A Diesel Bike of 200cc engine having a

mileage of 110 Km/L

SACHIN KUMAR DESWAL 1, 5, ABHINAV HIRA 2, 6, SACHIN GAUTAM 3, 7 AND SUDHANSHU
SHARMA 4, 8
1
Masters Student, Department of Mechanical and Process Engineering, Hochschule Dsseldorf,
Dsseldorf, 40223, North Rhine-Westphalia, Germany
2
Graduate Engineer Trainee, Department of Design and Modelling, ABC Motors Co. Ltd, Port Louis,
11201, Mauritius
3
Masters Student, Department of Business and Sciences, Federation University, Melbourne, 3004,
Australia
4
Graduate Engineer Trainee, Department of Mechanical Engineering, Kurukshetra University,
Kurukshetra, 136119, India
5
sachin.deswal@study.hs-duesseldorf.de
6
abhinavhira@gmail.com
7
sachingautam8april@gmail.com
8
sudhanshusharma503@gmail.com

Abstract: A diesel engine bike of 200 cc is made by transforming an older engine of Suraj
Company of 325 cc. It has been done by doing some changes in piston diameter, cylinder
head diameter, connecting rod length, flywheel weight, stroke of an engine, taper rod,
governor setting, aerodynamic design and many more small changes. This results in
increasing its mileage from 60 Km/L to 110 Km/L, 15% improvement in efficiency of an
engine, increase in acceleration and better stability of bike. It has been done so that the crisis
of fuel problem in 21st century can be overcome. In spite of knowing that diesel engine causes
more pollution than the petrol engine, so to overcome these problems a double silencer
catalytic converter has been fitted with zigzag filters which reduces the contamination of SO2
and NOx by 25% into the atmosphere.
2015 Society of Gandhian Young Technological Innovation
OCIS codes: (150.2945) Design; (300.2140) Emission.

References and links

1. Mohd. Muqeem, Navneet Saini, Electromechanical Governing Of Diesel Engine Of A Generator Set Through
Torque Sensing, IJARET 4(2), 27-32 (2013).
2. Rajinder Kumar Soni, Diesel Engine Air Swirl Messurements Using Avl Test Rig, IJMET 4(1), 79-91 (2013).
3. Pundlik R. Ghodke , Dr. J. G. Suryawanshi, Simulation And Optimization Of Hsdi Diesel Engine For Suv To
Meet Bharat 4 Emission Norms In India, IJMET 3(2), 494-510 (2012).
4. Pundlik R. Ghodke , Dr. J. G. Suryawanshi, Advanced Turbocharger Technologies For High Performance
Diesel Engine - Passanger Vehicle Application, IJMET 3(2), 620-632 (2012).
5. Om Banna, Historical Bikes, http://www.bikewale.com/royalenfield-bikes/
6. R.S. Khurmi, A textbook of Machine Design (S. Chand, 2006)

1. Introduction
Diesel engine plays a dominant role in the field of power, propulsion and energy. The diesel
engine is a type of internal combustion engine, more specifically it is a compression ignition
engine, in which the fuel ignited solely by the high temperature created by compression of the
air-fuel mixture. The engine operates using the diesel cycle. A Diesel Bike is
an automobile with a diesel engine. Earlier such diesel bikes of 1990s traditionally have poor
ratio. Most diesel engines are generally unsuited for use on motorcycles which normally
require low weight, compact size, high RPMs and rapid acceleration. To tackle the starting
problem in cold condition, high noise, vibration and more pollution a modern methods are
implemented in this project for solving each of these problems which are discussed in detailed
in this paper.
1.1 Features of Diesel Bikes
They burn less fuel than a petrol engine performing the same work, due to the engine's higher
temperature of combustion and greater expansion ratio. They have no high voltage electrical
ignition system, resulting in high reliability and easy adaptation to damp environments. They
generate less waste heat in cooling and exhaust. Diesel engines can accept super- or turbo-
charging pressure without any natural limit, constrained only by the strength of engine
components. Diesel engine has high compression ratio 9.5:1 and high calorific value of 42
MJ/kg.
1.2 Accessories for the Diesel Engine
There are some accessories that can be added bikes to enhance its quality performance.
Glow plug: During winter season, cold intake air is heated up due to high compression
pressure. Thus a glow plug is a heating element that projects into the main combustion
chamber, thereby helps with ignition during start. Thus glow plug will avoid the delay starting
of diesel bikes shown in Figure 1.

Figure 1: Glow plug

Muffler: It is a material of stainless steel & wool inserted between the chassis of bike and the
engine shown in Figure 2. The function is to absorb or minimize the sound & vibration
thereby preventing the breakdown of the chassis of bike & engine & absorbs shocks at high
speed.

Figure 2: Muffler material

Catalytic converter: It is a vehicle emission controlling device that filters out the un burnt
smoke particles such as HC, NOX emissions to a larger extent shown in Figure 3. It is of two
way type and three way type depending upon no. of passages used for filtering the exhaust
smoke.

Figure 3: Catalytic converter

2. Literature Survey
Paper Mohd Muqeem, Navneet Saini (2013) had studied the Electromechanical governing of
diesel engine of a generator set through torque sensing of Governing is the action of varying
the fuel supply in accordance with the load demand so that the engine runs at practically
constant speed. Before the speed of the engine gets changed, this signal will stipulate the fuel
regulating system to increase or decrease the fuel supply so that the speed may not be
fluctuated. [1]
Rajinder Kumar Soni, Pranat Pal Dubey (2013) studied the experiment of diesel engine air
swirl measurements using avl test rig. Knowledge of air flow in induction port and air motion
within the cylinder of High-speed direct injection diesel engine is of primary importance as
it influences fuel air mixing, combustion and hence fuel economy. It is necessary to study
the characteristics of inlet ports. The methods often used for measuring swirl and other air
motion features include steady flow test rig with AVL paddle wheel anemometer. [2]
Pundlik R. Ghodke,Dr. J. G. Suryawanshi (2012)experimentally studied the advanced
turbocharger technologies for high performance diesel engine - passenger vehicle application.
Expectation in next coming years is CO2 emissions reduction for vehicles. One approach to
this problem is the reduction of the displacement of the combustion engine while maintaining
the characteristics of large displacement engine. This paper summarizes review of
advancements in turbocharger technology to meet the demand of high performance and low
emission of passenger car vehicle application. [3]
Pundlik R. Ghodke, Dr. J. G. Suryawanshi (2012) has experimentally checked the direct
injection diesel engine offers Performance and fuel economy benefit. Use of performance
prediction software helps to reduce engine optimization time, reduces effort and cost of
development. In the present work, base engine performance prediction was done by use0
AVL Boost software. These 14 modes were used for emission optimization on engine test
bed. It was used for emission optimization. INCA base CAMEO software is used for
optimizing combustion parameters. This technique of emission development reduces engine
and vehicle emission development time. [4]
3. Work Undertaken
An old diesel engine bike of 325cc has been taken. Then some repair in its pump and nozzle
has been done to make it again in running condition to measure its mileage which can be
compared with later results. The mileage was measured about 60km/hr of an old bike which is
shown in Figure 4 with the help of full tank to tank method.

Figure 4: Earlier diesel engine bike

Then after it we dismounted the engine from the chassis of the bike and completely
disassemble the engine parts to measure the dimensions of each and every part (Piston,
flywheel, pump, nozzle, cylinder block, head, connecting rod, crank shaft and other parts) and
then the weight and dimensions are recorded and illustrated in the Table 1 to compare them
later with the modified engine of 200cc and then some parts are modified with the help of
lathe machine and some parts are casted with the wooden dye.
Sr. No. Description Specifications
 1 Weight of Engine 60650g
2 Weight of Bike 170000g
3 At 3600 RPM 6.5 HP
4 Current mileage 60kmpl
5 Piston diameter 79.01mm
6 Piston circumference 250.0mm
7 Piston Length 73.2mm
8 Piston weight 550g
9 Cylinder diameter 80.2mm
10 Bore length 128.5mm
11 Cylinder weight 3350g
12 Flywheel diameter 250.1mm
13 Flywheel weight 11050g
14 Connecting rod length 160.6mm
15 Connecting rod weight 650g
16 Crank shaft length (Oil inlet) 170.0mm
17 Crank shaft circumference ( Main Bearing) 128.3mm
18 Crank shaft diameter ( Flywheel end) 32.1mm
19 Crank shaft diameter ( Pump end) 29.3mm
20 Crank shaft weight 4500g
Table 1: Original (Earlier) specifications of bike

4. Calculations of piston & cylinder block

4.1 Estimated diameter
The dimensions of subsystem of engine of 200cc diesel bike was pre checked by amount of
reduction in bore ratio and stroke from 500 cc petrol bike and 350 cc petrol bike shown in
Table 2
Sr. No. Dimensions of Piston
500 cc bike 84mm
350 cc bike 72mm
Table 2: Reference Dimensions [5]

Difference b/w the cc in above two bikes = 150 cc

Difference b/w the dimensions of pistons = 12 mm
From the above table, it can be estimated that 1mm=12.5 cc
Observed value of piston diameter of 325cc bullet diesel bike = 79.6 mm
Clearance between cylinder liner and piston =.25mm on one side
Net diameter of piston crown = 79.6-9.0-.25-.25 = 69.6mm
Since diameter of piston skirt is 0.04 mm more than that of piston skirt; therefore diameter of
piston skirt calculated is 69.6+ 0.04= 66.64mm
Diameter of cylinder block = 70.5 mm
Stroke of the piston = 64.2 mm

4.2 Calculated diameter [6]

Brake power = 6 KW = 6000W
Indicated mean effective pressure = 0.75 N/mm
Speed = 3400 r.p.m
Mechanical efficiency = 80%
B.P. =6000KW
N = 3400 r.p.m
n = 1700
Piston diameter = 69.6mm
Stroke length = 58mm
5. Calculations of piston & cylinder block
The current piston and cylinder block is designed in solid works. First of all, on the basis of
calculation of cylinder block and piston made above the following designs are made. Then, a
sketch of cylinder block and piston is made on the sketcher. It is then extruded to form a 3-D
model from 2-D sketch. The different views of both piston and cylinder block are taken as
shown below. These casting of these designs are done and the improved parts are used to
modify the engine shown in Figure 5 and Figure 6.
5.1 Cylinder block design

Figure 5: Earlier diesel engine bike

5.2 Piston design

Figure 6: Earlier diesel engine bike

6. Fabrication procedure
The parts of diesel engine are cylinder, cylinder head, piston, exhaust and inlet valves,
camshaft, crankshaft, connecting rod, the fuel injector, fuel pump, flywheel etc. These sub
parts are needed for the assembly of the diesel engine. Firstly all the above mentioned parts
are cleaned by oil to remove all the dust particles. Then the outer casing of engine is placed at
its position. The crankshaft is placed in it and bearing cap is inserted at their corresponding
positions. Then bearing cap is fixed with the one end of the connecting rod with the help of
M280 bolts. The top end of connecting rod is connected to the piston through the gudgeon pin
and the cir clip lock is inserted and the lock screw is inserted. After this, cylinder block is
placed properly on the piston. The main point to be kept in mind is the correct alignment of
cylinder block with piston. The governor is kept back in its original position and we know
that the function of governor is to control the speed. The fuel injector is kept back into its
original slot. Cover on timing gear is placed back. Now the cylinder head is placed at its
respective slots provided. The rocker arm assembly is put in the slots provided which controls
the timing of the inlet and outlet valves. Now fuel injector is placed in its position. Then the
fuel pump is placed to supply the fuel. Then the lubrication level is checked in the oil sump.
All the new description of bike parts is mentioned below in Table 3.

Sr. No. Description Specifications

1 Weight of Engine 54750g
2 Weight of Bike 143000g
3 At 3600 RPM 6.5 HP
4 Current mileage 60kmpl
5 Piston diameter 69.6mm
6 Piston circumference 218.54mm
7 Piston Length 70.2mm
8 Piston weight 450g
9 Cylinder diameter 70.5mm
10 Bore length 128.5mm
11 Cylinder weight 3000g
12 Flywheel diameter 250.1mm
13 Flywheel weight 10000g
14 Connecting rod length 160.6mm
15 Connecting rod weight 650g
16 Crank shaft length (Oil inlet) 170.0mm
17 Crank shaft circumference ( Main Bearing) 128.3mm
18 Crank shaft diameter ( Flywheel end) 32.1mm
19 Crank shaft diameter ( Pump end) 29.3mm
20 Crank shaft weight 4000g
Table 2: Modified specifications

A modified diesel engine bike with new aerodynamic design, 200 cc engine and double
catalytic silencer is fabricated which is shown in Figure 6.

Figure 6: Modified diesel engine bike

7. Results & discussion

Fabrication of the engine is done with new modified parts. The total weight of the modified
engine is reduced from 60,650 g to 54,750 g. These results in better performance of the bike
as it has to carry less weight. Hence the acceleration of the bike is increased. The swept
volume of the new engine is reduced to 200 cc instead of 325 cc. This results in the decrease
in fuel consumption of the engine which increases the mileage of the bike from 60 Km/L to
110 Km/L. The muffler material has inserted between the chassis of bike and engine to
minimize the unwanted vibrations in the bike. The fabrication of the bike is completed with
new parts and improved aerodynamics. The total weight of the bike has been reduced from
173 kg to 143 kg. The design of the bike has been made aerodynamic to decrease the wind
resistance. Double silencers are installed with catalytic convertors to minimize the pollution
caused.
8. Conclusion & Future Work
5.1 Conclusion
The complete bike is fabricated along with the improved engine and mileage of the engine
has been improved and the weight of the bike has decreased as well. The 325cc engine has
successfully been reduced to 200cc.
5.2 Future work
The bike is fabricated in this semester and the engine is put on it and various tweaks have
been done to make it successful.
Glow plug can be installed to heat the air before entering in the chamber to avoid delay in
starting in cold seasons.
The engine can be harmonically balanced to increase the efficiency further for a smoother
ride.
The diesel engine can be changed to a diesel and electric hybrid engine to make it eco
friendly.
Acknowledgments
The success and final outcome of this project required a lot of guidance and assistance from
many people and we are extremely fortunate to have got this all along the completion of our
project work. We are thankful to Er. Vinod Chauhan for his aspiring guidance, invaluably
constructive criticism and friendly advice during the project work. We are also obliged to
thank Dr. Viraj Tyagi, Head of Department of Mechanical Department for sharing their
truthful and illuminating views on a number of issues related to the project. We are also
grateful to Er. Anil Taya for the valuable information provided by him in their respective
fields.
We are highly grateful to Dr. P.J. George, Director-Principal, Kurukshetra University for
providing this wonderful opportunity to carry out the present work and to support us in every
possible way throughout.
Furthermore, we are ineffably indebted to Er. Teg Raunak, Mr. Shakil, Mohammed
Yakub who took keen interest in our project work and guided us all along till the completion
of our project work.
At last but not the least, we acknowledge with a deep sense of reverence, gratitude towards
Almighty God, our parents and members of our families, who supported us morally as well as
economically and to all my friends who directly or indirectly helped us to complete this
project. Any omission in this brief acknowledgement does not mean lack of gratitude.