Minor Project

Design exercise for Engine Cylinder

Name: Jaimini Parmar

Roll no.: 22BME081
Subject: Machine Design-1 Lab

1
1. Introduction

The engine cylinder is one of the most important part of an IC engine. It is a chamber
in an engine which contains piston, where the fuel is burned to generate power. The
engine cylinder is called as the heart of the engine too, there are major two types of
engine cylinder Single-Stage and Multi-Stage it is different because of the size and
cycles. In this report we will see what it is use for, which materials are been used for
making in engine cylinders, performance and failure and a lot more about engine
cylinder.

2. Applications of engine cylinder

Engines have been widely used in almost all applications throughout different
industries, such as automotive, aerospace, marine, power generation, and heavy
industrial machinery, Below are some applications of engine cylinders.

2.1 Application in Automobiles: One of the common application of engine cylinders

is in automobiles, which include cars, motorcycles, and heavy duty vehicles. An
internal combustion engine cylinder contains a piston which reciprocates in it,
resulting in the conversion of fuel combustion into mechanical energy.

Key Features in Automobiles:

A. Typically they are made of aluminum alloys or cast iron, these are designed to
withstand high temperatures and pressures.

B. Modern engines are employed in multi-cylinder configurations like inline-four, V6,

and V8 to increase the power and efficacy of an engine.

C. Cylinder liners are more commonly used to minimize wear and to enhance the
lifespan of an engine.

2
 Fig.1 Car engine cylinder.

Reference: https://images.app.goo.gl/XRUNKGs7G2h98UH66

2.2 Applications in Marine Engines: Larger engine cylinders produce thrust for large
marine engines found in ships and submarines. Generally, these engines are diesel
engines that operate on very low RPMs for best fuel efficiency and torque.

Key Features in Marine Engines:

A. Made from cast iron or high strength steel to prevent from corrosion in harsh
environments

B. They are equipped with water cooling systems to manage heat dissipation.

C. Large bore cylinders of up to 980mm in diameter are there to handle power output
because it is so high.

3
 Fig.2 Engine cylinder in ships.

Reference: https://images.app.goo.gl/ZeECfrF18kqKhyp67

2.3 Applications in power Generators: Engine cylinders play an essential role in

diesel and gasoline powered devices. Such devices can act as alternates or primary
sources of energy for industries, hospitals, and even remote locations. Most commonly
these engines are single- or multi-cylinder sets, depending on the amount of required
power.

Key Features in Power Generators:

A. Stationary cylinders designed for constant use.

B. Water-cooling systems for preventing overheating.

C. tough cast iron construction for durability

Fig.3 Diesel Generator

Reference: https://images.app.goo.gl/s8fQwFAnTdfFugCy7

2.4 Application in Industrial Machinery: Powerful engines who have larger

displacing cylinders are required in heavy-duty machinery such as excavators,
bulldozers, and mining trucks to produce high torque.

Main Features of Industrial Machines:

A. Reinforced walls of cylinders to withstand high load.

4
B. Hydraulic assisted cooling for temperature regulation.

C. Specially constructed to provide a high torque output and not for high speed.

Fig.4 Heavy-duty engine block.

Reference: https://images.app.goo.gl/byriVez7NVAmnS9V6

2.5 Application in Agricultural Machinery: Engine cylinders are mostly used in

agricultural machinery to power equipment which enhances productivity and efficiency
in farming

Key Features of Agricultural Machinery:

A. Used in tractors for high torque for plowing

B. Water air cooled systems used

C. Low maintenance and longevity

5
 Fig.5 Tractor Engine cylinder.

Reference:https://images.app.goo.gl/8Udt1sV59JHdre33

3. Industries Manufacturing Engine Cylinders

Many companies spread across the world manufacture good engine cylinders for
applications such as automobiles, motorcycles, aircraft, marine, industrial machinery,
and power generation. Such companies have advanced their manufacturing processes
with quality assurance, further research, and development of newer technologies to
enhance the cylinder durability, efficiency, and performance. Some of the companies
which manufactures engine cylinders in the whole world are mentioned below.

3.1 Kirloskar Oil Engines Ltd.: It is an Indian based company which manufactures
diesel and gas engines, they are specialised in making engine in agricultural
machinery, for industrial applications and for power generation.

Example Product: Kirloskar diesel engine cylinders which is used in agriculture.

6
3.2 Honda Motor CO., Ltd.: Honda is a global leader in automotive sector, they
produce high performance cylinder blocks which are light in nature and better fuel
efficient.

Example Product: K20CL 2.0L engine cylinder which is been used in Honda civic.

3.3 Rolls Royce Power systems: An UK based company which manufactures premium
and high performance engine cylinders for aviation, marine and even in defence they
have served in Boeing, their own cars like Ghost and Phantom.

Example Product: Rolls Royce Trent 100 Aircraft engine.

3.4 Cummins Inc.: Cummins Inc. is a major diesel and gas engine manufacturer which
manufactured engine blocks, cylinders and liners for heavy duty vehicles and also
serves in industrial applications.

Example Product: Cummins ISX15 diesel engine cylinders used in long-haul trucks.

3.5 Mahle Gmbh: it is a German company which majorly manufactures piston, engine
blocks and supply to major automakers, the engine cylinder which is made by the
company results in high performance and it is lightweight in nature. They have served
in BMW, Volkswagen and also in Formula-1

Example Product: Mahle’s Alusil-coated aluminium cylinder liners which is used in

formula cars for heat dissipation.

7
4. Indian Standards for Engine Cylinder Design

Indian Standards (IS) formulate and govern the design, production, assessment, and
performance specifications with regard to the cylinders. These standards ensure the
safety, reliability, and efficiency in automobile sectors, industrial, and power
generation sectors. These everything is governed by The Bureau of Indian Standards
also known as BIS in short it is government body. Some of the main IS standards used
while designing an engine cylinders are as follows:

A. IS 13648:1999: Internal combustion engine cylinders: Specifies design guidelines

and performance tests.

B. IS 9178: Guidelines for aluminum alloy and cast iron cylinder blocks.

C. IS 10759:1999: Methods for testing and inspection of engine components.

D. IS 7898:1993: Specifications for automotive engine cylinder liners.

E. IS 16081:2013: Fatigue and wear resistance requirements for engine blocks and
liners.

5. Materials Used in Engine Cylinders

As engine cylinders are operated in various environment condition and in various

performing conditions so selecting perfect materials is very necessary to withstand
stress, fatigue and failure. Some of materials which are used in manufacturing engine
cylinders are below.

A. Cast Iron: An useful material in the automotive industry, cast iron possesses an
unsurpassed wear resistance coupled with the advantage of easy casting. This makes
cast iron the most common material for manufacturing engine blocks in automotive
and industrial engines.

8
B. Ductile Iron: It offers an additional strength and flexibility above cast iron, more
suitable for utilization in highly specialized high-performance applications.

C. Aluminum Alloys: More used in motorcycles, automobiles, and certain industrial

machines to cut down on total engine weight.

D. Steel Alloys: Steel alloys are usually used in certain gas turbines or large industrial
engines, handling very high temperatures and pressures.

E. Titanium & Superalloys: They are been served in aerospace applications, due to
capability of withstanding extremely high temperature and stress, thus perfect for
their use for cylinders in jet engines.

6. Analytical models used for design

1. Heat Transfer Analysis

dT
Conduction Equation: q = − k A
dx

dT
Where k = thermal conductivity, A = area, = temperature gradient.
dx
2. Stress Analysis

P ⋅ ri2
Hoop Stress (σₕ): σh =
ro2 − ri2

Where P = internal pressure, r_i = inner radius, r_o = outer radius.

3. Thermodynamic Analysis

Equation: PV = nRT

9
 Where P = pressure, V = volume, T = temperature, R= gas constant, n= no. of moles

4. Fatigue life Analysis

Basquin’s Equation: σa = σ ′f (2Nf )b

Where σa = stress amplitude, Nf = number of cycles to failure.

7. Free Body Diagram

A free body diagram is a sketch illustration that provides a visualisation of all the forces and
movements applied on a body in a given condition. Free Body diagram is used to analyze the
forces acting on a cylinder.

Fig.6 Free Body Diagram of engine cylinder

Reference: https://images.app.goo.gl/KdEFb1epAtgBXJHb9

10

8. Forces Acting on an Engine Cylinder

An engine cylinder experiences numbers of forces during combustion pressure, piston

movement and because of vibration. These forces affects the cylinder by creating wear it
affects on their fatigue life and a lot more. There are various kinds of forces which acts on an
engine cylinder some are mentioned below.

A. Piston Side Force: It occurs when the piston shows upward and downward movements
than it applies a lateral force on to the cylinder. These forces cause friction and wear
because of this the overall performance gets affected.
B. Inertial Force due to Piston Movement: When the piston moves rapidly it causes some
dynamic forces these forces depends on the engine RPM, piston mass and stroke length.
C. Vibrational and Torsional Forces: Torsional vibrations occurs due to the crankshaft and
connecting load which overall impacts on cylinders walls.

Fig.7 Forces acting on the engine cylinder

Reference: https://images.app.goo.gl/r2dCS8E72rJXaFcn8

11
9. Design Constraints for Engine Cylinders

An engine cylinder must be designed while ensuring several constraints like cooling
efficiency, mechanical properties, cost, weight, durability and manufacturability some of the
key constraints its which we need to remember while designing an engine cylinder are below.

A. Size and Space: Engine cylinders need to be designed to occupy space in the engine block
while considering space from components such as pistons, valves, and crankshafts.
B. Cost: Economical to manufacture, particularly mass production, for vehicles delivered to
the mass market.
C. Temperature: Materials must be chosen to withstand extreme temperatures generated
during combustion.
D. Weight: Lightweight designs are critical in automotive applications to improve fuel
efficiency.

10. Factor of Safety

Factor of Safety expresses how much stronger a system is than it needs to be for an intended
load. Basically it prevents sudden failure under extreme load.
Factor of Safety = Ultimate Strength/Working Stress

9.1 Factors Affecting Factor of Safety are below.

A. material type and loading type

B. Presence of cyclical loads
C. Intensity of stress distribution
D. Impact of failure
E. Maintenance frequency

12
11. Ergonomic Design Considerations for Engine Cylinders

Ergonomics in engine design means to ease of use, performance optimization and

maintenance the aim of this activity is to enhance efficiency by reducing size and overall
reduce vibration for comfort.

11.1 Key Ergonomic Design Considerations

A. Cylinder shape and size: optimized bore to stroke ratio to balance power output and
efficiency and to design compact engine for reducing overall noise.
B. Maintenance Accessibility: wet cylinder liners to be used for easy replacement of entire
engine.
C. Heat Dissipation Improvements: Cooling jackets been designed to prevent overheating.

12. Cost Considerations in Engine Cylinders

The cost of an engine cylinders depends upon many things some of them are mentioned
below.
A. Material Costs: The Aluminum alloys are lot costlier than cast iron but they are
efficiently lighter so for high performance engines, titanium or composite materials they
are used.
B. Design Complexity: Production costs increases with more complicated designs or
complex cooling channels.
C. Surface Treatments: Coatings to enhance durability, such as Nikasil plating, are costly.
D. Economies of Scale: Bring down per-unit costs with higher production volumes.

Approximate Cost Breakdown For A Standard Car Engine Cylinder:

Materials: 30%
Manufacturing: 35%-40%
Quality Control and Testing: 15%-18%
Logistics and Overhead: 12%-15%
The average cost of a car engine cylinder could be around 20,000-25,000 for a family car
where else the marine ship and in defence it can go up-to 4,00,000 INR.

13
13. Performance of Engine Cylinders

The performance of an engine cylinder is influenced by several factors like the material
strength of engine, fuel efficiency, cooling efficiency and surface treatments. So some of the
key performance metrics which need to take care are mentioned below.

A. Thermal Efficiency: Thermal efficiency deals with the efficiency with which the cylinder
converts fuel energy to work energy.
B. Endurance: Resistance to high pressures and thermal cycling and time fatiguing.
C. Heat Dissipation: The cylinder should have efficient thermal conductivity for cooling so
as to prevent overheating.
D. Friction Loss: Reduced piston-cylinder wall friction is intended to maximize the fuel
economy optimization.
E. Corrosion Resistances: Coatings are applied to prevent rusting, specially in ships, and
aeroplanes.

14. Complexity in Design

The design of an engine cylinder is complex because of mechanical, thermal and material
constraints involved in it. The manufacturers should take note of that the engine can
withstand high pressures, high temperatures and high stress. Some of the factors are as
follows:

A. Thermal Stresses: Engine cylinders have to cope up with temperature gradients that are so
huge that they will never warp.
B. Material Selection: While balancing lightweight requirements against durability-important
in high-performance engines.
C. Cooling System Integration: Constructing sophisticated water jackets and oil ducts will
ensure that the engine will always be at the right temperature.

14
D. Manufacturing Constraints: Achieving tolerances during cast or machined parts is
sometimes hard to realise.
E. Combustion optimization: The configuration of the cylinder head is an important aspect in
the fuel-air mixing, which has its effect on efficiency and emission.

15. Breakage of Engine Cylinder Components

This is a big issue which can lead to engine failures the breakage generally occurs due to high
thermal stress, material fatigue, defects and improper cooling of a system. It is mainly seen in
heavy duty vehicles and high performance cars because they operate in several harsh
conditions. Some of the factors are mentioned below.

A. Fatigue Failure: Microscopic cracks develop on repeated stress cycles that enlarge over a
long time.
B. Seizure: Because of overheating and lack of lubrication that leads to the sticking of the
piston.
C. Blow-by Damage: Combustion gases will leak through the piston rings, eroding the
cylinder walls.
D. Corrosion: It is also mostly in marine engines when the engine is exposed to moisture and
is not maintained properly.
E. Overloading: Crack may form, or total failure may occur due to exceeding the pressure
limits which are designed.
F. Thermal Cracking: It occurs mainly due to very fast heating and cooling cycles which
leads to expansion and contraction.

15
 Fig.8 Engine component failure in a ship

Reference: https://images.app.goo.gl/R1rN2eqYu4x7mUi68

16. Failure Criteria to be Considered

The failure of an engine cylinder could be happen due to several factors like thermal fatigue
failure, wear failure, overloading failure and mechanical fatigue failure. So the designers
need to take a note of these failure to ensure the safety and overall performance of engine
cylinder for knowing the failure they uses a software name Finite Element Analysis, Some of
the Failure criteria are as follows:

A. Von Mises Stress Criterion: It predicts whether or not material will fail under hydraulic
failure or complex loading conditions.
B. Maximum Principal Stress Criterion: When the maximum shear stress reaches failure
value.
C. Fatigue Limit: Stress level below which the material can withstand an infinite number of
cycles without breaking.
D. Thermal Fatigue Criterion: It gives the number of thermal cycles by which a cylinder can
withstand before breaking.
E. Buckling Failure Criteria: Important for thin wall cylinders under very high internal
pressure.
F. Creep Failure Criterion: Long-term deformation with constant high temperature and
stress analysis.

16
 Fig.9 Stress Strain curve for failure

Reference:https://images.app.goo.gl/EmfNB8kjCeh2LoME8

Fig.10 Durability and Fatigue Life analysis by FEA.

Reference:https://images.app.goo.gl/tNh1fRqqyrnKhff16

17
17. Challenges in Engine Cylinder

The design of an engine cylinder comes with a lot of challenges like high thermal stress,
material selection, efficiency, durability and weight. Manufacturers need to overcome these
challenges to design an ideal Engine Cylinder, Some of the major challenges in today's era
are mentioned below.

A. Resistant to Extremely High Pressures and Temperatures

1. Engine cylinders survive heat and pressure up to 200 bar from combustion.
2. At high temperatures (800-1,200 °C), materials undergo thermal expansion that
results in fatigue.
Solution: Heat resistant materials including aluminum-silicon alloys and ceramic coatings.

B. Weight Reduction without Loss of Strength.

1. Auto manufacturers want engines that are lighter for efficient fuel consumption.
2. Thinning walls may normally lead to structural failure.
Solution: Titanium or Magnesium Alloys to be used for hi-performance applications.

C. Wear and Friction Problems.

1. Pistons rub on either side of the cylinder wall hence losing energy in the process.
2. Engine seizes when lubrication fails.
Solution: Add Diamond-Like Carbon (DLC) Coating or Nikasil Linings for reduction
friction.

D. Manufacturing Complexity and Cost: CNC machining, die casting, precision honing are
expensive processes for production and also pores and cracks may cause early failure.
Solution: 3D printing complex cooling channels and AI-based detection of defects.

18. Advanced Research in Engine Cylinder Design

The evolution of engine cylinder key focus is to increase its efficiency, sustainability and
durability so researchers are developing advanced materials, coatings, combustion techniques

18
and manufacturing processes to make better performance than older ones. Some of the key
advancements are mentioned below.

A. Lightweight and High-Strength Materials

1. Replacement of traditional cast-iron cylinders has focused on the use of aluminum alloys,
titanium alloys, and composites, whose aim is to make the engines lighter and more
efficient.
2. Carbon fiber-reinforced polymers are being studied mainly due to their advantages in
strength-to-weight ratio.
3. Magnesium alloys present additional possibilities to reduce weight, leading to better
power-to-weight ratios in performance engines.

B. Thermal Barrier Coatings

1. Plasma-sprayed zirconia coatings are ones improving thermal resistance and further the
temperature of combustion to make energy conversion better.
2. Diamond-like carbon coatings are supposed to lower friction and wear, which is expected
to add to the life of the engine cylinder.

C. Advanced Manufacturing Techniques

1. A cylinder fabricated by additive manufacturing bears all the attributes aforementioned:
it is light, complex, and gives a design not realizable by any traditional machining.
2. Extreme tolerances put on precision CNC machined parts allow for a radical
improvement in defects, quality speaking, and in repeatability.
3. Laser-assisted manufacturing solves much about surface treatment in relation to
improvement in durability.

D. AI and Smart Sensors for Real-Time Monitoring

1. AI-driven simulations helps in optimizing the combustion process, heat dissipation, and
stress distribution in cylinder designs.
2. Smart sensors installed in the cylinder which monitors the temperature, pressure, and
wear.

19
3. Big data analytics enables the fine-tuning of engine parameters for optimal performance
and fuel savings.

19. Old and Recent Applications of an Engine Cylinders

A. Old Applications of Engine Cylinders

1. Steam Engines: It was first introduced in the mid 18th century, where large single
cylinder and multi cylinder steam engines were used to generate power in locomotives
and industrial machinery, In these cylinders the steam was produced before entering the
cylinder.
2. Early Automobiles: In the late 19th century The first ever internal combustion engine was
made which was running on petrol or kerosene, they were too inefficient and was
producing high emissions.
3. Aircraft and Marine Engines: In the early 20th century there were large radial and inline
cylinder engines which were generating power in aeroplane and big ships, they were so
heavy that they were needed regular maintenance.

B. Recent Applications of Engine Cylinders

1. High Performance Automotive Engines: it is established in the modern cars, high

performing vehicles. They are in 4,6 or 8 cylinders for better efficiency and power.
2. Hybrid and Electric Vehicles: Some of the hybrid engines uses small engine cylinders to
work alongside EV’s cars to improve their fuel economy.
3. Hydrogen and Alternative Fuel Engines:Modern advances in technology have developed
designs for hydrogen combustion engine cylinders to reduce the carbon emissions from
the engine.

20
20. Scope of Optimization in Engine Cylinder Design

It is very important to optimized engine cylinder for better efficiency, durability and
sustainability. As the industries are transitioning to zero carbon emissions it is very crucial to
optimize engine cylinders. Some of the key techniques are mentioned below.

A. Material optimization for performance and weight reduction:

1. Replacement of current cast iron materials by aluminum alloys, magnesium, and other
composite materials that provide improved power-to-weight ratios.
2. Self-healing materials that repair small cracks occurring in a component and thus do not
need maintenance.

B. Temperature and mechanical losses:

1. Nano-coating and thermal barrier coating would help in reducing heat loss from friction
and enhance energy efficiency.
2. Advanced lubrication systems reduce the friction between the walls of the cylinder and
the piston ring, thus prolonging the life of the component.

C. Increasing Efficiency of Combustion:

1. Effective fuel injection systems and variable valve timing guarantee that air and fuel mix
better and combust more efficiently within the cylinder.
2. Advanced CFD improves combustion chamber design with a focus on higher efficiency
and lower emissions.

D. Adding Smart Technologies for Performance Monitoring:

1. IoT-enabled cylinders measure and display temperature, pressure, and performance
metrics for real-time diagnosis.
2. AI-based predictive maintenance hardware will be able to detect wear before it fails so
that maintenance can be performed early.

21
E. Alternative Fuels and Green Technologies Adaption:
1. Hydrogen-compatible cylinders will require materials that are heat resistant, and the
injection system must also be tweaked to suit the features of combustion.
2. Biofuel-compatibility will require that the design should be optimized to avoid corrosion
and ensure efficiency using either ethanol or biodiesel.

21. Conclusion

The engine cylinder is an important part of internal combustion engine which influence
performance, efficiency and durability in a lot of field like automobiles, agricultural, marine
and defence. Advancements in material selections has improved the cylinder strength,
reduction of weight and more. In the end engine cylinder technology has evolved by AI
driven monitoring, 3D printing and alternate fuels. Ongoing innovations will make the engine
cylinders more efficient than as of now.

22