Steady State Thermal Analysis Of Piston Using Different Profile Of .

2022 IJRAR July 2022, Volume 9, Issue 3 www.ijrar.org (E-ISSN 2348-1269, P- ISSN 2349-5138) STEADY STATE THERMAL ANALYSIS OF PISTON USING DIFFERENT PROFILE OF PISTON HEAD BY FINITE ELEMENT ANALYSIS 1 Ritesh Tanwar, 2 Dr. Roopesh Tiwari, 1 PG Scholar, 2Professor MED, SIRT, Sage University, Indore, 2 MED, SIRT, Sage University, Indore (M.P.), India 1 Abstract: The reciprocating piston in an engine is responsible for the conversion of thermal energy to mechanical energy. On the Piston, there is a thermal-mechanical load. Due to cyclic thermal and mechanical loads, there occurs fatigue failure. More work has been done on improving the piston's design, material, and design in order to extend its service life. This research examines the temperature distribution for a basic piston and a piston with a shorter skirt. In order to determine which piston is best for a given thermal load, one may alter the piston's shape. Analysis of the Piston's thermal conductivity in ANSYS 19.2 has been completed. IndexTerms - Thermal stress, ANSYS 19.2, Heat flux, Thermal analys I. INTRODUCTION Thermal-mechanical loading is applied to a reciprocating portion of the engine known as the piston. When fuel is used in an engine, a significant quantity of heat is released, causing the temperature to rise and the pressure to rise, both of which put pressure on the piston. With temperatures ranging from 300-600 K and pressures up to 15 MPa, the piston may be considered hot. Since it must be able to sustain maximum pressure and high temperatures, thermal stresses must be reduced while designing the piston, its strength and heat-resistant material must be taken into consideration. The material must be both strong and lightweight in addition to being temperature resistant. As the piston reciprocates, its movement is transmitted to the crankshaft through the connecting rod. The inertial force required to initiate motion is reduced in proportion to the weight of the object being carried. It lowers the amount of gasoline used and improves the vehicle's efficiency. The piston should be made of a material that is chemically stable and has a low thermal expansion. [2] The piston undergoes a variety of alterations throughout time in order to meet the needs of the vehicle and to increase its performance. In the case of a diesel engine, for example, the piston's material must be able to withstand a higher degree of heat. In a diesel engine, the crown surface of the piston is usually shaped like a bowl, which reduces inertial forces and ensures that the air and fuel are mixed properly. Stiffness, temperature resistance, lightness, and chemical stability are all being improved in today's materials. The crown surface of the piston should be coated with ceramic material because of the above-mentioned characteristics. It lessens the engine's heat rejection while also reducing thermal stresses. [4] Its benefit is that it lowers the temperature of the exhaust gas and minimises pollutants by burning all of the unburned hydrocarbons. TBC is the abbreviation for this (thermal barrier coating). As a result, less gasoline is used. It protects the piston's material by reducing heat flow into the piston. IJRAR22C1146 International Journal of Research and Analytical Reviews (IJRAR) www.ijrar.org 208

2022 IJRAR July 2022, Volume 9, Issue 3 www.ijrar.org (E-ISSN 2348-1269, P- ISSN 2349-5138) An engine's rotational speed may be increased by reducing its weight by altering its piston shape. Reducing the length of the piston skirt alters the piston geometry. The piston material was not altered in any way throughout the process. In order to increase useful efficiency, all adjustments were made. II. LITERATURE SURVEY: Vaishali R. Nimbarteet al. [1] The stress distribution of the piston under real engine conditions was researched and evaluated. Pressure, temperature, and thermo-mechanical analyses of the piston were carried out in their work. They employed operating gas pressure, temperature, and piston material qualities as parameters to study the piston. The piston was examined under boundary circumstances, such as the pressure on the piston head and the temperature distribution from the piston head to the skirt during operation. Kethavath Vishalet al [2] worked on the design and study of the piston. An examination of pistons was conducted here. The study's objective was to compare the results of finite element analysis with those obtained by measuring the temperature fluctuations of the piston at various points on the piston during the transition from cold start to steady state. Amit B. Solankiet al. [3] designed and optimised a hybrid piston for a 10-horsepower 4-stroke single-cylinder diesel engine, and the results were presented (7.35 kW). The piston wall was composed of a light alloy like aluminium alloy, while the piston crown was built of high-strength cast steel. Through the use of FEM, they tracked the distribution of piston stress and the actual engine condition throughout the combustion process. Piston failure may have been avoided if the combustion stresses had been considered. Dr. L.N. Wankhade et al. [4] Using a microscope, the top surface of a piston was inspected to determine its stress and heat content. CATIA V5 would be used to create the piston's structural model. They then imported the CAD model into Hyper Mesh and used it to clean up the geometry and mesh it. III. THERETICAL CALCULATION: In the combustion process, a large quantity of heat is created, which is distributed throughout the engine. heat is transferred from one section of the engine to another depending on its temperature. Conduction, convection, and radiation all play a role in heat transmission. When it comes to heat transport, convection is mostly taken into account. Q ℎ 𝐴 T Where, Q amount of heat to be transferred h Heat transfer coefficient A Area for the heat transfer T temperature difference Thermal stress is distributed throughout the piston's many surfaces. The surface of the crown is subjected to wide swings in temperature. The piston crown surface exhibits temperature change. IJRAR22C1146 International Journal of Research and Analytical Reviews (IJRAR) www.ijrar.org 209

2022 IJRAR July 2022, Volume 9, Issue 3 IV. METHODOLOGY: www.ijrar.org (E-ISSN 2348-1269, P- ISSN 2349-5138) The following procedures are used to conduct a steady-state thermal study of the piston. Figure 1: Methodology V. CAD DESIGNING OF PISTON Figure 2: Convex type Figure 2: Flat type Figure 3: Concave type VI. MESHING & BOUNDARY CONDITION: Figure 4: Convex type Figure 5: Concave type Figure 6: Flat type Table 1: Mesh detailing IJRAR22C1146 International Journal of Research and Analytical Reviews (IJRAR) www.ijrar.org 210

2022 IJRAR July 2022, Volume 9, Issue 3 VII. BOUNDARY CONDITION www.ijrar.org (E-ISSN 2348-1269, P- ISSN 2349-5138) Figure 7: Applied Boundary Condition VIII. STEADY STATE THERMAL ANALYSIS GRAY CAST IRON Figure 8: Temperature Figure 9: Heat Flux Figure 10: Heat Flux Direction AL 2024 Figure 11: Temperature Figure 12: Heat Flux Figure 13: Heat Flux Direction ALUMINUM 6061 Figure 14: Temperature Figure 15: Heat Flux Figure 16: Heat Flux Direction TI-6AL-V4 Figure 17: Temperature IJRAR22C1146 Figure 18: Heat Flux Figure 19: Heat Flux Direction International Journal of Research and Analytical Reviews (IJRAR) www.ijrar.org 211

2022 IJRAR July 2022, Volume 9, Issue 3 IX. RESULT SUMMARY www.ijrar.org (E-ISSN 2348-1269, P- ISSN 2349-5138) GRAY CAST IRON ALUMINUM 6061 X. AL 2024 TI-6AL-V4 CONCLUSION Heat study illustrates the thermal stress on the piston in various regions. It aids in the prediction of the piston's crucial parts, allowing us to choose the most appropriate material and design for the piston's crown. As seen in the above graphs and tables, altering the skirt piston temperature reduces it by 10-20' compared to using a basic piston. Reduced skirt length pistons also lower overall heat flux variance as compared to basic pistons. Piston failure is caused by over-fueling and inadequate intercooling, which results in thermo-mechanical stress. XI. REFERENCES [1] F.Szmytka,M.salem, F.Rezai-Aria ,A.Oudin ,Thermal fatigue analysis of automotive diesel piston:Experimental procedure and numerical protocol , international journal of fatigue 73(2015) 48-57. [2] Z.J. Saroka, Thermal load of tuned piston ,Archieves of civil and mechanical engineering 12(2012) 342-347. [3] O.P.Singh , Yogesh Umbarkar, T.Sreenivasulu , E.vetrivendan , M.kannan , Y.R.Babu Piston seizure investigation : Experiments ,modeling and future challanges , Engineering Failure Analysis 28 (2013) 302-310. [4] Ekrem Buyukkaya , Thermal analysis of functionally graded coating AlSi alloy and steel piston, Surface & Coating Technology 202 (2008) 3856-3865. [5] Muhammet Cerit , Mehmet Coban , Temperature and thermal stress analysis of ceramic coated aluminium alloy piston used in diesel piston , International Journal of Thermal Sciences 77 (2014) 11- 18. [6] Muhammet Cerit , Thermomechanical analysis of partially ceramic coated piston used in SI engine , Surface & Coating Technology 205 (2011) 3499-3505. [7] G.Floweday , S.Petrov, R.B.Tait , J.Press ,Thermo-mechanical fatigue damage and failure of modern high performance diesel piston , Engineering Failure Analysis 18 (2011) 1664-1674. [8] F.S. silva, Fatigue on engine pistons-A compendium of case studies, Engineering Failure Analysis 13 (2006) 480-492. [9] M.Cerit , V.Ayhan ,B. Parlak , H.Yasar , Thermal analysis of partially ceramic coated piston: effect on cold start HC emissio n in a spark ignition engine, Applied Thermal Engineering 31 (2011) 336-341. [10] Ravindra Gehlot, Brajesh Tripathi , Thermal analysis of holes created on ceramic coating for Diesel engine piston, Case Studies in Thermal Engineering 8 (2016) 291-299. IJRAR22C1146 International Journal of Research and Analytical Reviews (IJRAR) www.ijrar.org 212

The piston wall was composed of a light alloy like aluminium alloy, while the piston crown was built of high-strength cast steel. Through the use of FEM, they tracked the distribution of piston stress and the actual engine condition throughout the combustion process. Piston failure may have been avoided if the combustion stresses had been .