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11

CHAPTER 3

THEORITICAL CALCULATIONS

3.1 DESIGN FOR PRESSURE CALCULATION

Consider 150cc Engine Speifications


Engine type = Air cooled 4-stroke

Bore x Stroke (mm) = 57 x 58.6mm²


Displacement = 149.5 CC

Maximum Power = 13.8 bhp @ 8500 rpm

Maximum Torque = 13.4 Nm @ 6000 rpm

Compression Ratio =9.35:1

Density of Petrol (C&HË8) = 737.22 kg/m?


Auto ignition temp. = 60°F =288.85°K
Mass = Density x volume = 737.22x 10-9% 149.5x 10 =0.110214 kg
Molecular weight of petrol = 114.228 g/mole = 0.11423 kg/mole

From gas equation,


PV=m x Rspecific XT

Where,

P =Gas Pressure, MPa

V= Volume
m = Mass, kg

T = Temperature, °k

Rspecific = Specific gas constant = R/M

Rspecific =8.3144/0.114228

12

Rspecific = 72.788 Nm/kg K

P =mx Rspecific XTV

P=0.110214 x72.788 x(288.85 / 149.5) = 15.49 MPa 16 MPa

Calculation is done for maximum Pressure of 16 MPa.


3.2 DESIGN CALCULATION FOR THECONNECTING ROD
Thickness of the flange & web of the section = t

Width of the section, B = 4t

Height of the section, H =5t

Area of the section, A = 11t?

Moment of inertia about x-axis, Ixx =34.91t4


Moment of inertia about y-axis, Iyy =10.91t

Therefore lylyy = 3.2

Length of the connecting rod (L) = 2 times stroke L= 117.2 mm


Total Force acting F= Fp -Fi
Where,

Fp= force acting on the piston

Fj= force of inertia

Fp= (n 4)D xGas pressure


Where,
D = Bore Diameter

Fp= (n4) 57²x 15.49 = 38275 N


F= mxw'xr (cosØ +cos20 In)
Where,

13

M= Mass

w = 218500/60 890.118 rad/sec

n= length of connecting rod(l) / crank radius(r)


-(2 x stroke) (stroke2)
=117.2/29.3

i.n= 4

The maximum gas load occurs shortly after the dead centre position at Ø = 3.3 °
cos(3.3) = 0.9983 1
:F=0.110214 x 890.1182 x 0.0293 (1 + 1/4 )

=3200

So,
So,

F=38275-3200 =35075 N

According to Rankin's - Gordon formula,

F = (GcA) /+a(l Kxx)2


Where,
A = cls area of connecting rod

l=Length of connecting rod


O= Compressive yield stress

F= Buckling load
a= Constant depending upon material and end fixity coefficient

KXx and Kyy = Radius of gyration of the section about x - x and y -y axis
respectively.

On substituting to Rankin's formula

35075 = 170×11t /1+0.002(117.2/1.78t)2


By solving this,

14

t=5.5 mm

Therefore,

Width B= 4t = 22 mm

Height H=5t = 27.5 mm

Area A= 11t 2 =332.75 mm?

3.2(a) Design of small end:


Load on the small end (Fp) - Projected area xBearing pressure

=dplp x Pp
Where,

Fp = 38275 N load on the piston pin

dy = Inner dia. of the small end

lp= length of the piston pin


= 1.5bp to 2bp

Pbp = Bearing pressure

= 10.0 for oil engines.

= 12.5 to 15.4 for automotive engines.


We assume it is a 150cc engine, thus

Pbp = 15.4 Mpa

3.2(b) Design of Big end:


Load on the big end (Fe) = Projected Area >XBearing pressure
= dele xPbe

Where,
Fe= 38275 N load on the crankpin

de = Inner dia. of the big end

15

le= length of the crank pin


= 1.25 de to 1.5 de

Pbe =5 to 12.6 Mpa

Height at the small end HË 0.75H to 0.9 H


H, = 0.9x 27.5= 24.75 mm

Height at the big end


H2 = 1.1H to 1.25H

H2 = 1.25x 27.5 = 34.375 mm

Substituting,
38275 =2dp x dp x 15.4
. dp = 35 mm

lp =2dp= 70 mm

Outer diameter of small end = dy + 2tb + 2tm

-35 + [2x2] + [2x5]

= 49 mm

Where,
Thickness of bush (tb) = 2 to 5 mm

Marginal thickness (tm) 5 to 10 mm

Substituting,
38275 = 1.5de x de x 12.6 : de = 45 mm

le= 1.5dc= 67.5 mm

Outer diameter of big end= de + 2tb + 2tm +2db


17

3.3 FINAL DIMENSIONS

Table 3.1 Parameters of Connecting Rod


Parameters Size (mm)

Thickness of the connecting rod 5.5


()
Width of the section (B = 4) 22

Height of the section (H = 5t) 27.5

Height at the big end (HI) 24.75

Height at the small end (H2) 34.375

Inner diameter of the small end 35

Outer diameter of the small end

Inner diameter of the big end 45

Outer diameter of the big end 63

18

CHAPTER 4

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