This document summarizes the analysis and automation of a single cylinder piston engine design project. Key parts like the engine block, crankshaft, connecting rod, and piston were modeled in Solidworks. A motion study was performed at 2000 RPM along with applying a 1000 lbf gas pressure force on the piston. Static analysis determined the maximum von Mises stresses, displacements, and safety factors of each part across the operating cycle. The connecting rod diameter was optimized to minimize mass while maintaining stresses below yield. Automation was achieved by exporting part properties to Excel macros and Solidworks API to allow changing diameters and updating analyses.

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ANALYSIS AND AUTOMATION OF
SINGLE CYLINDER PISTON ENGINE
ME 630 DESIGN PROJECT
AJINKYA SHEWALE (106617938)
DEEPAK KUMAR SINGH (106667949)
EDWARD KOJAYAN (102140686)
KABILAN PRABHAKAR (106611516)
TEJASHKUMAR PATEL (105919253)
May 14, 2015

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ACKNOWLEDGEMENT
In this opportunity, we would like to express our sincere appreciation to our instructor Dr. Stewart
Prince for the excellence of supervision, unreserved guidance, thought provoking discussion and
continuous encouragement throughout this study. This Design project is all about sincere work,
thoughtful research and strong belief. For this happen I would like to thank all my group members.
Without support from all this project may not be as successful.I appreciate work of each and every person
for this and I am grateful more than they might know.

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ABSTRACT
The accompanying undertaking is automation of single cylinder internal
combustion engine, where the principle parts to be examined are engine block,
crank shaft, connecting rod, piston. This engine parts and assembly are made on
SolidworksTM. The motion study, static and dynamic investigation is done to
decrease the factor of safety alongside changing of connecting rod diameters. The
fundamental objective is to make the methodology at the snap of the mouse and
getting the outcomes just by entering the associating pole measurement qualities
utilizing the control alternatives. We have done the outlining and macros alongside
alternate examinations on SolidworksTM 2014. Changing the diameters, Mass
properties, Part recovery, Static study, loading are finished. We studied how to
design, dissect the loads, computerize and control the Solidworks part report in the
Final task.

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INTRODUCTION
The fundamental point of the task is to outline the connecting rod and
camshaft in such a path, to the point that their primary highlights are effortlessly
controlled, to perform a motion study consider on the assembly to yield force and
motion data, to perform an anxiety recreation think about so as to legitimately
estimate segments in light of a sought variable of security, to perform a design
study to enhance component weight and to mechanize this procedure.

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In our problem, all the dimensional parameters for various components were
already given but for other mechanism analyses; synthesis must be initially
preformed in order to verify the mechanism movement. Once graphical or
modeled synthesis has been performed and we are satisfied with the results of the
mechanism movement, we can now preform analysis. In order to complete
analysis, all the dimensional parameter for the linkages has to be obtained from the
synthesis stage. The following stages will consist of position, velocity and
acceleration. After these three things have been completed, we now preform force
analysis and mass balancing from the equivalent mass equations as seen in the
appendix.
Firstly the assembly is modeled as a four bar slider crank mechanism. As the
crank shaft rotates, the piston reciprocates and the connecting rod connects the two
together, while the connecting rod is actually an assembly of its own. The block
acts as a ground link. It is assumed that the crank shaft rotates at constant angular
velocity while the piston is subjected to gas forces via cylinder pressure due to
combustion and that a constant speed.
To limit the factor of safety and to change the connecting rod parameters we
need to figure Von Misses stresses, Shear stresses, Maximum Principle stress,
motion study, Fatigue Analysis and Optimization in the current Connecting bar. On
the off chance that the current outline demonstrates the higher FOS, then
recommend the base configuration changes in the current Connecting bar. A ton
has been done and still a considerable measure must be done in this field. In this
Project the static and element FEA is finished by Solidworks, shaking strengths
and balancing is finished by Matlab, Automation is finished by exceed expectations
and visual nuts and bolts.

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ASSUMPTIONS
1. Solidworks assembly has been created, consisting of block, crankshaft, piston
wrist pin, head, valves, cam, and connecting rod parts.
2. Piston and head material is 6061 aluminum alloy, crank, valves, valve springs,
wrist pin and connecting rod are 1020 CD steel, block is cast iron.
3. Any part of the engine can be added and altered to make a more “realistic”
engine design.
4. Crankshaft has crank pin diameter “Dia_Cpin.”
5. Starting dimensions are taken directly off of solid models; both stroke and
bore are fixed.
6. All static FOS are 2.5 based on Von Mises.

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DEFINING THE MATERIAL AND MASS PROPERTIES
The cylinder piston material is to be chosen as aluminum, crank and
connecting rod are 1020 CD steel and block is of cast iron. While doing this,
the macro is recorded. Presently the macro scale is altered for the mass
properties and properties of the pole, for example, Description, Part No.,
Material, Cost and Weight. The yield ought to be given as the qualities are
gone into the interface. It is demonstrated macro appended.
DISCUSSION
Design of connecting rod
I. The connecting rod.prt is made utilizing SolidworksTM.
II. The SolidworksTM is opened and another part is chosen from the File
tab.
III. A circle of distance across manager of 3 inch width with balance
separation of dia_cpin of 1.58 inch in front plane.
IV. This manager is Bose expelled with 1.9 inches. From focus purpose of
this manager at 8.5 inch another circle of wrist pin breadth 2 inch is
made with the counterbalance of .787 inch.
V. This wrist pin is bose expelled with 1.9 inch.
VI. After that both the external elements are changed over and the cross
lines are made.
VII. Every other line and external elements are trimmed.
VIII. The Line from supervisor to wrist pin is reflected regarding focus line
and it is expelled with width of 1.7 inch.
IX. Finally the balance is taken as 0.3 inch to evacuate the material and all
the measurements are specified utilizing savvy measurement apparatus.

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Assembly of Engine Block, Connecting Rod, Piston, Crank Shaft
In the new assembly file all the parts are open and must be mate at
each section to rotate the engine properly. The selected mates are
mentioned below which gives the motion of the engine
• Concentric3 (Piston, Engine Block)
The engine block inner curve and piston outer surface are
concentric3 which moves only upward and downward. It will not
move in any other direction
• Distance11 (Crankshaft, Engine Block)
The crank shaft center axis and engine block are fixed with the
distance so they cannot move at any distance.
• Coincident33 (Piston, Engine Block)
The piston front face and engine block’s front face of side are
coincident33 from which the piston moves only for that part.
• Distance12 (Crankshaft, Engine block)
The Engine block’s top edge to the Crankshaft’s axis1 distance is
fixed so it cannot make any changes in motion.
• Parallel20 (Engine Block, Crank Shaft)
The Engine Block’s front face and crank shafts right plane are
parallel so that the engine motion can start at zero degree.
• Concentric4 (Crankshaft, Connecting rod)
The Connecting rods dia_cpin and crankshaft pin are concentric4 so
that they can fix it at one axis place.
• Coincident34 (Crankshaft, Connecting Rod)
The crankshaft’s front plane and Connecting rods front planes are taken
to coincide both the parts.

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• Concentric5 (Piston, Connecting rod)
The piston pin diameter and connecting rods wrist pin are concentric5
to fix two parts on the same axis.
Performance of Motion study at 2000 rpm & Gas pressure
I. To open the motion study tab we have to first go to tools/add ins and
check the box of solidworks Motion and solidworks Simulation.
II. At the end of solidworks screen the motion study tab will popup.
III. By clicking that we will get the new part above that to get the motion.
IV. In this motion study we can get different types of motion with forces,
torque, damper, spring, motor, gravity, contact.
V. After putting this different constrains we can get the animation.
First we have put the motor to the axis of crank shaft at 2000rpm with
the reverse direction and which is for 0.06 second. We have put force on
the top surface of the piston which is 1000lbf in the downward direction.
After that the calculation made for the motion study which gives the
motion analysis option to get the Motion Analysis.
Motion Analysis
In movement investigation we can get the von misses stress, deformity,
factor of safety charts at distinctive part of the part. For that first we need to
choose reenactment setup. In which we have chosen connecting rod as a part
and include the time which is .06 sec. After that the estimation of reproduction
results is done which ascertain the diagrams of the FOS, Stress and
displacement. After computation we are taking the consequences of FOS is
checked.

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Static Study for connecting rod
For static study we need to import the loads in the 360 degree cycle so
we can get for the various frame study. For that following process is carried
out:
I. From the menu bar recreation tab we have chosen import movement
loads.
II. In that the choice of connecting rod is done and the frame is chosen as
well.
III. After that we have open the old connecting rod.
IV. It opens two new tabs which is for single framing and multi frame.
V. In multi frame we need to run the methodology which gives situation
for diverse edge.
VI. It gives the diagram for distinctive situation at anxiety level.
VII. From which we can get the greatest stresses at diverse situation.
VIII. After that we need to open the single edge study tab in which we need
to run and study the outcomes.
IX. This outcome issues us the variable of factor of safety at distinctive
level.
X. From this we can get the most extreme and least FOS of the part.
XI. To limit the factor of safety we need to improve the associating pole.

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OPTIMIZATION
Target of the improvement assignment was to minimize the mass of the
connecting rod under the impact of a load reach containing the two great loads,
the crest compressive gas load, such that the most extreme, least, and the
comparable stress adequacy are inside the cutoff points of the suitable hassles.
The creation expense of the connecting rod was likewise to be minimized.
Besides, the buckling load figure under the top gas burden must be passable.
Mathematically stated, the optimization statement would appear as
follows:
Objective: Minimize Mass
Subject to:
Compressiveload = peak compressivegas load.
Maximum stress < Allowable stress.
Side constraints (Component dimensions).
Manufacturing constraints.
Buckling load > Factorof safety x the maximum gas load (Recommended
FOS, 2-4)
Optimization of connecting rod
To enhance the connecting rod we need to open the new outline study
tab. In design configuration study we need to first choose the distinctive
parameters like measurement of diameter of boss, profundity of con rod,
diameter across of pin. In compel we have taken von misses stress, and our
objective is to decrease the mass.

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Static study of crank shaft
We have to do the same process for the crank shaft to get the static
study. By opening the separate part we have to run the process in the multiple
frames and from the graph we can get the maximum stress value of the crank
shaft. After that open the new single frame in which we are getting the
maximum and minimum Factor of Safety.

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VBA CODING PROCEDURE
I. First exported part material, weight and all the characteristics of
the material to SolidworksTM.
II. In SolidworksTM we did perform the material handling and
exported to Excel.
III. We automated the diameter of Crankpin using Excel VBA.
IV. Then crank pin dia is coordinated with the connecting rod dia so
that in the event that we change the crank pin dia , the dia of
connecting rod changes naturally relating to the crank pin dia.
V. Importing mass properties from solidworks to VBA.
VI. By using MATLAb we did iterations.
VII. We prformed motion analysis and compared it to Matlab output.
VIII. The comparison states it all; we did perfect coding.

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ANALYSIS
Connecting Rod:
I. Connecting rod with constraints:
II. Connecting Rod displacement:

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III. Connecting rod factor safety:
IV. Connecting rod strain:

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V. Connecting rod stress:
Crankshaft:
VI. Crankshaft with constraints:

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VII. Crankshaft with displacement:
VIII. Crankshaft Factor of safety:

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IX. Crankshaft Strain:
X. Crankshaft Stress:

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Piston:
XI. Piston Constraints:
XII. Piston Displacement:

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XIII. Piston Factor of Safety:
XIV. Piston Strain:

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XV. Piston Stress:

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Engine Assembly Views:

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GRAPH:
a. Velocity vs Time:
b. Acceleration vs Time :
0.000 0.006 0.012 0.018 0.024 0.030 0.036 0.042 0.048 0.054 0.060
Time (sec)
-151
-76
-1
74
149
0.000 0.006 0.012 0.018 0.024 0.030 0.036 0.042 0.048 0.054 0.060
Time (sec)
-38628
-23425
-8223
6980
22182
Acceleration1(inch/sec**2)

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c. Angular Acceleration vs Time:
0.000 0.006 0.012 0.018 0.024 0.030 0.036 0.042 0.048 0.054 0.060
Time(sec)
44
862
1679
2496
3313

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MOTION STUDY GRAPHS:
FX VS FY:

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FX VS FY:
FX VS FY:

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CONCLUSION
This undertaking is about mechanizing the SolidworksTM assembly plan
utilizing the API. This helps us to know the different systems utilized as a part
of combining VBA coding, Matlab and Designing on a Popular Design
programming. We have the capacity to get the static Factor of Safety as close
to 2.5. These techniques are utilized these days as a part of each programming
interface. We learned the fundamental ideas of making a computerization
code. This can be the eventual fate of outline for 'standard parts' similar to the
Single barrel motor which we made on perceived Design programming like
Solidworks-TM. It's a decent opportunity to take such a class in graduate level
and feel it as a group.

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REFERENCES
Machinery Design book by Robert Norton.
Kinematics of machine By Robert Norton.
Automating SolidworksTMusing Macros, MikeSpens.
Solidworks Library for macros
ME 630 CADMclass by Dr. Stewart Prince.

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APPENDIX
Calculations for Connecting Rod Equivalent Mass:

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Equivalent mass approach:
𝑚3 = 𝑚3𝐴 + 𝑚3𝐵
𝑚3𝐵 ∙ 𝑙1 = 𝑚3𝐴 ∙ 𝑙2
𝑚3 =
𝑚3𝐵 ∙ 𝑙1
𝑙2
+ 𝑚3𝐵
𝑚3 = 𝑚3𝐵 (
𝑙1
𝑙2
+ 1)
Solving for m3B yields:
𝑚3𝐵 =
𝑚3
(
𝑙1
𝑙2
+ 1)
Crank Equivalent Mass
Equivalent mass approach:
𝑚2 = 𝑚2𝐴 + 𝑚2𝐵
𝑚2𝐵 ∙ 𝑙3 = 𝑚2𝐴 ∙ 𝑙4
𝑚2 =
𝑚2𝐵 ∙ 𝑙3
𝑙4
+ 𝑚2𝐵
𝑚2 = 𝑚2𝐵 (
𝑙3
𝑙4
+ 1)
Solving for m2B yields: 𝑚2𝐵 =
𝑚2
(
𝑙3
𝑙4
+1)

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θ2 (deg) θ2 (rad) θ3 (rad) θ3 (deg) R1 ω3 (rad/s) V1 (in/s) α3 (rad/s^2) A1
Description Value Units 0 0.000 0.000 0.000 3.190 -57.805 0.000 0.000 -21913.154
r2 (Crank Length): 0.69 in 5 0.087 -0.024 -1.378 3.187 -57.602 -16.059 975.638 -21917.707
r3 (Conrod Length): 2.5 in 10 0.175 -0.048 -2.747 3.177 -56.993 -31.923 1948.874 -21929.414
ω2: 2000 RPM 209.4395 rad/s 15 0.262 -0.071 -4.096 3.160 -55.979 -47.400 2917.054 -21942.405
α2: 0 rad/sec^2 20 0.349 -0.095 -5.417 3.137 -54.563 -62.303 3877.021 -21946.899
25 0.436 -0.117 -6.698 3.108 -52.749 -76.456 4824.895 -21929.214
30 0.524 -0.138 -7.932 3.074 -50.544 -89.694 5755.874 -21871.835
35 0.611 -0.159 -9.109 3.034 -47.956 -101.869 6664.089 -21753.573
40 0.698 -0.178 -10.219 2.989 -44.995 -112.848 7542.515 -21549.858
45 0.785 -0.196 -11.254 2.940 -41.676 -122.520 8382.963 -21233.222
50 0.873 -0.213 -12.206 2.887 -38.016 -130.798 9176.164 -20774.015
55 0.960 -0.228 -13.067 2.831 -34.037 -137.617 9911.961 -20141.392
60 1.047 -0.241 -13.829 2.773 -29.765 -142.939 10579.614 -19304.571
65 1.134 -0.253 -14.486 2.712 -25.232 -146.752 11168.204 -18234.360
70 1.222 -0.262 -15.032 2.650 -20.471 -149.071 11667.130 -16904.865
75 1.309 -0.270 -15.462 2.588 -15.523 -149.935 12066.660 -15295.315
80 1.396 -0.275 -15.772 2.526 -10.430 -149.405 12358.490 -13391.834
85 1.484 -0.279 -15.959 2.464 -5.240 -147.565 12536.261 -11189.029
90 1.571 -0.280 -16.022 2.403 0.000 -144.513 12595.972 -8691.221
95 1.658 -0.279 -15.959 2.344 5.240 -140.361 12536.261 -5913.181
100 1.745 -0.275 -15.772 2.286 10.430 -135.230 12358.490 -2880.289
105 1.833 -0.270 -15.462 2.231 15.523 -129.243 12066.660 371.927
110 1.920 -0.262 -15.032 2.178 20.471 -122.525 11667.130 3798.837
115 2.007 -0.253 -14.486 2.129 25.232 -115.195 11168.204 7348.234
120 2.094 -0.241 -13.829 2.083 29.765 -107.366 10579.614 10962.215
125 2.182 -0.228 -13.067 2.040 34.037 -99.140 9911.961 14579.240
130 2.269 -0.213 -12.206 2.000 38.016 -90.609 9176.164 18136.216
135 2.356 -0.196 -11.254 1.964 41.676 -81.852 8382.963 21570.479
140 2.443 -0.178 -10.219 1.932 44.995 -72.935 7542.515 24821.550
145 2.531 -0.159 -9.109 1.903 47.956 -63.910 6664.089 27832.628
150 2.618 -0.138 -7.932 1.879 50.544 -54.819 5755.874 30551.778
155 2.705 -0.117 -6.698 1.858 52.749 -45.692 4824.895 32932.836
160 2.793 -0.095 -5.417 1.840 54.563 -36.550 3877.021 34936.053
165 2.880 -0.071 -4.096 1.827 55.979 -27.406 2917.054 36528.537
170 2.967 -0.048 -2.747 1.818 56.993 -18.266 1948.874 37684.519
175 3.054 -0.024 -1.378 1.812 57.602 -9.131 975.638 38385.518
180 3.142 0.000 0.000 1.810 57.805 0.000 0.000 38620.420
185 3.229 0.024 1.378 1.812 57.602 9.131 -975.638 38385.518
190 3.316 0.048 2.747 1.818 56.993 18.266 -1948.874 37684.519
195 3.403 0.071 4.096 1.827 55.979 27.406 -2917.054 36528.537
200 3.491 0.095 5.417 1.840 54.563 36.550 -3877.021 34936.053
205 3.578 0.117 6.698 1.858 52.749 45.692 -4824.895 32932.836
210 3.665 0.138 7.932 1.879 50.544 54.819 -5755.874 30551.778
215 3.752 0.159 9.109 1.903 47.956 63.910 -6664.089 27832.628
220 3.840 0.178 10.219 1.932 44.995 72.935 -7542.515 24821.550
225 3.927 0.196 11.254 1.964 41.676 81.852 -8382.963 21570.479
230 4.014 0.213 12.206 2.000 38.016 90.609 -9176.164 18136.216
235 4.102 0.228 13.067 2.040 34.037 99.140 -9911.961 14579.240
240 4.189 0.241 13.829 2.083 29.765 107.366 -10579.614 10962.215
245 4.276 0.253 14.486 2.129 25.232 115.195 -11168.204 7348.234
250 4.363 0.262 15.032 2.178 20.471 122.525 -11667.130 3798.837
255 4.451 0.270 15.462 2.231 15.523 129.243 -12066.660 371.927
260 4.538 0.275 15.772 2.286 10.430 135.230 -12358.490 -2880.289
265 4.625 0.279 15.959 2.344 5.240 140.361 -12536.261 -5913.181
270 4.712 0.280 16.022 2.403 0.000 144.513 -12595.972 -8691.221
275 4.800 0.279 15.959 2.464 -5.240 147.565 -12536.261 -11189.029
280 4.887 0.275 15.772 2.526 -10.430 149.405 -12358.490 -13391.834
285 4.974 0.270 15.462 2.588 -15.523 149.935 -12066.660 -15295.315
290 5.061 0.262 15.032 2.650 -20.471 149.071 -11667.130 -16904.865
295 5.149 0.253 14.486 2.712 -25.232 146.752 -11168.204 -18234.360
300 5.236 0.241 13.829 2.773 -29.765 142.939 -10579.614 -19304.571
305 5.323 0.228 13.067 2.831 -34.037 137.617 -9911.961 -20141.392
310 5.411 0.213 12.206 2.887 -38.016 130.798 -9176.164 -20774.015
315 5.498 0.196 11.254 2.940 -41.676 122.520 -8382.963 -21233.222
320 5.585 0.178 10.219 2.989 -44.995 112.848 -7542.515 -21549.858
325 5.672 0.159 9.109 3.034 -47.956 101.869 -6664.089 -21753.573
330 5.760 0.138 7.932 3.074 -50.544 89.694 -5755.874 -21871.835
335 5.847 0.117 6.698 3.108 -52.749 76.456 -4824.895 -21929.214
340 5.934 0.095 5.417 3.137 -54.563 62.303 -3877.021 -21946.899
345 6.021 0.071 4.096 3.160 -55.979 47.400 -2917.054 -21942.405
350 6.109 0.048 2.747 3.177 -56.993 31.923 -1948.874 -21929.414
355 6.196 0.024 1.378 3.187 -57.602 16.059 -975.638 -21917.707
360 6.283 0.000 0.000 3.190 -57.805 0.000 0.000 -21913.154
Input Parameters
Position Analysis Velocity Analysis Acceleration Analysis