DESIGN OF SINGLE CYLINDER 4-STROKE

DIESEL ENGINE
Submitted in partial fulfillment of the requirements
For the Design of Mechanical System
Fourth Year
by

Ali Zakir Thakur

Suraj Subramaniam
Sharun Sajeevan Ponnoran
Rohit Rajan

Lecturer:
Prof. G.V.Patil
Department Of Mechanical Engineering

Pillai College of Engineering, New Panvel, Navi Mumbai

University of Mumbai
2017- 18

1 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 Acknowledgement

It gives us immense pleasure to thanks our Lecturer Prof. G.V.Patil of Mechanical

Engineering for his pedagogy and unswering guidance in writing this report, We are very
much thankful to our respected, Principal Dr. Sandip Joshi, and HOD of mechanical
department, Dr, Dhanraj Tambuskar for their necessary help and encouragement.

2 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 INTRODUCTION
An engine is a machine designed to convert one form of energy into mechanical
energy. Heat engines burn a fuel to create heat which is then used to do work. Electric
motors convert electrical energy into mechanical motion; pneumatic motors use compressed
air; and clockwork motors in wind-up toys use elastic energy. In biological
systems, molecular motors, like myosins in muscles, use chemical energy to create forces and
eventually motion. In modern usage, the term engine typically describes devices, like steam
engines and internal combustion engines, that burn or otherwise consume fuel to
perform mechanical work by exerting a torque or linear force (usually in the form of thrust).
Devices converting heat energy into motion are commonly referred to simply as engines.
[3]
 Examples of engines which exert a torque include the familiar automobile gasoline and
diesel engines, as well as turboshafts. Examples of engines which produce thrust
include turbofans and rockets.

The first commercially successful automobile, created by Karl Benz, added to the
interest in light and powerful engines. The lightweight petrol internal combustion engine,
operating on a four-stroke Otto cycle, has been the most successful for light automobiles,
while the more efficient Diesel engine is used for trucks and buses. However, in recent years,
turbo Diesel engines have become increasingly popular, especially outside of the United
States, even for quite small cars.

The diesel engine (also known as a compression-ignition or CI engine), named

after Rudolf Diesel, is an internal combustion engine in which ignition of the fuel which is
injected into the combustion chamber is caused by the elevated temperature of the air in the
cylinder due to mechanical compression (adiabatic compression). Diesel engines work by
compressing only the air. This increases the air temperature inside the cylinder to such a high
degree that atomised diesel fuel that is injected into the combustion chamber ignites
spontaneously. This contrasts with spark-ignition engines such as a petrol
engine (gasoline engine) or gas engine (using a gaseous fuel as opposed to petrol), which use
a spark plug to ignite an air-fuel mixture. In diesel engines, glow plugs (combustion chamber
pre-warmers) may be used to aid starting in cold weather, or when the engine uses a lower
compression-ratio, or both. The original diesel engine operates on the "constant pressure"
cycle of gradual combustion and produces no audible knock.

3 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 WORKING
The working principle is called the Diesel Cycle. In diesel cycle, fuel is added to
combustion chamber; then it is compressed which results in ignition. This is different
than Otto cycle which is used in petrol engines wherein a spark plug is used to ignite the
mixture of air and fuel.

4 stroke Diesel engines have four different cycles,

1. Suction stroke(Intake stroke)

2. Compression stroke
3. Expansion stroke(Power stroke)
4. Exhaust stroke

Fig.1. PV diagram of diesel cycle.

(a) Suction Stroke

In this stroke, the piston moves from the TDC to BDC which makes pressure difference
in the combustion chamber. This leads to the intake of air. In contrast to this, the
charge(petrol and air) is admitted in case of petrol engines.

(b) Compression stroke

In this stage, the air inside the chamber is compressed by the movement of piston from
BDC to TDC. At the end of the compression stroke, the fine droplets of diesel is
sprayed inside the combustion chamber by the fuel injectors and the once the diesel
attains the self igniting temperature the combustion takes place.

4 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 (c) Expansion Stroke (Power Stroke)

Once the combustion of diesel takes place, power stroke takes place. This stroke gives
the power to the automobile.

(d) Exhaust stroke

This is the final cycle where the CO2, unburnt HC, NOx are eliminated through the
tailpipe.

Fig.2.Working of Diesel Engine

The diesel engine gains its energy by burning fuel injected or sprayed into the
compressed, hot air charge within the cylinder. The air must be heated to a temperature
greater than the temperature at which the injected fuel can ignite. Fuel sprayed into air that
has a temperature higher than the “auto-ignition” temperature of the fuel spontaneously reacts
with the oxygen in the air and burns. Air temperatures are typically in excess of 526 °C (979
°F); however, at engine start-up, supplemental heating of the cylinders is sometimes
employed, since the temperature of the air within the cylinders is determined by both the
engine’s compression ratio and its current operating temperature. Diesel engines are
sometimes called compression-ignition engines because initiation of combustion relies on air
heated by compression rather than on an electric spark.

5 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 LITERATURE REVIEW
In 1897, when the first Diesel engine was completed, Adolphus Busch traveled to
Cologne and negotiated exclusive right to produce the Diesel engine in the US and Canada. In
his examination of the engine, it was noted that the Diesel at that time operated at
thermodynamic efficiencies of 27%, while a typical expansion steam engine would operate at
about 7-10%.

In the early decades of the 20th century, when large diesel engines were first being
used, the engines took a form similar to the compound steam engines common at the time,
with the piston being connected to the connecting rod by a crosshead bearing. Following
steam engine practice some manufacturers made double-acting two-stroke and four-stroke
diesel engines to increase power output, with combustion taking place on both sides of the
piston, with two sets of valve gear and fuel injection. While it produced large amounts of
power, the double-acting diesel engine's main problem was producing a good seal where the
piston rod passed through the bottom of the lower combustion chamber to the crosshead
bearing, and no more were built. By the 1930s turbochargers were fitted to some engines.
Crosshead bearings are still used to reduce the wear on the cylinders in large long-stroke main
marine engines.

6 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 PROBLEM DEFINITION
In this project Designing of a Four Stroke Single Cylinder Diesel Engine is Carried
out. The engine considered for designing with specifications is given in the table below:

Fig.3.Specification Table

From the given models, SL-6 Series of Diesel engine is considered for designing
aspect. First the parameters required are taken from the specification table and the the
designing procedures are carried out.

7 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

Calculations are done to find out the following dimensions of the engine:

 Bore and Stroke

 Piston
 Piston Rings
 Piston Pin
 Connecting Rod
 Crankshaft

After calculating the required data, the components are structured in 3Dmodel with the help of
3D designing software. Finally the detailed assembly of the engine is made as per the results
obtained from the calculation.

8 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 CALCULATIONS

9 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE

 RESULT AND CONCLUSION
The designing of Diesel engine is completed and the results are tabulated below:

PARAMETER VALUE DIMENSION

Stroke 132 mm
Bore 110 mm
Crown Thickness 10 mm
Radial Thickness of Piston Ring 5 mm
Depth of groove 14.1 mm
Total length of Piston 167.1 mm
Length of Piston Pin 44 mm
Outer diameter of Pin 39 mm
Inner diameter of Pin 24 mm
Lc 297 mm
Rc 66 mm
Crank pin diameter 77 mm
Length of Crank pin 77 mm
Width of Crank web 102 mm
Thickness Crank web 20 mm
Length of main Journal Bearing 46 mm
Length between both bearing 167 mm

The Engine is designed and Modelled as per the dimensions given above which was
calculated by our group.

10 DESIGN OF 4-STROKE SINGLE CYLINDER DIESEL ENGINE