Design And Analysis Of Piston On Different Materials Using .
Special Issue - 2021International Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181ETEDM - 2021 Conference ProceedingsDesign and Analysis of Piston on DifferentMaterials using CAE ToolsM.Viswanath1 S Ajay2 S Bharathraja2 R Deepika2 J Jegatheesh Ramnath21-Assistant Professor ,2-Ug Scholar Department of Mechanical Engineeering,Hindusthan Institute Of Technology , Coimbatore-32Abstract:- Piston plays a main role in energy conversion.Failure of piston happens due to various thermal andmechanical stresses. The working condition of the piston is soworst in comparison of other parts of the internal combustionengine. The main objective of this work is to investigate andanalyze the stress distribution of the piston. Design andanalysis of a piston using four different materials is carriedout in this project. Materials like Ti-6Al-4V, Al alloy 4032,Copper, Al alloy 2024 are used for structural and thermalanalysis of the piston. Applied the pressure as 13.6 Mpa andtemperature of 1500 degrees on the piston head. Design of thepiston is carried out using Solid works software, structuraland thermal analysis is performed using Finite ElementAnalysis. After the analysis on different materials thesuitable one for the piston is selected.1.INTRODUCTIONPiston is one of the mechanical component, invented byGerman scientist Nicholas August Otto in the year 1866.Piston is considered to be one of the most important partsin a reciprocating Engine, reciprocating pumps, gascompressors and pneumatic cylinders, among the othersimilar mechanisms in which it helps to convert thechemical energy obtained by the combustion of fuel intouseful (work) mechanical power. The purpose of the pistonis to provide a means of conveying the expansion of gasesto the crankshaft via connecting rod, The piston acts as amovable end of the combustion chamber Piston isessentially a cylindrical plug that moves up & down in thecylinder .It is equipped with piston rings to provide a goodseal between the cylinder wall.1.1Objectives of the projectare as followsTo develop structural modeling ofpistonTo develop structural and thermalanalysis ofthe piston1.2Major Force Acting OverPistonDue to explosion of fuel gasesDue to compression of fuel gasesSide wall friction and forcesThermal loadInertia force due to high frequencyofreciprocation of pistonFriction and forces at crank pinhole1.3Functions Of PistonTo reciprocate in the cylinder as a gas tight plug causingsuction, Compression , expansion, and exhauststrokes.To receive the thrust generated by the explosion of thegas in the cylinder andtransmit it to the connecting rod.To form a guide and bearing to the small end of theconnecting rod and to take the side thrust due toobliquity of the rod.Volume 9, Issue 101.4Factors Considered For Proper FunctioningOf PistonThe piston should have enormous strength and heatresistance properties to withstand gas pressure andinertia forces. They should have minimum weight tominimize the inertia forces.The material of the piston should have good and quickdissipation of heat from the crown to the rings andbearing area to the cylinder walls. It should form aneffective gas and oil seal.Material of the piston must possess good wearingqualities, so that the piston is able to maintainsufficient surface-hardness unto the operatingtemperatures.Piston should have rigid construction to withstandthermal,mechanical distortion andsufficient area to prevent undue wear. It has evenexpansion under thermal loads so should be free aspossible from discontinuitiesThe Piston Rings must be in good condition to providemaximum sealing during the stroke of the piston.There must be no Leakage between the piston and thewalls of the combustion chamber.Intake and Exhaust valves must close tightly so thatthere is no loss of compression at these points.Each piston design must have a provision forreturning oil to the oil reservoir and the crankcase.During operation, a significant amount of oil isaccumulated in the piston oil ring groove. This oil isreturned to the reservoir through piston windows orthrough a machinedchannel near the piston pin.LITERATURE REVIEWIn this paper [1], the coated piston undergonea Von misses test by using ANSYS for load applied on thetop. Analysis of the stress distribution was done on variousparts of the coated piston for finding the stresses due tothe gas pressure and Journal of Engineering and ScienceVol. 01, Special Issue 01, July 2016 Copyright @ JESwww.jes.ind.in 40 thermal variations. Von misses stress isincreased by 16% and deflection is increased afteroptimization. But all the parameters are well with indesign consideration.Design,Analysisand optimization of piston[2] which is stronger, lighter with minimum cost and withless time. Since the design and weight of the pistoninfluence the engine performance. Analysis of the stressdistribution in the various parts of the piston to know thePublished by, www.ijert.org37
Special Issue - 2021International Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181ETEDM - 2021 Conference Proceedingsstresses due to the gas pressure and thermal variationsusing with Ansys.With the definite-element analysis software,a three-dimensional definite-element analysis [3] hasbeen carried out to the gasoline engine piston. Consideringthe thermal boundary condition, the stress and thedeformation distribution conditions of the piston under thecoupling effect of the thermal load and explosion pressurehave been calculated, thus providing reference for designimprovement. Results show that, the main cause of thepiston safety, the piston deformation and the great stress isthe temperature, so itis feasible to further decrease thepiston temperature with structure optimization.This paper [4] involves simulation of a 2-stroke6S35ME marine diesel engine piston to determine itstemperature field, thermal, mechanical and coupledthermal- mechanical stress. The distribution andmagnitudes of the afore- mentioned strength parametersare useful in design, failure analysis and optimization ofthe engine piston. The piston model was developed insolid-works and imported into ANSYS for preprocessing,loading and post processing. Material model chosen was10-node tetrahedral thermal solid 87. The simulationparameters used in this paper were piston material,combustionpressure, inertial effects andtemperature.This work [5] describes the stressdistribution of the piston by using finite element method(FEM). FEM is performed by using computer aidedengineering (CAE) software. The main objective of thisproject is to investigate and analyze the stress distributionof piston at the actual engine condition during combustionprocess. The report describes the mesh optimization byusing FEM technique to predict the higher stress andcritical region on the component.The impact of crown thickness,thickness of barrel and piston top land height on stressdistribution and total deformation is monitored during thestudy [6] of actual fourstroke engine piston. The entire optimization is carried outbased on statistical analysis. FEA analysis is carried outusing ANSYS for optimum geometry. This paper describesthe stress distribution and thermal stresses of three differentaluminum alloys piston by using finite element method(FEM). The parameters used for the simulation areoperatinggaspressure, temperature and materialproperties of piston. The specifications used for the studyof these pistons belong to four stroke single cylinderengine of Bajaj Kawasaki motorcycle.DESIGN OF PISTONPistons are designed with features which perform specificfunctions during engine operation. The piston head orcrown receives the majority of the initial pressure and forcecaused by the combustion process. The piston pin area isexposed to a significant amount of force due to rapiddirectional changes. It is also subjected to thermalexpansion caused by the transfer of heat from the head tothe body of the piston. The piston pin area is subject tomore thermal expansion than other areas of the piston. ThisVolume 9, Issue 10occurs from the thermal expansion properties of castaluminum alloy and the mass in the piston pin area.Some pistons are cast and machined at the factory into acam ground (elliptical shape). An elliptical shape is anoval shape in which one-half is a mirror image of the otherhalf. These piston shapes provide an advantage inconforming to the ever- changing dimensions of thecylinder bore.The piston is designed to be an elliptical shape when cold.As the engine reaches operating temperature, the piston pinbore area expands more than other thinner areas of thepiston. At operating temperature, the piston shape becomesa circular shape, which matches the cylinder bore forimproved sealing and combustion efficiency. Some pistonsare designed with a taper, with the smallest diameter of thetaper at the piston head. The taper shape compensates forthermal expansion and thermal growth. Thermal growth isthe increase in size of a material when heated, with little orno change back to original dimensions. The taper designallows the piston to move freely in the cylinder boreregardless of the heat applied to the piston head. SomeBriggs & Stratton engines use a barrel-shaped piston skirt.The barrel shape provides a smoother transition duringdirectional changes of the piston. The piston rolls into thecylinder wall when changing direction at the end of astroke. This reduces noise, spreads the force of thedirectional change across a greater surface, and reducesside loading on the piston skirt. Some piston designs havethe piston pin offset from centre in the piston. The properorientation of the piston pin offset is marked by a notch oran arrow on the piston head. The mark on all Briggs &Stratton pistons should be facing or closest to the flywheelon all one- and two-cylinder engines. The offset piston pindesign offers a quieter running engine by reducing pistonwobble and related noise. This results in truer linearmovement of the piston in the cylinder bore.Figure 1 Assembly of PistonEach piston design must have a provision for returning oilto the oil reservoir and the crankcase. During operation, asignificant amount of oil is accumulated in the piston oilring groove. This oil is returned to the reservoir throughpiston windows through a machined channel near thepiston pin.Piston windows are a series of small holes machined intothe oil ring groove surface of the piston. The oil ringcollects excess oil from the cylinder bore. Piston windowsallow oil in the oil ring groove to drain into the oilreservoir. Another common method used to return oil tothe oil reservoir is through a machined channel near thePublished by, www.ijert.org38
Special Issue - 2021International Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181ETEDM - 2021 Conference Proceedingspiston pin. Oil collects in the rear of the oil ring grooveand is routed back to the oil reservoir through the channelending at the piston pin. This provides a path for oil toreturn to the oil reservoir along the outside surface of thepiston when the machined channel is exposed to the oilreservoir at BDC.MATERIAL SELECTION FORPISTONPistons are commonly made of a cast aluminum alloy forexcellent and light weight thermal conductivity. Thermalconductivity is the ability of a material to conduct andtransfer heat. Aluminum expands when heated, and properclearance must be provided to maintain free pistonmovement in the cylinder bore.Following section will describe the potential candidatematerials those can be used for piston application.Based on the properties, potential candidate materials forpiston are,Titanium Ti-6Al-4VAl Alloy 4032Copper AlloyAl Alloy 2024PropertiesHigh Fatigue Resistance,BioCompatbility,Osseoconductivity.Light Weight, High Strength andGood HeatConductor.High heat Resistance and IncreasedThermalConductivity.High Strength to Weight Ratio,Corrosion ResistanceLoad Density, High Thermal Conductivity, HighReliabilityEasy Machineability and very goodRecyclingCharacteristics.MODELLING AND ANALYSISOF PISTON DESIGNThe piston is designed according to the procedure andspecification which are given in machine design and datahand books. The dimensions are calculated in terms of SIUnits. The pressure applied on piston head, temperaturesof various areas of the piston, heat flow, stresses, strains,length, diameter of piston and hole, thicknesses, etc.,parameters are taken into consideration.DESIGN CONSIDERATIONS FOR APISTONIn designing a piston for an engine, the following pointsshould be taken into consideration:It should have enormous strength to withstand thehigh pressure.It should have minimum weight to withstand theinertia forces.It should form effective oil sealing in thecylinder.It should provide sufficient bearing area to preventunduewear.It should have high speed reciprocation without noise.It should be of sufficient rigid construction toVolume 9, Issue 10withstand thermal and mechanical distortions.It should have sufficient supportfor the piston pin.ASSUMPTIONS MADEIt is very difficult to exactly model the piston, in whichthere are still researches are going on to find out transientthermo elastic behavior of piston during combustionprocess. There is always a need of some assumptions tomodel any complex geometry. These assumptions aremade, keeping in mind the difficulties involved in thetheoretical calculation and the importance of theparameters that are taken and those which are ignored. Inmodeling we always ignore the things that are of lessimportance and have little impact on the analysis. Theassumptions are always made depending upon the detailsand accuracy required in modeling.The assumptions which are made while modeling theprocess are given below:The piston material is consideredashomogeneous andisotropic.Inertia and body force effects are negligible during theanalysis.The piston is stress free before the application ofanalysis.The analysis is based on pure thermal loading and thusonly stresslevel due to the above said is done theanalysisdoes not determine the life of the piston.Only ambient air-cooling is taken into account and noforced Convection is taken.The thermal conductivity of the material used for theanalysis is uniformthroughout.The specific heat of the material used is constantthroughout and does notchange with temperature.THE PISTON MODELThe following are the sequence of steps in which thepiston is modeled,Drawing a half portion ofpistonExiting the sketcherDeveloping the modelCreating a hole .SOLIDWORKSSolid Works is mechanical design automation softwarethat takes advantage of the familiar Microsoft Windowsgraphical user interface. It is an easy-to- learn tool whichmakes it possible for mechanical designers to quicklysketch ideas, experiment with features and dimensions, andproduce models and detailed drawings. A Solid Worksmodel consists of parts, assemblies, anddrawings.Typically, we begin with a sketch, create a basefeature, and then add more features to the model. (Onecan also begin with an imported surface or solidgeometry).We are free to refine our design by adding, changing,or reorderingfeatures.Published by, www.ijert.org39
Special Issue - 2021International Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181ETEDM - 2021 Conference ProceedingsAssociatively between parts, assemblies, and drawingsassures that changes made to one view areautomatically made to all other views.We can generate drawings or assemblies at any timein the design process.The Solid Works software lets us customizefunctionality to suit our needs.INTRODUCTIONTO SOLIDWORKSSolidworks mechanical design automation software is afeature-based, parametric solid modeling design toolwhich advantage of the easy to learn windows TM graphicaluser interface. We can create fully associate 3-D solidmodels with or without while utilizing automatic or userdefined relations to capture design intent.Parameters can be either numeric parameters, such as linelengths or circle diameters, or geometric parameters, suchas tangent, parallel, concentric, horizontal or vertical, etc.Numeric parameters can Solidworks mechanical designautomation software is a feature-based, parametric solidmodeling design tool which advantage of the easy to learnwindows TM graphical user interface. We can create fullyassociate 3-D solid models with or without while utilizingautomatic or user defined relations to capture design intent.Parameters refer to constraints whose values determine theshape or geometry of the model be associated with eachother through the use of relations, which allow them tocapture design intent.Design intent is how the creator of the part wants it torespond to changes and updates. For example, you wouldwant the hole at the top of a beverage can to stay at the topsurface, regardless of the height or size of the can. SolidWorks allows you to specify that the hole is a feature on thetop surface, and will then honor your design intent nomatter what the height you later gave to the can. Severalfactors contribute to how we capture design intent areAutomatic relations, Equations, added relations anddimensioning.Features refer to the building blocks of the part. They arethe shapes and operations that construct the part. Shapebased features typically begin with a 2D or 3D sketch ofshapes such as bosses, holes, slots, etc. This shape is thenextruded or cut to add or remove material from the part.Building a model in Solid Works usually starts with a 2Dsketch (although 3D sketches are available for powerusers). The sketch consists of geometry such as points,lines, arcs, conics (except the hyperbola), and spines.Dimensions are added to the sketch to define the size andlocation of the geometry. Relations are used to defineattributes such as tangency, parallelism, perpendicularity,and concentricity.It contains basic parts or data of standard boltand nut, gears, cams, bearings etc. These are the productdesign interface and are capable of 3D solid modeling,Conceptual design, Assembly structure planning, directmodel editing, large assembly design, advanced surfacedesign, sheet metal design, weldments, Plastic partsdesigning, CAD productive tools,Reverse engineering, Mold designing, Piping&tubing andelectrical cable harness&conduit designs.Volume 9, Issue 10This can increasing the productivity without lowering thecost, because it gives various data and technicalcommunication, which helps to your design and helps tovalidate with standards. This can help's the productdesigners to convert new product ideas into reality. Itcontains simulation technology, which enables to verifyyour design.DESIGN PROCEDURE OFPISTONFor designing the piston, the following procedure hasto be followed.Draw the sketch with the given dimensions and thenrevolve it.After theabovestep make a through hole inthe piston.Figure: 2 PistonFINITE ELEMENTANALYSIS INTRODUCTIONFinite Element Analysis (FEA) is a computer-basednumerical technique for calculating the strength andbehavior of engineering structures. It can be used tocalculate deflection, stress, vibration, buckling behaviorand many other phenomena. It also can be used to analyzeeither small or large scale deflection under loading orapplied displacement. It uses a numerical technique calledthe finite element method (FEM). In finite elementmethod, the actual continuum is represented by the finiteelements. These elements are considered to be joined atspecified joints called nodes or nodal points. As the actualPublished by, www.ijert.org40
Special Issue - 2021International Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181ETEDM - 2021 Conference Proceedingsvariation of the field variable (like displacement,temperature and pressure or velocity) inside the continuumis not known, the variation of the field variable inside afinite element is approximated by a simple function. Theapproximating functions are also called as interpolationmodels and are defined in terms of field variable at thenodes. When the equilibrium equations for the wholecontinuum are known, the unknowns will be the nodalvalues of the field variable. In the finite element approach,the nodal values of the field variable are treated asunknown constants that are to be determined. Theinterpolation functions are most often polynomial formsof the independent variables, derived to satisfy certainrequired conditions at the nodes. The interpolationfunctions are predetermined, known functions of theindependent variables; and these functions describe thevariation of the field variable within the finite element.The simulations used in FEA are created using a mesh ofmillions of smaller elements that combine to create theshape of the structure that is being assessed. Each of thesesmall elements is subjected to calculations, with thesemesh refinements combining to produce the final result ofthe whole structure.INTRODUCTION TOSIMULATIONSimulation is a design analysis system. Simulationprovides simulation solutions for linear and nonlinearstatic, frequency, buckling, thermal, fatigue, pressurevessel, drop test, linear and nonlinear dynamic, andoptimization analyses. Powered by fast and accuratesolvers, Simulation enables you to solve large problemsintuitively while you design. Simulation comes in twobundles: Simulation Professional and Simulation Premiumto satisfy your analysis needs. Simulation shortens time tomarket by saving time and effort in searching for theoptimum design. After building your model, you need tomake sure that it performs efficiently in the field. In theabsence of analysis tools, this task can only be answeredby performing expensive and time-consuming productdevelopment cycles. A product development cycletypically includes thefollowing steps:Building your model.Building a prototype of the ssTesting the prototype in the field.Evaluating the results of the fieldtests.Modifying the design based on the field test results.Analysis can help you accomplish the following tasks:Reduce cost by simulating the testing of yourmodel on the computer instead of expensive field test.Reduce time to market by reducing the numberof product developmentcycles.Volume 9, Issue 10Published by, www.ijert.org41
Special Issue - 2021StrainDisplacementAl Alloy 4032StressInternational Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181ETEDM - 2021 Conference ProceedingsCOPPER ALLOYStressStrainDisplacementStrainAl Alloy 2024StressDisplacementVolume 9, Issue 10Published by, www.ijert.org42
Special Issue - 2021International Journal of Engineering Research & Technology (IJERT)ISSN: 2278-0181ETEDM - 2021 Conference [5][6][7]LINEARSTATICSTRUCTURALANALYSISOFOPTIMIZED PISTON FOR BIO-FUEL USING ANSYSInternational Journal of Mechanical and Production EngineeringResearch and Development (IJMPERD) ISSN 2249- 6890 Vol.3, Issue 2, Jun 2013, 11-20 TJPRC Pvt. Ltd. By CH.VENKATA RAJAM, P. V. K. MURTHY , M. V. S. MURALIKRISHNA.Design Analysis and Optimization of Piston using CATIA andANSYS International Journal of Innovative Research inEngineering & Science ISSN 2319-5665(January 2013, issue 2volume 1)by CH. VENKATA RAJAM, P. V. K. MURTHY, M.V. S. MURALI KRISHNA, G. M.PRASADA RAO.AN ANALYSIS TO THERMAL LOAD AND MECHANICALLOAD COUPLING OF A GASOLINE ENGINE PISTONJournal of Theoretical and Applied Information Technology 20thFebruary 2013. Vol. 48 No.2 2005 - 2013 JATIT & LLS. ByHONGYUAN ZHANG, ZHAOXUN LIN,DAWEI XU.Simulation of Thermal-Mechanical Strength for Marine EnginePiston Using FEA Journal of Engineering Research andApplications www.ijera.com ISSN : 2248- 9622, Vol. 4, Issue3( Version 1),by Elijah Musango Munyao, Jiang Guo He, YangZhiyuan, Zou Xiang Yi .Piston Strength Analysis Using FEM Swati S Chougule, VinayakH Khatawat / International Journal of Engineering Research andApplications (IJERA) ISSN: 2248-9622 www.ijera.com Vol. 3,Issue 2, March -April 2013, pp.1724- 1731 by Swati SChougule, Vinayak H Khatawate.6] Design a four-cylinder Internal Combustion EngineInternational Journal of Mechanical Engineering Research &Applications Vol. 1 Issue 5, October – 2013 .ISSN: 2347-1719by Radoslav Plamenov Georgiev,Dr. Pedro Villanueva RoldanDk.Design, Analysis and Optimization of Three Aluminium PistonAlloys Using FEA Ajay Raj Singh et al Int. Journal ofEngineering Research and Applications www.ijera.com ISSN :2248-9622, Vol. 4, Issue 1( Version 3, January 2014, pp.94102 by Ajay Raj Singh, Dr. Pushpendra Kumar Sharma.Volume 9, Issue 10Published by, www.ijert.org43
the piston pin offset from centre in the piston. The proper orientation of the piston pin offset is marked by a notch or an arrow on the piston head. The mark on all Briggs & Stratton pistons should be facing or closest to the flywheel on
For the analysis of piston input conditions and process of analysis, a lot of literature survey has been done. Comparative study is done to select best material. . gas pressure and the working condition may cause the failure of piston such as piston side wear, piston head or crown cranks and piston over heating-seizure and so on. Therefore .
for the simple piston and reduced skirt length piston. by changing the geometry of the piston and it is suggested that which piston is better for same thermal load. Steady state thermal analysis of the Piston have been done in ANSYS 14.5. KEYWORDS . Thermal stress, ANSYS 14.5, Heat flux, Thermal analysis. 1.INTRODUCTION
surface of the piston. Pistons fail mainly due to mechanical stresses and thermal stresses. Analysis of piston is done with boundary conditions, which includes pressure on piston head during working condition and uneven temperature distribution from piston head to skirt. Jadhav failure of piston due to various thermal and mechanical stresses is
A piston is a component of reciprocating IC engines. It is the moving component with in a cylinder and is made of gas-tight by piston rings. In an engine, piston is used to transfer force from expanding gas in the cylinder to the crankshaft via a piston rod. Piston endures the cyclic gas pressure and the inertial forces at work, and this working
Temperature at the center of piston head T. c 260. 0. c to 290. 0. c Temperature at the edge of piston head T. e 185. 0. c to 215. 0. c Maximum gas pressure p 15.454N/mm. 2 Bore or outside diameter of piston D 57mm Thickness of piston headt. h 5.45mm. Piston rings
How A Piston Works Proprietary and Confidential 8 ① Incoming pressure to the upper chamber seals the piston down over the main seat Moving the handle causes the piston to slide up, releasing water into the fixture The piston re-seats as the upper chamber re-pressurizes Sloan Piston Valves are also "non-hold open" design ② ③
Intake valve Outlet valve Piston Cylinder Piston rod Crank shaft. 5 Industry and trade need safe solutions: Therefore, BOGE piston compressors . Piston compressor Compressed air receiver Refrigerant dryer Piston Compressors. 6 The K Series: compact, cost efficient, consistently oil free.
Failure occurred of piston due to various thermal and mechanical stresses. The working condition of the piston is . piston analysis methods have been reported in the past years. Silva 2006 has analyzed fatigue damaged piston. Damages initiated at the crown, ring grooves, pin holes and skirt are assessed. An analysis of both thermal fatigue .
