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Design of Piston
by Amit Kumar,Arunesh Kumar,Abhinav Singh,Harsh Kulhara,Pushpendra Kumar Contents
Introduction A piston is a component of reciprocating engines, pumps and gas compressors. It is located in a cylinder and is made gas-tight by piston... Link Citation Email Print Favorite Collect this page

Introduction
A piston is a component of reciprocating engines, pumps and gas compressors. It is located in a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. In a pump, the function is reversed and force is transferred from the crankshaft to the piston for the purpose of compressing or ejecting the fluid in the cylinder. In some engines, the piston also acts as a valve by covering and uncovering ports in the cylinder wall.

1.Design Methodolgy
The objective of this exercise is to design the piston of Bajaj Pulsar 180 cc,DTS-I, 4 stroke single cylinder aircooled engine . Technical specification Engine Type Displacement Compression Ratio Maximum Power Maximum Torque Cylinder Bore Stroke Ignition 4 Stroke Single Cylinder Air Cooled 180 cc 9.5:1 16.5@8000 BHP@RPM 15.22@6000 Nm@ rpm 9.5:1 56.4 mm CDI

We are making the assumption that piston is made of cast iron & the piston head is taken as flat with the provision of cupping at the top. 1.Piston Head

According to the flat plate theory,we calculate the thickness of piston head t=D(3p/16f)^ F=permissible stress for cast iron=375 kg/cm2 Putting the data in the eqn 1,we get t=.690 cm As per our design assumption the top of the piston head is cupped with a radius of .7D=.75.64=3.948 cm.(Combustion chamber) 2.Piston rings & thickness of rings We are incorporating three rings,n=3 The radial thickness if ring is Tr=D(3Pw/f)^1/2 .2 .1 Here D=5.64 cm ,p=maximum pressure=30kg/cm2

pw is the radial wall pressure and ft is the permissible stress for piston ring pw = 0.4 Kg/sq cm and ft =1000 Kg/sq cm,substituting the values,we get Tr =.384 cm Now we will calculate the axial thickness Ta=D/(10n) ,n=3,we get Ta=.2 cm Distance of the 1 ring from the edge of the crown d1=.185.64=1.015 cm Width of the piston land between ring grooves = 3/(4Ta) =.15 cm 3.Length of the piston Lp=1.55D=1.555.64=8.742 cm Length of the skirt, Ls=Lp-d1-nTa-(n-1)Tw,substituting Ls=8.742-1.015-3.2-(3-1).15=6.827 cm The center of the piston pin above the center of the skirt equals= 0.02 D = .025.64=.112 cm distance from the bottom of piston to the axis of gudgeon pin is = Ls/2 + .112= 6.827/2 +.112=3.525 cm Thickness of the piston wall below rings = .690 cm Thickness of the piston wall at open ends = 0.355.64=1.974 cm
st

Bearing area provided by the skirt = Length of skirt Diameter of cylinder bore Ab = Ls D = 6.827 5.64 = 38.50 cms

Maximum gas load = /4D^2P =/45.64^230 =749.49 kg Where P is the maximum combustion pressure. Side thrust = 749.49 0.09 = 67.75 kg 4. Bearing pressure between the side walls and the piston = Side thrust / Ab 67.75/38.50=1.752 kg/cm^2 which is within the design limit ,so we can say that the design is feasible

Flow process chart for Manufacturing of Piston

YouTube Video

Manufacturing Process
1. Die Casting of Cast Iron Casting is the beginning of the piston. At the foundry the die is prepared by heating it to operating temperature for approximately one hour. This process allows the die to readily accept the molten material when it is poured. Process starts by heating the material to 1200 degrees Celsius. The material is then scooped up with a ladle from the crucible (the pot that holds the molten material). This is then poured into the die through the sprue. The material is then allowed to cool before it is removed from the die and placed into a bin of hot water. This water is used to facilitate a more even settling of the hot metal. After the castings have had time to cool they are placed into a heat treatment plant overnight. This

process tempers the casting and ensures the piston will have improved qualities. After it is removed from the heat treatment the casting has its runner removed. Process Parameters: Dies used are 5 piece . Temperature: 1200 (approx) degrees Celsius Dimension -Length of the piston is obtained from the process(Including piston skirt). 2.Pin Boring At this stage of the piston manufacturing process the casting has the gudgeon pin hole rough machined and the locating bung machined. This process is where the casting is machined on the base to allow placement of the casting in other machines. This is carried out on a simple lathe. The pin bore Pin boring is done in conjunction with the bung turning, as one casting is removed from having the bung face machined it is placed on the pin borer. The pin borer is only a rough machining process which allows the reamer to enter the gudgeon hole later. 3.CNC Turning Turning of the casting is carried out on CNC (Computer Numeric Control) machinery. This equipment is the most accurate and fastest available for this application with very high tolerances and fast spindle speeds. The castings are placed in the lathe on a bung and held in place by a solid rod through the gudgeon pin hole. A draw bolt is activated in the chuck which draws the rod toward the chuck and holds the piston in place. The lathe is then started and the machining cycle begun. This cycle is programmed into the lathe in a basic language called G-Code (After the piston is machined it is removed from the lathe and the part number stamped on the crown (top) of the piston. Machine specifications: Machine used : CNC Lathe ECONO CNC 26. Maker : HMT Height of centres : 260 mm Swing over bed : 575 mm Swing over cross slide : 340 mm Distance between centers : 1000 mm Speed range : 40-2040 rpm

Process parameters: Turning(Rough): Speed : 25 m/s Feed : 0.5 mm per rev Depth of cut : 0.4 mm Grinding This process involves the final size being machined on the piston. The grinder machines the skirt of the piston only and in the majority of cases is cam ground. Cam grinding ensures the piston will "grow" evenly in the bore of the engine. A perfectly round piston will expand unevenly during use because of the uneven placement of material in the casting (gudgeon pin bosses and ribbing used for strengthening). Machine specifications: Machine used : CNC Grinding machine - PMT-AWH-100 Maker : PMT Grinding length (max) : 1000 mm Height of centres : 450 mm Grinding diameter (max) : 450 mm Grinding wheel diameter : 350 mm Process parameters: Grinding(Rough): Speed of wheel : 20 m/s Feed of workpiece : 1 mm per min Depth of cut : 0.05 mm Finish grinding: Speed of wheel : 40 m/s Feed of workpiece : 0.5 mm per min Depth of cut : 0.02 mm

4.Reaming The final machining process for the piston is of reaming. This process involves the piston being placed in a bath of oil and reamed at different sizes to reach the final size required. Since the pin boring process is only rough it is necessary to ream the pin bore a number of times to achieve the surface finish and size required. Reaming is not a fast process and is only partially automated (there are automatic feeds on the reaming machines). Radial drilling machine is used for performing reaming operation.

Machine specifications: Machine used : Radial drilling machine - KML -40A Maker : KML Drill capacity (in steel) : 40 mm Drill depth : 180 mm Taper spindle nose socket :MT-4 No. of speeds and range : 6 (45-660 rpm) Process parameters: Drilling: Speed : 20 m/s Feed : 0.1 mm per rev. References 1.http://www.loeser.de/index.php?id=127&L=1 2.Automotive Mechanics by Willam Crouse & Donald Anglin .

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