts such as fit tolerance, dimensioning, and assembly alignment
were applied in real-time during the CAD modeling and printing process,
enhancing learning and offering practical insights.

5. Project Report Documentation and Analysis: The project outcomes and

findings were documented in a detailed report, covering all aspects of the
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project from design to challenges faced and solutions implemented. This
documentation will be useful for future reference and for sharing
knowledge gained from the project with peers or instructors.

Conclusion: The IC engine cylinder project was a success, providing a

thorough understanding of the design, prototyping, and analysis process
for engine components. By using 3D printing, a cost-effective and accurate
model was achieved, meeting the educational objectives of the project and
providing valuable insights into material selection, manufacturing
processes, and practical design considerations in mechanical engineering.

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