DESIGN OF PNUMATIC SIX CYLINDER RADIAL

ENGINE
Dhiraj Rathod, B.Tech Production Engineering, 211040026
1.ABSTRACT
This radial engine is an internal combustion engine configuration, wherein the cylinders point outward from
a central crankshaft just like the spokes on a wheel. This configuration was generally used in plane engines
earlier, than being outdated with the aid of using faster shaft and turbojet engines, where it is a reciprocating
engine. The cylinders are linked to the crankshaft with a cylindrical bolt-rod assembly. One cylinder has a
master rod with a direct attachment to the crankshaft. The foremost goal of this project is to design the radial
engine in described parameters and to simulate the stress, shear, tensile loads and thermal evaluation through
the usage of SOLIDWORKS SIMULATION Software. This Analysis technique is carried out in every
Production Industries earlier than assembling the components.
KEYWORDS - Radial engine, stress, shear, tensile loads, thermal analysis, SOLIDWORKS software.

2.INTRODUCTION
The radial engine has been the work horse of military & industrial fighter aircraft ever since 1920‘s
and the World War-I. Radial engine was utilized in all U.S. Bombers and transports plane and with inside the
maximum of the other classes of aircrafts. They have been advanced to the top of performance and
dependable on them even today.
In the jet age, many people are skilled in these types of operation at some stage in the sector of all
kinds of duty. The Radial engines reached their peak during WWII (World War II). There are a few radial
engines around nowadays, however they're now no longer that common. Most propeller-driven planes
nowadays use more conventional engine configurations (like a flat four-cylinder) or modern gas turbine
engines. Gas turbines are a lot lighter than radial engines for the energy they produce.
The radial engine concept may be very simple, as it takes the pistons and arranges them in a circle
across the crankshaft. The radial engine has the identical kind of pistons, valves and spark plugs that any
four-stroke engine has. The big distinction is with inside the crankshaft. Instead of the lengthy shaft that is
being utilized in a multi-cylinder automobile engine, there is a single hub from which all of the pistons
connecting rod connect with this respective circular hub. One rod is fixed, and it is commonly referred to as
the Master rod. The others are known as Articulating rods. They are mounted on the pins that permit them to
rotate as the crankshaft and the pistons moves.

3.PROBLEM STATEMENT
Design a Novel Project with an idea that serves a specific application in any engineering field,
referring to a recently published SCI journal article. More weightage is given to the novelty of the report's
design, application and presentation. Further, the design should have a minimum of five parts.
Model the parts using any CAD Software by assembling them to make a complete design. Simulate
the working of the assembly and also present drawings for all the components. Test the strength of the
components in any CAE software. Create path Planning for each part with the respective machine and
generate G-code for that respective part. (Make sure you minimize cost and time in machining)
4.METHODOLOGY
Modelling of Engine:
This phase involves the modelling of various parts of the engine and assembling them to form our
proposed radial engine. For this purpose, SOLIDWORKS software is selected, which is modelling software
being used for designing various mechanical models. Initially, the Crankcase of the engine is modelled, then
remaining parts are modelled with respect to the crankcase, keeping it as a standard reference. Components
made individually are assembled. Care has been taken to keep the computer model dimensionally in
accordance with the Real-World model and its usage. The assembled engine with all the parts in the model is
shown below in figure 1.1. The design is validated by performing thermal analysis and dynamic analysis on
the models using the same SOLIDWORKS SIMULATION software.

FIG.1.1 Final Assembly of Radial Engine FIG.1.2 Working of Radial Engine

List of Components:
Base, Pillar support, bearing support, Piston, Piston pin, connecting rod, Piston ring, Cylinder body,
Cylinder cover, Cylinder bolt, Valve, Valve housing, Flywheel, Crankshaft valve crank, Connecting rod hub,
Counter weight, Crankshaft rod, Crankshaft pin, Crankcase, Crankcase gasket, Crankcase cover, Hub pin.

Stress, Strain and Displacement analysis:

Static analysis of the designed components of the radial engine is done in SOLIDWORKS simulation
software. The components modelled in SOLIDWORKS software are imported in simulation workbench to
perform dynamic analysis and decided whether they are safe for usage.
ANALYSIS OF PISTON:

Stress Distribution in Piston (Material Used: Cast Alloy Steel)

The maximum stress of the piston occurs at the hole in the piston present in Gudgeon pin, which is 9.244 x
106 N/m2 and the minimum Stress in piston occurs at the point inside the piston and piston pin which is
6.270 x 104 N/m2

Strain Distribution in Piston

The maximum strain of the piston occurs at the hole in the piston present near Gudgeon pin, which is 2.999
x10-5 , and the minimum Strain in piston occurs at the point inside the piston and piston pin which is 5.367 x
10-7
 Total Deformation of Piston
The maximum displacement of the piston occurs at the hole in the piston present near Gudgeon pin, which is
6.040 x 10-4 mm and the Minimum displacement in piston occurs at the point inside the piston and piston pin
which is 1 x 10-30 mm.

ANALYSIS OF CONNECTING ROD:

Stress Distribution of Connecting Rod (Material Used Alloy Steel SS)

The maximum stress of the connecting Rod occurs at outside the circular region, which is 8.964 x 107 N/m2
and the minimum Stress in connecting rod occurs inside the circular region at fixed end which is 6.465 x 105
N/m2.
 Strain Distribution in Connecting Rod

The maximum strain of the connecting Rod occurs at outside the circular region, which is 3.501 x 10-4 and
the minimum strain in connecting rod occurs inside the circular region at fixed end which is 3.701 x 10-6

Total Deformation of Connecting Rod

The maximum displacement of the connecting Rod occurs at outside the circular region, which is 2.027 x
10-2 mm and the minimum in connecting rod occurs inside the circular region at fixed end which is 1 x 10-30
mm.
ANALYSIS OF CRANKSHAFT ASSEMBLY:

Stress Distribution in Crankshaft (Material Used: AISI 4340 Steel, Normalized)

The maximum stress of the crankshaft assembly occurs at the bottom arc, which is 9.825 x 1012 N/m2 and
the minimum Stress in crankshaft assembly occurs at the top part, which is 7.893 x 1010 N/m2.

Strain Distribution in Crankshaft

The maximum stress of the crankshaft assembly occurs at the bottom arc, which is 9.825 x 1012 N/m2 and
the Minimum Stress in crankshaft assembly occurs at the top part, which is 7.893 x 1010 N/m2.
 Total Deformation in Crankshaft
The maximum deformation of the crankshaft assembly occurs at the bottom arc, which is 1.033 x 1010 mm
and the minimum deformation in crankshaft assembly occurs at the top part, which is 6.815 x 102 mm.
5.DESCRIPTION
A 6-cylinder radial engine is a type of internal combustion engine characterized by its cylinder
arrangement and configuration. In a radial engine, cylinders are arranged in a circle around the crankshaft,
resembling the spokes of a wheel. In the case of a 6-cylinder radial engine, there are six cylinders evenly
spaced around the crankshaft. Unlike inline or V engines where cylinders are aligned in a row or in a V
shape, radial engines position cylinders in a radial pattern, with the crankshaft at the centre. This
configuration allows for a more compact design and efficient cooling. Radial engines are often air-cooled,
with fins on the cylinders to dissipate heat generated during combustion. This eliminates the need for a
separate liquid cooling system, making the engine lighter and simpler. Radial engines are known for their
simplicity and reliability. A 6-cylinder radial engine typically produces a moderate amount of power suitable
for various applications such as aircraft, vintage cars, and industrial machinery. The power output can vary
depending on factors like displacement, compression ratio, and fuel type. Radial engines were widely used
in aviation during the early to mid-20th century, powering iconic aircraft like the Boeing B-17 Flying
Fortress and the Lockheed P-38 Lightning. Overall, a 6-cylinder radial engine combines a unique cylinder
arrangement with simplicity, reliability, and historical significance, making it a fascinating piece of
engineering history.
6.CONCLUSION
In this project it is focused on the design and analysis of the six-cylinder radial engine. Design and
analysis of the engine is done based on the literature work with the help of SOLIDWORKS software.
Analysis is done for the main components like piston, connecting rod, crank shaft, etc. because these are the
most important components of the engine and most of the engine load is taken up by these components.
During the study of result the material properties are considered into account. Based on analysis it is
observed that the analysed components are found safe. It is proposed to calculate engine performance
parameters for the final design of the engine that is obtained based on the trial and error done by analysis
(design obtained after optimizing the dimensions for the compactness). Also, the engine can be fabricated
for the further testing to check engine capabilities.
7.REFERENCES
[1] D. Ravi, "Fabrication of Radial Engine", Middle-East Journal of Scientific Research.
[2] Design of Radial Engine, Kuldeepak, Kshitij Chaurasia, Mayank Kumar
G-Codes for Machining Operation:
1]Crankshaft Pin 2]Crankcase Gasket

O0001
N1 G21 O0001
N2 (8MM X 90DEG CRB SPOT DRILL) N1 G21
N3 G91 G28 X0 Y0 Z0 N2 (10MM X 90DEG CRB SPOT DRILL)
N4 T14 M06 N3 G91 G28 X0 Y0 Z0
N5 S12000 M03 N4 T14 M06
N5 S9915 M03
N6 (Center Drill1)
N6 (Center Drill1) N7 G90 G54 G00 X0 Y51.
N7 G90 G54 G00 X0 Y33. N8 G43 Z26. H14 M08
N8 G43 Z30.994 H14 M08 N9 G82 G98 R4. Z0 P1000 F1712.611
N9 G82 G98 R9. Z4.65 P1000 F1828.8 N10 X-44.167 Y25.5
N10 Y5. N11 Y-25.5
N11 G80 Z30.994 M09 N12 X0 Y-51.
N12 G91 G28 Z0 N13 X44.167 Y-25.5
N13 (3.0mm SCREW MACH DRILL) N14 Y25.5
N14 T15 M06 N15 G80 Z26. M09
N15 S12000 M03 N16 G91 G28 Z0
N17 (7.0mm JOBBER DRILL)
N18 T15 M06
N16 (Drill1) N19 S11490 M03
N17 G90 G54 G00 X0 Y33.
N18 G43 Z30.994 H15 M08 N20 (Drill1)
N19 G83 G98 R9. Z-6.621 Q2. F762. N21 G90 G54 G00 X0 Y51.
N20 Y5. N22 G43 Z26. H15 M08
N21 G80 Z30.994 M09 N23 G83 G98 R4. Z-2.101 Q2. F1284.127
N22 G91 G28 Z0 N24 X-44.167 Y25.5
N23 G28 X0 Y0 N25 Y-25.5
N24 M30
N26 X0 Y-51.
N27 X44.167 Y-25.5
N28 Y25.5
N29 G80 Z26. M09
N30 G91 G28 Z0
N31 G28 X0 Y0
N32 M30
3] Piston N49 G02 X-90.7 Y0 I89.423 J15.168 F89.072
O0001 N50 I90.7 J0
N1 G21 N51 X-89.423 Y15.168 I90.7 J0
N2 (10MM X 90DEG CRB SPOT DRILL) N52 G03 X-92.021 Y26.539 I-15.025 J2.549
N3 G91 G28 X0 Y0 Z0 N53 G40 G01 X-137.897 Y91.158
N4 T14 M06 N54 G00 Z-21.
N5 S9915 M03 N55 Z25. M09
N56 G91 G28 Z0
N6 (Center Drill1) N57 (20MM X 90DEG CRB SPOT DRILL)
N7 G90 G54 G00 X0 Y12. N58 T16 M06
N8 G43 Z41. H14 M08 N59 S4957 M03
N9 G82 G98 R19. Z13.75 P1000 F1712.611
N10 G80 Z41. M09 N60 (Center Drill3)
N11 G91 G28 Z0 N61 G90 G54 G00 X0 Y0
N12 (5.0mm JOBBER DRILL) N62 G43 Z25. H16 M08
N13 T15 M06 N63 G82 G98 R3. Z-9. P1000 F1183.716
N14 S12000 M03 N64 G80 Z25. M09
N65 G91 G28 Z0
N15 (Drill1) N66 (20.0mm JOBBER DRILL)
N16 G90 G54 G00 X0 Y12. N67 T17 M06
N17 G43 Z41. H15 M08 N68 S4928 M03
N18 G83 G98 R19. Z8.182 Q2. F1097.28
N19 G80 Z41. M09 N69 (Drill3)
N20 G91 G28 Z0 N70 G90 G54 G00 X0 Y0
N21 (10MM X 90DEG CRB SPOT DRILL) N71 G43 Z25. H17 M08
N22 T14 M06 N72 G83 G98 R3. Z-24. Q2. F751.128
N23 S9915 M03 N73 G80 Z25. M09
N74 G91 G28 Z0
N24 (Center Drill2) N75 (5MM HSS 90DEG COUNTERSINK)
N25 G90 G54 G00 X0 Y12. N76 T18 M06
N26 G43 Z41. H14 M08 N77 S9546 M03
N27 G82 G98 R-6.682 Z-11.932 P1000 F1712.611
N28 G80 Z41. M09 N78 (Contour Mill3)
N29 G91 G28 Z0 N79 G90 G54 G00 X0 Y0
N30 (5.0mm JOBBER DRILL) N80 G43 Z3. H18 M08
N31 T15 M06 N81 G01 Z-1.4 F125.
N32 S12000 M03 N82 G41 D38 X-10.909 Y1.693 F678.972
N83 X-11.829 Y.847
N33 (Drill2) N84 G03 X-11.99 Y.5 I.339 J-.368
N34 G90 G54 G00 X0 Y12. N85 X-12. Y0 I11.99 J-.5 F1357.944
N35 G43 Z41. H15 M08 N86 I12. J0
N36 G83 G98 R-6.682 Z-17.501 Q2. F1097.28 N87 X-11.99 Y-.5 I12. J0 F678.972
N37 G80 Z41. M09 N88 X-11.829 Y-.847 I.5 J.021
N38 G91 G28 Z0 N89 G40 G01 X-10.909 Y-1.693
N39 (6MM CRB 2FL 19 LOC) N90 X0 Y0
N40 T01 M06 N91 G00 Z3.
N41 S373 M03 N92 Z25. M09
N93 G91 G28 Z0
N42 (Contour Mill1) N94 (25MM HSS 90DEG COUNTERSINK)
N43 G90 G54 G00 X-137.897 Y-91.158 N95 T19 M06
N44 G43 Z25. H01 M08 N96 S2980 M03
N45 Z-21.
N46 G01 Z-25.5 F22.268 N97 (Countersink1)
N47 G41 D21 X-92.021 Y-26.539 F66.804 N98 G90 G54 G00 X0 Y0
N48 G17 G03 X-89.423 Y-15.168 I-12.427 J8.822 N99 G43 Z25. H19 M08
N100 G82 G98 R3. Z-10.15 P1000 F431.514
N101 G80 Z25. M09
N102 G91 G28 Z0
N103 (6MM CRB 2FL 19 LOC)
N104 T01 M06
N105 S373 M03

N106 (Contour Mill4)

N107 G90 G54 G00 X-137.897 Y-91.158
N108 G43 Z55. H01 M08
N109 Z31.5
N110 G01 Z27. F22.268
N111 G41 D21 X-92.021 Y-26.539 F66.804
N112 G03 X-89.423 Y-15.168 I-12.427 J8.822
N113 G02 X-90.7 Y0 I89.423 J15.168 F89.072
N114 I90.7 J0
N115 X-89.423 Y15.168 I90.7 J0
N116 G03 X-92.021 Y26.539 I-15.025 J2.549
N117 G40 G01 X-137.897 Y91.158
N118 G00 Z31.5
N119 Z55.

N120 (Contour Mill5)

N121 Y-91.158
N122 Z27.
N123 G01 Z22.5 F22.268
N124 G41 D21 X-92.021 Y-26.539 F66.804
N125 G03 X-89.423 Y-15.168 I-12.427 J8.822
N126 G02 X-90.7 Y0 I89.423 J15.168 F89.072
N127 I90.7 J0
N128 X-89.423 Y15.168 I90.7 J0
N129 G03 X-92.021 Y26.539 I-15.025 J2.549
N130 G40 G01 X-137.897 Y91.158
N131 G00 Z27.
N132 Z55. M09
N133 G91 G28 Z0
N134 G28 X0 Y0
N135 M30