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DESIGN AND ANALYSIS OF IC ENGINE CYLINDER
21MEC301P – DESIGN OF MECHANICAL SYSTEMS
A PROJECT REPORT
Submitted by
Nishanth A (RA2211054040030)
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
1 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 “NISHANTH A (RA2211054040030)”, 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
2 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 NISHANTH A
3 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.
4 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
5 6 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.
1 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.
2 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.
3 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
4 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.
5 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.
6 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
7 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,
8 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.
9 Chapter 4
Model sum Question:
A four-stroke diesel engine has the following specifications:
11 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:
12 \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
13 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 14 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.
