ICE Component Design Pistons 2021

‘I C Engine Component Design’
Design <?>  Engineering Design <?>  Mech. Engg Design<?>  Machine Design <?>
Synthesis of; Machine <?>  Assembly (of mechanisms & devices) <?> Sub-assembly<?> 
Sub-….-sub-assembly <?>  component/part/element <?>  Drawings  Manufacturing 
Assembling  Testing  Usage…..
‘Probable’ Process of ICE component design ;<?>
1. Deciding qualitative & quantitative functional requirements.

2. Selecting existing or synthesizing idea/scheme and ‘space dimensions’.
3. Estimating ‘forces’ acting on it and their actual effects.
4. Selecting Material of construction (MoC) and Factor of Safety (FoS).
5. Computing ‘safe’ cross sectional dimensions for strength/rigidity, and fatigue.<?>
6. Additional criteria to be considered <?>
7. Communicating ‘design’ through drawing for manufacturing & assembly.
8. Etc.
Adoption of Slider-crank mechanism for ICE <?>
Reciprocating fluid machines like pumps, compressors, hydraulic & pneumatic cylindersand
Internal Combustion egnine are adoption of slider-crank mechanism to convert reciprocating
motion in to rotary. In IC engines the slider and crank are transformed in to piston and
crankshaft respectively and connected by connecting rod (conrod). Shapes and sizes (‘space’
and cross sectional dimensions of these main parts could be found on the basis of desired
functional strength/rigidity, wear & fatigue, and manufacturing-assembling requirements.
IC engine (basics: types, working, important parts/‘elements’…)
Capacity, Compression ratio, Bore/Stroke, Crank/Conrod length, Clearance volume,….etc.

Piston(s)
It is the key component in reciprocating fluid machines; pumps, compressors, hydraulic

cylinders, and IC Engines. There are quite a number of different designs of pistons are
existing in the world of ICE today.
Development of basic ‘shape’ & ‘size’ of piston:
Diameter of this cylindrical slider/disc depends on volumetric capacity of engine,

configuration <?>, and bore-stroke ratio <?>. while height includes added ‘features’ necessary
to perform several main and auxiliary functions.
Functions required to be performed by ICE Pistons are to: <How?>
 bear and transfer major force of combustion pressure to connecting rod (through
piston pin) at high temperature.
 bear other/minor forces developed through cycle; side thrusts, inertia forces…
 seal high pressure & temperature combustion gases.
 dissipate heat generated due to combustion & friction due to relative movement of
contact surfaces to maintain material properties.<?>
 ‘apply’ lubricating oil to rubbing surfaces and wipe/scrap back.
 accommodate open valve(s) near TDC (esp. in high speed engines)
 provide ‘combustion space’ (esp. in diesel engines).
 ‘adjust’ clearance volume/compression ratio.
 give ‘cross-head’ + ‘anti-rocking’ effect, crank clearance, and reduce wear.
 maintain-acquire shape-size at working temperature.
All of the above for ‘very long & useful life’ with lower weight and cost…..with other design
considerations like manufacturing, assembly, repair..etc.
A near realistic yet simplified generic piston is presented here. Final shape & size may arrive
after ‘optimum’ design.
A
generic piston for a 4S, SI Engine (Simplified) <for CI?, 2S?>
Further modfication in shape of piston(s);
 Crown/top; valve clash pockets, clearance volume control dome, combustion space,…
 Barrel/skirt; recess to reduce weight reduction & crank clash, thermal expansion
compensating taper & ellipticity…<?>
Determining size of piston features for functioning with strength and/or rigidity:
For such complex shape, stress and deformation analysis would be extremely difficult using
simple equations. Numerical techniques like Finite Element Analysis could only help. <?>
Simplified analyses of stresses induced using strength equations may be made to have ‘feel’ as
follows;
i. Considering deck/top of the piston as a uniformly loaded

circular plate fiexd at edges would induce maximum stress
and deflection, could be used for finding piston thickness at
top; <which one is important? How to reduce?>
3 p  D2 0.011  p  D 4
 t max  MPa and y  mm,
E  tT 3
max
16 tT 2
ii. Forces of inertia of piston and combustion pressue transfer to
bosses through barrel and web above it. These would cylclically
induce tensile and compressive stress respectively, and ‘raised’
due to ring grooves and oil holes, could be considered for
finding barrel thickness<?>
Annulus of piston barrel at oil ring groove = thickness - ring groove +
‘web’ connecting boss and crown under compression and tension; <to be
demonstrated>
iii. Boss with web would experience same forces said in ii. and its size may
be caclulated using shear and bending considerations.<?>
iv. Side thrust of the piston due to pressure force and conrod inertia
would cause deformation and crushing stress on the barrel with sliding
motion to cause and wear of the piston. These may be used to set skirt
thickness and height.
FST
Deformation <to be demonstrated> and crushing for wear  c 
D  hBeff
v. etc.
Thus finding ‘size’ (dimensions) of piston features using strength or rigidity

would be considerably complex and ‘standard formula’ are not readily
available even basis of their proportions with respect to bore in ‘desi’ books are not explained.
However, the easiest ‘design calculations’ can be made for piston pin.
Piston pin:
Connects piston bosses (the fork) to small end of
conrod (the eye) with a ‘head-less’, hollow<?>, and
floating <?> pin under variable loading. The strength
consideration would be same as the pin-jointed links
under tension or compression as described at MD-1.
‘Realistic’ pistons
MoC and Manufacturing process:
Desirable properties of piston material are, good strength and wear resistance at operating
temperature with lower density, …..easy to manufacture through Casting, Forging, and
Machining …..Generally cast iron, cast steel, and aluminium alloys are used. Some times
combination and ‘locally’ different material may be used. <?>
Piston rings:
Two types of piston rings are employed commonly. Functionally upper set (head side) seal
high pressure gases of combustion while lower ring (skirt side) maintains proper lubrication
between rubbing surfaces. Rings also improve heat transfer from piston to cylinder.
Piston ring set
MoC and Manufacturing process:
Alloyed cast iron having good wear resistance at high temperature is employed..
Manufacturing <?>
A modern piston and associated terminology
A CIE piston
Simplified CIE piston

ICE Component Design Pistons 2021

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‘I C Engine Component Design’

‘Probable’ Process of ICE component design ;<?>

1. Deciding qualitative & quantitative functional requirements.

Adoption of Slider-crank mechanism for ICE <?>

IC engine (basics: types, working, important parts/‘elements’…)

Capacity, Compression ratio, Bore/Stroke, Crank/Conrod length, Clearance volume,….etc.

It is the key component in reciprocating fluid machines; pumps, compressors, hydraulic

Development of basic ‘shape’ & ‘size’ of piston:

Diameter of this cylindrical slider/disc depends on volumetric capacity of engine,

Functions required to be performed by ICE Pistons are to: <How?>

i. Considering deck/top of the piston as a uniformly loaded

Thus finding ‘size’ (dimensions) of piston features using strength or rigidity

MoC and Manufacturing process:

Piston ring set

MoC and Manufacturing process:

Simplified CIE piston

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