Machine Design Project

5th Semester

Instructor: Dr. Syed Maaz Hassan Date of Submission:

13/12/24

Session: ME-14 Section: A

Design Firm: RONIN

Sr no. Name CMS

1 Muhammad Zohaib Nazir 428170
2 Abdullah Faheem 411819
3 Syed Zain Abbas 405242
4 Muhammad Abdullah 408693
Table of Contents
Abstract.......................................................................................................................................3
Introduction .................................................................................................................................3
Components................................................................................................................................4
Piston Cylinder: ........................................................................................................................4
Connecting Rod:.......................................................................................................................5
Wrist Pin: .................................................................................................................................5
Crankshaft: ..............................................................................................................................6
Material Utilized ...........................................................................................................................7
Stress Analysis.............................................................................................................................8
Mesh information .........................................................................................................................8
Study Properties .......................................................................................................................9
Units ...................................................................................................................................... 10
Loads and Fixtures ..................................................................................................................... 10
Study Results ............................................................................................................................. 11
Discussion................................................................................................................................. 12
Conclusion ................................................................................................................................ 12
References ................................................................................................................................ 12
Abstract
The main objective was to design and analyze a w12 6000cc engine consisting of components piston,
connecting rod, pin and crankshaft using SolidWorks. The aim was to conduct a simulation and
determine the mechanical behavior of these components when subjected to an external Pressure.
Advanced modeling techniques were employed in the SolidWorks simulation software to ensure
precise geometries and optimized solution of the parts. Stress analysis was conducted to evaluate
the structural performance of the components, identifying potential failure points and validating the
design's reliability. The results offer insights into the mechanical behavior of W12 engine
components, contributing to improved design strategies in high-performance automotive
applications.

Introduction
The W12 engine is a high-performance configuration widely recognized for its compact design and
ability to generate significant power output. Comprising twelve cylinders arranged in a “W” layout,
with cylinders arranged at angles of 72o and 102o this engine is often used in luxury and sports
vehicles. The components of such an engine, particularly the crankshaft, connecting rod, piston, and
pin, play a critical role in its functionality, efficiency, and durability.

This project focuses on the detailed design and assembly of these components using SolidWorks, a
robust 3D modelling and simulation software. By leveraging its design capabilities, this study aimed
to achieve precise geometries, ensure component integration, and simulate real-world performance
conditions. Furthermore, stress analysis was performed to evaluate the structural integrity of these
components under typical loading scenarios.

The following report details the methodology used in the design and assembly process, the stress
analysis performed, and the key findings derived from the simulations. It aims to provide insights into
the mechanical performance of a W12 engine's core components and highlight considerations for
their effective design and application in engineering.
Components
The following section provides a detail of the components used in the assembly

Piston Cylinder:
A piston-cylinder assembly was designed and analysed with the following
key specifications:

1. Cylinder Bore Diameter: 85 mm

2. Piston Stroke: 88.11mm
3. Piston Design:
• The piston was equipped with three grooves, each 6 mm Figure 1 Piston Cylinder

thick, to accommodate piston rings for effective sealing

and heat dissipation.
• The piston skirt, responsible for maintaining stability during
motion, had a height of 55.2 mm and a smooth curved profile
to reduce friction and wear.
• The piston crown featured a flat surface with a surface area
of 5750.59 mm², optimized for efficient combustion
chamber geometry.
4. Piston Pin Boss:
• Two pin bosses, each with a bore diameter of 33.8 mm, were
integrated to accommodate the wrist pin. Figure 2 Piston pin boss

• The piston pin boss diameter was made sure to be equal to the diameter of the wrist
pin

Using the piston bore and stroke we calculated the Engine displacement (cc) using the following
formula:

𝝅 𝑩𝒐𝒓𝒆 𝟐 𝑺𝒕𝒓𝒐𝒌𝒆
Engine displacement (cc) = 𝟒 × ( 𝟏𝟎
) ×( 𝟏𝟎
)× 𝟏𝟐 = 6000 cc
Connecting Rod:
The connecting rod was modelled with the following specifications:

1. Small end bore:

• A small end bore of diameter 33.8mm was made
• The diameter of the small end bore was made sure to be
equal to the diameter of the wrist pin
2. Shank:
• A 148.2mm shank was made
3. Connecting rod cap:
• The cap mainly functions to attach bolts to the
Figure 3 Connecting rod top
connecting rod in order to connect the upper and lower
bearings
• A 9mm dia hole was made to fasten M9 bolts
4. Lower bearing:
• Lower and upper bearing are connected through the
connecting rod cap using bolts

Figure 4 Connecting rod bottom

Figure 5 Labelled diagram

Wrist Pin:
1. Length = 82 mm
2. Diameter = 33.8mm
• The diameter of the wrist pin was
modelled to be equal to the small end
bore and piston pin boss diameter for
precise alignment
3. Chamfer:
• A 2mm chamfer at 45o angle was made
• Chamfers make it easier to insert the wrist
pin into the piston and connecting rod
Figure 6 Wrist pin
 bores and reduce the risk of damaging the pin during assembly
• Chamfers help distribute stress more evenly around the pin, reducing the likelihood
of stress concentrations at sharp edges.

Crankshaft:
1. Total length = 783.5mm
2. Crack pin:
• Diameter = 50mm the diameter of the crack pin was made equal to the diameter of
the upper bearing
• The length of the crack pin was made to be 37mm
3. Main journal bearing:
• Diameter = 50mm
• Used to provide stability
• They provide a smooth and precise bearing surface for the crankshaft to rotate on,
minimizing friction and wear.
• During stress analysis it was fixed in place to avoid buckling of crankshaft
4. Counterweight:
• Used to connect the main journal bearings with the crack pin
• Crank radius = 45mm
5. Crank pin oil hole:
• Used to provide effective lubrication and reduce stress concentration
• Diameter = 4mm

Main journal bearing

Crack-pin

Crack pin hole

Counterweight

Figure 7 Labeled diagram of crankshaft

Material Utilized

Figure 8 Material for piston Cylinder

Figure 9 Material for Connecting Rod

Figure 10 Material used for wrist pin

 Figure 11 Material used for Crankshaft

Stress Analysis
The stress analysis was performed using the SolidWorks simulation software. In order to prevent
buckling the main journal bearing of the crankshafts were made fixed as shown in the figure below

Figure 12 Fixtures

After this Pressure of 1MPa was applied upon the 4 power pistons (piston 1,4,8 and 11) and the mesh
was formed, during mesh generation the curvature feature of the simulation software was also used
to get a more precise and accurate mesh as shown in the image below

Mesh information
Mesh type Solid Mesh
Mesher Used: Blended curvature-based mesh
Jacobian points for High quality mesh 16 Points
Maximum element size 51.1797 mm
Minimum element size 2.55899 mm
 Figure 13 Mesh Formation

Study Properties
Study name Static 1
Analysis type Static
Mesh type Solid Mesh
Thermal Effect: On
Thermal option Include temperature loads
Zero strain temperature 298 Kelvin
Include fluid pressure effects from Off
SOLIDWORKS Flow Simulation
Solver type Automatic
Inplane Effect: Off
Soft Spring: Off
Inertial Relief: Off
Incompatible bonding options Automatic
Large displacement Off
Compute free body forces On
Friction Off
Use Adaptive Method: Off
Result folder SOLIDWORKS document
(C:\Users\mnazir.ug22smme\Downloads\W12
Semester Project)
Units
Unit system: SI (MKS)
Length/Displacement mm
Temperature Kelvin
Angular velocity Rad/sec
Pressure/Stress N/m^2

Loads and Fixtures

Fixture name Fixture Image Fixture Details

Entities: 7 face(s)
Type: Fixed Geometry
Fixed-1

Resultant Forces
Components X Y Z Resultant
Reaction force(N) -1.0318 16,325.2 -1.12949 16,325.2
Reaction Moment(N.m) 0 0 0 0

Load name Load Image Load Details

Entities: 4 face(s)
Type: Normal to selected
face
Pressure-1 Value: 1
Units: N/mm^2 (MPa)
Phase Angle: 0
Units: deg
Study Results

Figure 14 Stress Contours Side view

Figure 15 Stress contours top view

As shown by the above images Pressure along the pistons and crankshaft is minimum. The
connecting rods subjected to Pressure display a much higher Von Mises Stress as shown by the green
and yellow contours while the connecting rods subjected to no Pressure show minimum stress as
the contour is still blue. The maximum stress experienced by the connecting rods is 70MPa which is
lower than the yield strength of the Aluminum 2024 alloy used to make the connecting rod which is
why significant deformation did not occur in the connecting rods.

Discussion
The project required the assembly of a w12 Engine. The 3D model of the parts was made and
assembled in the SolidWorks software. The Aluminum 2024 alloy was selected for the connecting
rod, AISI 1045 steel for the wrist pin etc. Using the SolidWorks simulation software the results were
obtained and the connecting rod did not undergo any significant deformation. The contours obtained
through the stress analysis showed that significant stresses were experienced on the connecting
rods subjected to external Pressure of 1MPa.

Conclusion
This project showcased the importance of precise material selection and simulation in mechanical
design, it also provided us valuable insights into the SolidWorks design and Analysis about engines.
Stress analysis confirmed significant stress distribution but no notable deformation, highlighting the
design's integrity. All in all, the project explains every aspect regarding the design of w12 engine and
stress analysis.

References
1. Heywood, J. B. (1988). Internal Combustion Engine Fundamentals. McGraw-Hill Education.

2. Pulkrabek, W. W. (2004). Engineering Fundamentals of the Internal Combustion

Engine. Pearson Education.

3. Costex Tractor Parts. Connecting Rods. Retrieved from

https://www.costex.com/connecting-rods/.

4. High Power Media. Piston Pin Design Features. Retrieved from

https://www.highpowermedia.com/Archive/piston-pin-design-
features#:~:text=A%20shallow%2Dangle%20chamfer%20is,the%20piston%20and%20rod
%20bores.