1. Cylinder Design Cylinder Liner (Barrel) Design
The liner functions both as
a structural member
a bearing surface for the piston and rings
Material
Cast Iron for wet liners
Steel for dry liners
Dry liners are inserted into wet liners
Only Wet Liners are normally used in large Diesel Engines

4. Cylinder Design In passenger car engines and small industrial engines
Liner is cast integrally with the jacket structure
Worn-out bore surfaces may be refinished to a larger diameter, and over-sized pistons are inserted.
For long-life industrial and commercial use
Separate removable cylinder liners are used
Repair and replacement is possible
Appropriate materials can be used
cast iron is preferred
steel is occasionally used

5. Cylinder Liner Loading
The liner thickness may be calculated from
tl = Liner thickness (m)
sc= Permissible cicumferential stress (kN/m2)
Pmax= Maximum combustion Pressure (kPa)
D = Inner liner Diameter (m)
sc = ( ) x 105 kN/m2 for steel
sc = ( ) x 105 kN/m2 for cast iron
tl = tl1 + tl2 for composite dry liners
tsteel > 2 mm

6. Effect of Thermal Stresses

7. Typical Wet Liner Configuration

8. Typical Dry Liner Configuration

9. Advantages of Wet Type Liners
It can be removed and replaced with great ease and without the need for any special tools or equipment.
It is possible to provide for a high-velocity water circulation around the liner and therefore reduce the piston temperature.
Since the liner is held only by a flange at the top end, it is free to expand without any restraint.

10. Advantages of Dry Liners
Suitable when cylinder block and crankcase are formed in one piece with detachable cylinder heads
Cooling water can come nearer to the top end of the liner
No gas or water joints are required
Stiffness of the cylinder block is increased
Main Disadvantage
A dry liner must be pressed or shrunk into the cylinder barrel.
It is difficult to remove or replace without special equipment

11. Lcen/D = 1. 20 - 1. 28 for SI engines Lcen/D = 1. 25 - 1
Lcen/D = for SI engines Lcen/D = for CI engines

12. Liner Flange Design Calculation
Taking moments around A ;
Section Modulus of the
cross-section between B&C ;

13. Design Notes on Water Cooled Cylinder Blocks
Walls are tensioned by the gas forces transmitted to the studs via the cylinder head
Tensile forces are only applied to the walls of the water jacket and the partitions between the cylinders
In-Line and V-Engines with water cooling usually have cylinders cast integral with the upper half of the crankcase
Main casting forming the cylinder block and crankcase may be made from alimimium alloy.

14. Design Notes on Cylinder Blocks
The crankcase width is determined from the trajectory of the extreme point of the connecting rod bolt head.
Minimum distance between bolt head and internal surface of crankcase is mm
Wall Thicknesses
Cast-Iron crankcase walls and partitions are mm
Cast-Iron water jacket thickness : mm
Aluminium casting thicknesses are mm more.
Die-cast Aluminium thickness is less than cast-iron