1) The document summarizes a student project that aims to design and develop a mechanism for a four-stroke, four-revolution internal combustion engine. 2) The objectives are to analyze, design, model, manufacture and test a prototype that modifies the engine to have four revolutions of the crankshaft per cycle. 3) According to the theoretical calculations, the modified engine design could improve the thermal efficiency from around 32.5% to 36.5% compared to a conventional diesel engine.

1. K.E. Society’s
Rajarambapu Institute of Technology, Rajaramnagar
Department of Mechanical Engineering
Academic Year 2016-17
B.TECH PROJECT PRESENTATION

2. Introduction:
•Transportation and vehicles
• EIA report(2016):- Supply is adequate to meet the world’s demand for liquid fuels through 2040.
• Need to find solution
• Current engines and efficiency

3. Project Title and objectives:
“Design and Development of Mechanism for Four Stroke Four Revolution I.C. Engine.”
Objectives:
•To develop mechanism for four revolutions of crankshaft
•To analyze four revolution mechanism.
•To design the parts for four revolution mechanism.
•To model the modified parts in CATIA V5R20.
•To manufacture the prototype.

4. Conventional engine:

5. Concept:

6. Concept:

7. Concept:

8. Concept:

9. Concept:

10. Concept:

11. Concept:

12. Concept:

13. Reverse Engineering:
• Reverse engineering, is the process of extracting design information from anything man-
made and re-producing anything based on the extracted information.
• Pmax and theoretical efficiency has been calculated
• Piaggio Ape engine has been selected.
• Piaggio Ape Engine Features:
•Diesel engine
•Naturally Cooled Engine
•Single Cylinder Naturally Aspirated Engine

14. Parameter Diesel Engine (%) Modified Diesel Engine (%)
Air Standard cycle efficiency 60.65 64.5
Losses due to variation of specific heat and
chemical
13 13
Loss due to progressive combustion 5.5 5.5
Loss due to incomplete combustion 3.5 3.5
Direct heat loss 4.5 4.5
Exhaust heat loss 1.5 1.5
Pumping loss 0.5 0.5
Rubbing friction loss 3.5 3.5
Fuel Air cycle efficiency 47.65 51.5
Gross indicated thermal efficiency 32.65 36.5
Brake thermal efficiency 28.65 32.5

15. Design of components:
• The components are designed on basis of maximum pressure obtained by reverse engineering
which is calculated as 6 MPa.
•The following components are designed-
1. Design of piston
2. Design of crankshaft:
3. Design of connecting rod 1.1 and 1.2
4. Design of telescopic rod.

16. Design of connecting rod:
• Design of connecting rod is based on Soderberg approach for fatigue failure.
• t = 3.5 mm
• As stress in XX plane is higher than endurance limit, hence
t = 4 mm.
• Dimensions
1. C.R. 1.1 I.D= 19mm & O.D= 25mm
2. C.R 1.2 I.D= 18mm & O.D.= 24mm (Small end)
3. C.R 1.2 I.D= 42mm & O.D.= 54mm (Big end)

17. Design of crankshaft:
• Design of crankshaft is also based on Soderberg approach for fatigue failure.
• Plain Carbon Forgeable Steel

18. Design of telescopic rod:
•Design of crankshaft is also based on Soderberg approach for fatigue failure.
•

19. Manufacturing:
• Manufacturing of connecting rod:
i. Surface milling on billets.
ii. O.D turning of both ends.
iii. Drilling operation is performed followed by reaming.
iv. Sections are welded on MIG welding machine.

20. Manufacturing:
• Manufacturing of crankshaft:
i. Profile cutting is done on disc.
ii. Face milling is done to obtain the required dimensions.
iii. Drilling and tapping is done on balancing masses.
iv. Centre circular disc is cut by profile cutting and its surfaces are grinded.

21. Manufacturing:
• Design of telescopic rod:
i. Standard hollow shaft are selected and cut to required shapes by hacksaw.
ii. These hollow bars turned on centre lathe to obtained required I.D. and O.D.
iii. The slot are made on bars on vertical milling machine.
iv. The drills are made at the required position by hand drill machine.

22. Assembly:

23. Cost Estimate(material):
Sr. no Material Rate (Rs)
1 Box Pipe 320
2 M S plate 40
3 Bearing Bock 500
4 Shaft 2200
5 Plate 250
6 Square Rod 400
7 Square plate 450
8 Nut and Bolts 250
Total 4410

24. Cost Estimate:
Sr. no Process Rate (Rs.)
1 Cutting 600
2 Profile Cutting 1200
3 Milling 6300
4 Tapping 350
5 Welding 200
6 Grinding 250
Total 8800

25. Benefits:
• More work output in single power stroke.
• Increased theoretical thermal efficiency.
• Better utilization of exhaust gases.
• Engine operates at lower temperature.
• Cooling requirements are less as compared to conventional diesel engine.
• Can be applicable for multi cylinder engines.

26. Practical limitations:
• Size of engine increases.
• Increased maintenance cost.
• Complex telescopic rod working.
• Cold starting problem is increased.
• Overall weight of engine is increased.
• Applicable to only square and under square engines.

27. Future scope:
• Design of flywheel
• Modifications in valve timing
• Cam profile design
• Can be applicable to petrol engines.

28. Conclusion:
The 4 stroke 4 revolution engine mechanism is mainly developed for getting more work output
than traditional engine. Theoretically it can be justified that efficiency increases by 4%. So that
can get more work output.
But on the other hand there are some practical limitations in working of model viz. precision of
telescopic rod, plunger pin. Also the engine is more bulky. If limitations overcome by alternatives
in the future then this engine will ready to give more output.

29. THANK YOU !!!!