DESIGN AND ANALYSIS OF IC ENGINE CYLINDER

21MEC301P – DESIGN OF MECHANICAL SYSTEMS

A PROJECT REPORT

Submitted by
S HARI VITTAL (RA2211002040003)

Under the guidance of

Dr. M. KAMATCHI HARIHARAN M.E., Ph.D.,

(Assistant Professor (S.G), Department of Mechanical Engineering)

in partial fulfillment for the award of the degree

of

BACHELOR OF TECHNOLOGY
In

MECHANICAL ENGINEERING
of
FACULTY OF ENGINEERING AND TECHNOLOGY

November 2024

1
 SRM Institute of Science and Technology
(Deemed to be University Under Section 3 of UGC Act, 1956)

BONAFIDE CERTIFICATE

Certified that this project titled “DEISGN AND ANALYSIS OF IC ENGINE

CYLINDER” is the Bonafide work of“KUMARAN G (RA2211054040028)”,
who carried out the project work under my supervision. Certified further, that to
the best of my knowledge the work reported herein does not form any other
project report or dissertation on the basis of which a degree or award was
conferred on an earlier occasion on this or any other candidate.

SIGNATURE SIGNATURE

Dr. M. KAMATCHI HARIHARAN M.E., Ph. D Dr. R. RAJARAMAN, M.E., Ph.D.

GUIDE HEAD OF THE DEPARTMENT

ASSISTANT PROFESSOR (S.G) MECHANICAL

ENGINEERING DEPT. OF MECHANICAL ENGINEERING

Submitted for the Viva-Voce held on:

Signature of the Internal Examner-1 Signature of the Internal Examiner-2

2
ACKNOWLEDGEMENT

We express our humble gratitude to the management for the facilities extended
for the project work.
We extend our sincere thanks to the Dean Dr. C V Jayakumar, Vice Principal –
Academics Dr.C.Gomathy and Vice Principal- Examinations Dr.S.Karthikeyan
for their invaluable support.
We wish to thank Dr.R.Rajaraman, M.E., Ph.D., Professor & Head, Department
of Mechanical for his valuable suggestions and encouragement throughout the
period of the project work.
We are extremely grateful to our Project Coordinator Dr.Kamatchi Hariharan
M, M.E., Ph.D., Assistant Professor, Department of Mechanical for leading and
helping us to complete our course. He provided us the freedom and support to
explore the research topics of our interest.
We sincerely thank our management, all Mechanical faculty members, staff and
fellow students who have directly or indirectly helped our project.
Finally, we would like to thank our parents, our family members and friends for
their unconditional love, constant support and encouragement.
Regards
KUMARAN G

1
1. Introduction to Spigot and Sprocket Mechanisms
What is a Spigot and a Sprocket?

A spigot is typically a type of shaft or hub with a cylindrical projection designed

to fit into a corresponding part, allowing secure attachment and alignment. In
mechanical assemblies, spigots serve as connectors, often providing a pivot or a
rotational axis for other parts.

A sprocket is a wheel with teeth or cogs designed to mesh with a chain,

allowing for the transfer of rotational motion or power across different
components. Sprockets are commonly used in bicycles, motorcycles, and
various machinery.

Importance of Spigot and Sprocket Mechanisms

Spigots are crucial in applications where parts must be aligned precisely and
held securely, ensuring stability and reducing wear in moving assemblies.
Sprockets enable smooth power transmission, transforming rotary motion into
linear motion or vice versa, and are integral in timing mechanisms and drives
for machinery.

Applications and Relevance in Engineering

Sprockets are widely used in automotive, industrial, and manufacturing

applications where durability and precise movement control are essential.
Spigots are equally valuable in assembling parts with high stability
requirements, such as engines and complex machinery. Understanding these
mechanisms provides a foundation for designing efficient and stable mechanical
systems.
2. Objectives of the Project
Purpose of the Spigot and Sprocket Project

2
The project aims to design, model, and prototype a spigot and sprocket
assembly to demonstrate the principles of secure fitting and rotational power
transfer. This model will serve as an educational tool for understanding key
mechanical concepts and demonstrate the process of going from design to
physical model.

Project Goals

Design Accuracy: Create a spigot and sprocket that are dimensionally accurate
and functionally representative.
Prototyping: Develop a cost-effective prototype using 3D printing, making the
model accessible and easy to handle.
Learning Outcomes: Gain hands-on experience in design, material selection,
and assembly techniques.
Testing and Analysis: Evaluate the functionality and durability of the model for
educational use.
This project combines theoretical and practical aspects, contributing to a deeper
understanding of mechanical assemblies.

3. Material Selection for Spigot and Sprocket

Overview of Material Options

For the spigot and sprocket, material selection is essential to balance durability,
cost, and ease of prototyping. Common materials considered include:

Metal Alloys: Known for strength and durability, but difficult to machine for
prototyping.
Polylactic Acid (PLA): Ideal for 3D printing, PLA is affordable, biodegradable,
and sufficiently strong for a prototype.

3
ABS and Nylon: Both offer higher durability than PLA but require more
complex printing conditions.
Chosen Material: PLA

PLA was chosen for this project as it offers:

Ease of Printing: PLA’s low melting point and minimal warping make it
suitable for complex designs.
Cost-Effectiveness: PLA is affordable and accessible, which is ideal for a
prototype.
Environmental Benefits: Being biodegradable, PLA aligns with eco-friendly
prototyping.
While PLA is not suitable for high-stress applications, it serves well for
educational models.

4. Design Specifications and Calculations

Specifications

Spigot Dimensions: Diameter, length, and clearance for a precise fit within the
sprocket hub.
Sprocket Dimensions: Number of teeth, pitch, and overall diameter, designed to
mesh effectively with a standard chain.
Calculations

Strength Calculations: Ensure that both parts handle expected loads and
stresses.
Clearance and Fit: Spigot and sprocket designed with specific tolerances for
optimal assembly.
Gear Ratios and Pitch: Determine appropriate pitch for smooth chain
engagement and effective power transfer.

4
These calculations ensure the spigot and sprocket meet the required mechanical
and operational standards.

5. Modeling and CAD Design Process

Using CAD for Design

Computer-Aided Design (CAD) software was used to create accurate digital

models of the spigot and sprocket. Key steps included:

Initial Sketching: Outline basic shapes and dimensions.

Extrusion and Detailing: Add depth to 2D sketches and specify features like
teeth and fit.
Dimensional Precision: Fine-tune measurements to ensure proper assembly.
3D Model Validation

After completing the CAD model, the design was verified for dimensional
accuracy and exported in a format suitable for 3D printing. This model serves as
the foundation for prototype production.

5
6. Manufacturing Methods: 3D Printing vs. Traditional Techniques
3D Printing vs. Casting and Machining

3D Printing: Ideal for small batches and prototypes, allowing fast, low-cost
production.
Casting and Machining: Suitable for large-scale production but costly and time-
consuming for one-off models.
Benefits of 3D Printing

Rapid Prototyping: Print complex shapes with minimal preparation.

Cost-Effective for Small Batches: Ideal for single prototypes.
Design Flexibility: Quick adjustments based on testing.
Given the project’s scope, 3D printing offers a practical solution, combining
efficiency and flexibility.

7. Advantages of Selected Materials and Methods

6
PLA and 3D Printing Benefits

Ease of Production: Simple to print and modify.

Cost Savings: PLA is affordable, and 3D printing reduces tooling costs.
Environmental Impact: PLA’s biodegradability and low waste output make it an
eco-friendly choice.
Together, PLA and 3D printing enable efficient prototyping, ideal for design
testing and educational purposes.

8. Assembly and Fit Testing of Spigot and Sprocket

Assembly Process

Assemble the spigot and sprocket to ensure a snug fit and smooth movement.
Key tests:

Dimensional Fit: Check that the spigot aligns with the sprocket’s hub.
Rotational Movement: Test for smooth rotation without excessive friction.
Chain Engagement: Confirm proper meshing of the sprocket teeth with a test
chain.

7
8
Results of Fit Testing

Adjustments were made to ensure optimal fit and alignment. Final tests
confirmed smooth and reliable assembly, validating the design.

9. Challenges Encountered and Solutions

Common Challenges

Material Limitations: PLA’s strength limits required design adjustments.

Printing Issues: Warping and adhesion problems impacted the first few prints.
Dimensional Accuracy: Initial tolerance issues required recalibration.
Solutions Implemented

Adjustments in Design: Modified wall thickness and clearances.

Optimized Print Settings: Improved adhesion with bed heating.
Iteration Process: Reprinted to achieve better fit and function.
These solutions ensured a successful final prototype.

10. Conclusion and Project Outcome

Project Outcome

The project achieved a functional prototype of the spigot and sprocket,

demonstrating proper assembly, fit, and motion. Key learning outcomes
included understanding design principles, materials selection, and the benefits
of 3D printing for prototyping.

9
Concluding Insights

This project highlights the advantages of using PLA and 3D printing in

educational projects, providing a cost-effective way to model complex
components. By addressing real-world challenges in design and production, the
project provided valuable insights into mechanical design and manufacturing
methods.

10