DESIGN AND ANALYSIS OF A HEAVY-DUTY DIESEL ENGINE PISTON (original) (raw)

STRESS ANALYSIS OF 4STROKE DIESEL ENGINE PISTON

piston made of Al Alloy, acts as heart of the I.C. engine and is a crucial part of internal combustion engines. When the combustion of fuel takes place inside engine cylinder; high temperature and pressure are developed due to combustion of the fuel. Because of high speed and at high loads, the piston is subjected to high thermal and structural stresses. If these stresses exceed the designed values, failure of piston may take place. The stresses due to combustion are considered to avoid the failure of the piston. Intensity of thermal and structural stresses should be reduced to have safe allowable limits. In the present work the piston model is developed using SOLID WORKS software. The analysis part was carried out using ANSYS Workbench software. The stress analysis of these piston made of Aluminium alloy was performed. Appropriate average thermal boundary conditions such as heat transfer coefficient and heat fluxes were set on different surfaces of the FE model. Two different types of loads namely Thermal load and Static load were imposed on the piston. Ten nodded tetrahedral elements (solid-87) are used to discretize the solid piston model. A surface contact element (surf-152) was also used for applying the heat transfer boundary conditions. The analysis is based on the experimental values obtained a VCR Kirloskar diesel engine at compression ratio of 16.5. Index Terms-piston, Heat transfer coefficient, heat flux, Structural and thermal analysis.

MODELING AND ANALYSIS OF PISTON OF DIESEL ENGINE

The project DESIGN AND ANALYSIS OF PISTON AND CONNECTING ROD OF IC ENGINE according to the forces acting on it from the gases, which are released during the combustion. The piston head acts as a particular case and hence the piston is analyzed for the stresses developed due to the conditions. At first, the piston is designed according to the specifications. After the designing, the model is subjected to certain conditions. According to the conditions we have checked the stresses acting on it and checked the failures of the model. After the analyzing the changes are done to the model if required. In the analysis a model of piston and connecting rod is generated using CATIA. the finite element model of the piston is generated using Ansys. It is applied with loads and boundary conditions.

Analysis of Piston of Internal Combustion Engine under Thermo-mechanical Load

International Research Journal on Advanced Science Hub

The main objective of this article is to study the thermal and structural performance of piston using finite element based commercial software ANSYS. Piston is modelled using SOLIDWORKS and analysis would be performed through ANSYS workbench. Optimization analysis has been performed considering three different materials such as Grey Cast iron, structural steel and aluminium alloy because these three material have good compression strength and their thermal conductivity and density will different for each one. For the same amount of pressure Aluminium alloy has shown maximum deformation and equivalent strain, where von misses stress value is minimum for it. Whereas, Structural steel and Grey cast iron shows deformation and strain values less than that of Aluminium alloy for same pressure load. Aluminium alloy has highest heat flux and lowest temperature on piston head under thermal load. Piston receives thermal energy generated via combustion and higher heat flux ensures quick cooling of component by quick drainage of thermal energy. Grey cast iron and Structural steel has half of the value of heat flux to that of Aluminium alloy. Therefore, Aluminium alloy is the preferable material for the design of automobile piston among the given three materials.

Design Analysis and Optimization of Piston and Determination of its Thermal Stresses Using CAE Tools.

International Journal of Engineering Sciences & Research Technology, 2014

In I.C. Engine, piston is most complex and important part therefore for smooth running of vehicle piston should be in proper working condition. 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. The analysis predicts that due to temperature whether the top surface of the piston may be damaged or broken during the operating conditions, because damaged or broken parts are so expensive and difficult to replace and generally are not easily available. The main purpose of the preliminary analyses presented in the book is to compare the behaviour of the combustion engine piston made of different type of materials under thermal load. FEA analysis is carried out using ANSYS software. Development of the FEA model is also presented. Geometrical CAD model of the piston is developed based on the actual engine piston of TATA MOTORS four stroke diesel engine. The piston is loaded by a temperature field inside it. Appropriate averaged thermal boundary conditions such as temperatures and heat fluxes were set on different surfaces of the FEA model. In this study, firstly, thermal analyses are investigated on a conventional diesel piston, made of structural steel for design 1. Secondly, thermal analyses are performed on optimized piston, made of aluminium alloy and titanium alloy material by means of using a commercial code, namely ANSYS. The proposed new material is characterized by a low density, high thermal conductivity, easy machinability, high reliability and very good recycling characteristics. The results obtained for the piston made of a new material are compared with those for the current standard material. The analysis is carried out to reduce the stress concentration on the upper end of the piston i.e. (piston head/crown and piston skirt and sleeve) so as to increase life of piston.

DESIGN AND ANALYSIS OF PISTON USING VARIOUS MATERIALS

IRJET, 2023

An element of reciprocating engines is a piston. Its function is to use a connecting rod to transfer force from the expanding gas in the cylinder to the crankshaft. It is one of the most intricate parts of a car. This article uses the finite element technique (FEM) to analyse the structural integrity of three distinct piston materials. Al-2618, AL-4032, and AL- 7178 are the three distinct materials. SOLIDWORKS software is used for modelling different piston materials, and ANSYS software is used for finite element analysis. Utilising ANSYS WORKBENCH, static structural and steady state thermal analysis is carried out. Using FEA, the findings show what the equivalent stress, total deformation, and total heat flux will be on various piston materials. Stress analysis is used to choose the optimum material

Static and Thermal Analysis of Piston using FEM Analysis

International Journal for Research in Applied Science and Engineering Technology, 2018

This work describes the static and thermal stress distribution of the combustion engine piston using computer aided design software. Using computer aided design Autodesk Inventor software the solid model of a piston will be created and using SolidWorks the static and thermal analyses are investigated for two variants of a diesel piston, made of different type of materials, Aluminium 6061 Alloy and Gray Cast Iron material.

IJERT-Design and Analysis of Piston by using Finite Element Analysis

International Journal of Engineering Research and Technology (IJERT), 2015

https://www.ijert.org/design-and-analysis-of-piston-by-using-finite-element-analysis https://www.ijert.org/research/design-and-analysis-of-piston-by-using-finite-element-analysis-IJERTV4IS090411.pdf This paper describes the stress distribution of the piston four stroke engines by using FEM. The main objectives is to investigate and analyze the thermal stress and maximum or minimum principal stresses, Vanishes stresses distribution on engine piston at the real engine condition during combustion process. The paper describes the optimization techniques with using finite element analysis technique (FEM) to predict the higher stress and critical region on that component. The stress concentration on the piston head, piston skirt and sleeve are reduces by optimization with using computer aided design, Pro-ENGINEER/ CREO software the structural model of a piston will be developed. Furthermore, the FEM analysis is done using Computer Aided Simulation software.

Ijesrt International Journal of Engineering Sciences & Research Technology Thermal Analysis on Piston of Various Materials and Comparison with Each Other's by Using Finite Element Analysis Technique

This paper describes the Thermal(Steady state) analysis of cast iron, cast alloy steel and carbon graphite pistons by using finite element Analysis (FEA) .The parameters used for the simulation are operating gas temperature and material properties of pistons. The specifications used for the study of these pistons belong to four stroke 100cc hero bike engine. This paper illustrates the procedure for analytical design of cast iron , cast alloy steel and carbon graphite pistons using specifications of four stroke 100cc hero bike engine. The results predict the minimum and maximum value of GRADN: Resultant Temp Gradient on all of these pistons using FEAwith applied the temperature 100°C on the top of piston. The 3Dmodelling of piston is done inSolidworks (Feature module) and Simulation module was used to mesh the pistons, thermal analysis with temperature applied on the top of piston head KEYWORDS: Thermal analysis, FEA on piston, temperature applied on piston, resultant temperature gra...

Temperature and thermal stress analyses of a ceramic-coated aluminum alloy piston used in a diesel engine

International Journal of Thermal Sciences, 2014

The thermal stress distributions of the conventional and ceramic-coated diesel engine pistons were obtained, respectively. The calculated results obtained by wavelet finite-element method were compared with test results and the simulation results gained by Catia &ANSYS software. Through analyzing the calculation results, the wavelet finite-element method was convergent and had higher analysis precision than the traditional finite-element method. The wavelet finiteelement method avoids the numerical oscillation during analysis of the transient-state thermal stress fields of the piston. The wavelet finite-element method showed advantages for analyzing the high gradient problems. The wavelet finite-element method provides a preferable theoretical basis for optimizing the design of the ceramic-coated diesel piston. Introduction: Increasing competition and innovations in automobile sector tends to modify the existing products or replacing old products by new and advanced material products. A suspension system of vehicle is also an area where these innovations are carried out regularly. More efforts are taken in order to increase the comfort of user. Appropriate balance of comfort riding qualities and economy in manufacturing of leaf spring becomes an obvious Necessity. To improve the suspension system many modification have taken place over the time. Inventions of parabolic leaf spring, use of composite materials for these springs are some of these latest modifications in suspension systems.

Numerical Investigation and Fatigue Life Estimation of Conventional and Modified Piston of Diesel Engine

International Journal of Materials, Mechanics and Manufacturing, 2017

Nowadays engine components are subjected to higher load at elevated temperature than before, due to the increase requirement regarding weight, performance and exhaust gas emission. Thus, Fatigue due to simultaneous thermal and cyclic loading become determinant among the damage forms. At the same time, there is the need to reduce development time and cost to handle the growing number of model variant. Therefore, the development of suitable simulation tools, which reduces the number of necessary component tests, seems to be very rewarding. By using special material (aluminum alloy) we can reduce the fatigue load (Thermal and cyclic) on the piston by using finite element analysis, ANSYS work bench 14.5 version.