A MINI PROJECT REPORT ON MODELLING AND

ANALYSIS OF PISTON USING SOLIDWORKS AND HYPERMESH

CENTRAL INSTITUTE OF TOOL DESIGN

(Ministry of MSME – A Government of India society)

Balanagar, Hyderabad, 5000037.

E-mail:[email protected], website: www.citdindia.org

UNDER THE GUIDANCE OF

MR.Y.SRINIVAS
Dept. of CAD/CAM
Central Institute of Tool Design.
Submitted by
T.MAMATHA
G.V.PRASHANTH

DEPARTMENT OF MECHANICAL ENGINEERING

SREENIDHI INSTITUTE OF SCIENCE AND TECHNOLOG
YAMNAMPET, GHATKESAR.

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 ACKNOWLEDGEMENT
We are thankful to lot of people who helped us to make this project very much
successful.

We would like to express our sincere thanks to and deep sense of gratitude to our
Principal T.CH.SHIVA REDDY who granted us the permission to conduct our
project at Central Institute of Tool Design, Hyderabad.

Next we would like to thank Mr. Chandra shekhar, Principal Director, R K Pavitra
Kumar Director (Trg.), G Sanath Kumar, Dy.Director (Trg.) and K Babu Rao Sr.
Engineer (Trg.), CITD for giving us an opportunity to do our project in this
prestigious institute.We also express over whole hearted thanks to our head of the
department RAJESH RAVEENDRAN, who stood with us before initiating the
project.

We are also grateful to our external project guide Y SRINIVAS CAD/CAM Faculty,
CITD for the excellent guidance and unstinted support right from the beginning.

We are also thankful to the staff of CITD for co-operating with us. Not forgetting to
thank our project mates for working together in perfect co-ordination to make this
project a grand success.

Finally, special thanks to the entire faculty and staff of Department of Mechanical
Engineering, SREENIDHI INSTITUTE OF SCIENCE AND TECHNOLOGY for
all that they taught for all that they had done in the past years.

- Project Associates

T.MAMATHA

G.V.PRASHANTH

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 CONTENTS

1. Abstract

1. Information about Piston…………………………………….5

2. Introduction to Solid Works……………………………………..6
a. History
b. Where is solid works used?
c. Features and Capabilities
d. Industries using SOLID WORKS
e. File extensions for SOLID WORKS
3. Modelling of Piston in SOLIDWORKS:………………………..8
a) Model of piston
b) Tools used in modelling
c) Assembly view of a piston
4. Finite Element Methods (FEM) …………………………….9
Introduction
Introduction to Finite Element analysis (FEA)
a. Types of Engineering Analysis
b. Results of Finite Element Analysis
1. Pre-processing
2. Analysis
3. Post processing

5. HYPERMESH……………………………………………….15
Introduction to hyper mesh

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6. STATIC ANALYSIS OF PISTON………………………….16
a. Material Properties of piston
b. Procedure for Analysis
1. Meshing
2. Force
3. Solution
7. STRESS AND DISPLACEMENT RESULT IMAGES…..18
a. Von Misses Stress
b. Deformation
8. REFERENCES……………………………………………...19

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ABSTRACT

A piston is a component of reciprocating engines, reciprocating pumps, gas

compressors and pneumatic cylinders, among other similar mechanisms. It is the
moving component that is contained by a cylinder and is made gas-tight by piston
rings. In an engine, its purpose is to transfer force from expanding gas in the
cylinder to the crankshaft via a piston rod and/or connecting rod. In a pump, the
function is reversed and force is transferred from the crankshaft to the piston for
the purpose of compressing or ejecting the fluid in the cylinder. In some engines,
the piston also acts as a valve by covering and uncovering ports in the cylinder.
For the above blade profile has been modeled in SOLIDWORKS 19 and
analysis has been done in hypermesh 17.2 .In this project we are
conducting structural and model analysis by applying the different pressures
for different levels for different speeds.

INTRODUCTION TO PISTON

An internal combustion engine is acted upon by the pressure of the expanding

combustion gases in the combustion chamber space at the top of the cylinder. This
force then acts downwards through the connecting rod and onto the crankshaft. The
connecting rod is attached to the piston by a swiveling gudgeon pin (US: wrist
pin). This pin is mounted within the piston: unlike the steam engine, there is no
piston rod or crosshead (except big two stroke engines).
The typical piston design is on the picture. This type of piston is widely used in
car diesel engines. According to purpose, supercharging level and working
conditions of engines the shape and proportions can be changed.

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INTRODUCTION TO SOLID WORKS:

Solid Works (stylized as SOLIDWORKS), is a solid modeling computer-aided

design (CAD) and computer-aided engineering(CAE) software program that runs
on Microsoft Windows. The Solid Works is produced by the Dassault Systems— a
subsidiary of Dassault Systems, S. A. based in Vélizy, France— since 1997.
Solid Works is currently used by over 2 million engineers and designers at more
than 165,000 companies worldwide.
HISTORY:
Solid Works Corporation was founded in December 1993 by Massachusetts
Institute of Technology graduate Jon Hirschtick, Hirschtick used $1 million he had
made while a member of the MIT Blackjack Team to set up the
company.[4] Initially based in Waltham, Massachusetts, USA, Hirschtick recruited
a team of engineers with the goal of building 3D CAD software that was easy-to-
use, affordable, and available on the Windows desktop. Operating later
from Concord, Massachusetts, Solid Works released its first product Solid Works
95, in 1995.[5][6] In 1997 Dassault, best known for its CATIA CAD software,
acquired Solid Works for $310 million in stock.[5]
Solid Works currently markets several versions of the Solid Works CAD software
in addition to eDrawings, a collaboration tool, and DraftSight, a 2D CAD product.
Solid Works was headed by John McEleney from 2001 to July 2007 and Jeff Ray
from 2007 to January 2011. The current CEO is Gian Paolo Bassi from Jan 2015.
Gian Paolo Bassi replaces Bertrand Sicot, who is promoted Vice President Sales of
Dassault Systems’ Value Solutions sales channel

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INDUSTRIES WHERE CATIA IS USED:
Commercial Industries
Every industry faces a unique set of challenges in today’s increasingly competitive
marketplace. SOLIDWORKS offers solutions that can help with the toughest
engineering problems. Even yours.

Government
SOLIDWORKS makes software that enable federal agencies, the Department of
Defense (DOD), and contractors to quickly design strategic defense equipment,
arms, vehicles and vessels.

Education
Bridging the gap between ideas and technology, SOLIDWORKS prepares students
for rewarding engineering careers and gives them vital skills that employers
demand.

SOLID WORKS SIMULATION CAPABILITIES:

Easy-to-use CAD-embedded analysis capabilities power SOLIDWORKS

Simulation software tools and solutions to enable all designers and engineers to
simulate and analyze design performance. You can quickly and easily employ
advanced simulation techniques to optimize performance while you design, to cut
down on costly prototypes, eliminate rework and delays, and save you time and
development costs.

PARAMETRIC MODELLING:

The parametric nature of a software package is defined as its ability to use its
standard properties and parameters in defining the shape and size of a geometry.
The main function of this property is to drive the selected geometry to a new size
or shape without considering its original dimensions. We can change or modify the
shape and size of any feature at any stage of the design process.

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MODELLING OF PISTON

3D MODEL MADE USING REVOLVE COMMAND

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FEM CONCEPT:
INTRODUCTION TO FEM:

Discritization or Idealization of an object is known as Finite Element

Method. In simple words, In FEM we are dividing object into countable no.
of parts to check object into countable no. of parts to check the results at
desired position.
Example:

1. LINE:

Image: This line is divided into 3 line Elements and 4 nodes

2. PARALLELOGRAM:

Image: This parallelogram is divided into 42 square elements and 56 Nodes.

ADVANTAGES:

1. We can apply loads at any desired position i.e. at any node and at any element.
2. We can check results at any desired point or node on the object.

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INTRODUCTION TO FEA:

Finite Element Analysis (FEA) was first developed in 1943 by R. Courant,

who utilized the Ritz method of numerical analysis and minimisation of
variational calculation to obtain approximate solution to vibration systems.
Shortly thereafter, a paper published in 1956 by M.J Turner, R.W Claough,
H.C Martin and L.J Topp, Established a broader definition of a numerical
analysis. The paper centered on the “Stiffness and deflection of complex
structures”.

By the earlier 70’s, FEA was limited to expensive mainframe Computers,

Generally owned by Aeronautics, Automotive, Defence and nuclear
industries. Since the rapid decline in the cost of the computers and the
phenomenal increase in compute ring power, FEA have been developed to an
incredible precision. Present day super computers are now able to produce
accurate results for all kind of parameters.

FEA consists of a computer model of material or design i.e. stressed and

analysed for specific results. It is used in new product design and existing

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product refinement. Accompany is able to verify a proposed design will be
able to perform the clients specification prior to the manufacturing or
construction. Modifying an existing product for structure is utilised to qualify
the product or structure for a new service conditions. In case of structure
failure FEA may be used to help determine the design modifications to meet
the new conditions.
There are generally two types of analysis that are used in Industry; 2-D
Modelling and 3-D Modelling.

While 2-D Modelling conserves simplicity and allows the analysis to be run
on a relatively normal computer, It tends to less accurate results. 3-D
Modelling however produce more accurate results while sacrificing the
ability to run on all but the fastest computers effectively. Within each of these
modelling schemes the programmer can insert numerous algorithms
(functions) which may make the system behave linearly or non- linearly.
Linear systems are far less complex and generally do not take into account
plastic deformations. Non- linear systems do account for plastic deformations
and May also are capable for testing a material all the way to fracture.

FEA use a complex system of points called Node which make a grid called a
mess. This mess is programmed to contain the material and structural
properties which define how the structure will react to certain loading
conditions. Node are assigned at ascertain density throughout a material
depending on the anticipated stress level of particular area. Regions which
will receive large amount of stress usually have higher node density then
those which Experience little or no stress. Points of interest may consist of;
Fracture point of previously tested material, fillets, corners, complex detail, a
high stress areas. The mesh acts like spider web in that form each nodes.
Their extends a mesh elements to each of the adjacent nodes. This web
vectors is what carries the materials properties of object, creating many
elements.

A wide range of objective functions (variables within the system) are

available for minimization and maximization.

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1. Mass, Volume, Temperature
2. Strain energy, Stress –Strain
3. Force, Displacement, Velocity, acceleration
4. Synthetics(user defined)

Their multiple loading Conditions which may be applied to a system. Some

examples are shown
1. Point, pressure, thermal, gravity and centrifugal static loads.
2. Thermal loads from solution of heat transfer analysis
3. Enforce displacements
4. Heat flux and Convection
5. Point pressure and gravity, dynamic loads

Each FEA program may come with an element library or one is constructed over
time. Some sample examples are:

1. Road elements
2. Beam elements
3. Plate/ Shell/composite Elements
4. Shear panel
5. Solid elements
6. Spring elements
7. Mass elements
8. Rigid elements
9. Viscous damping elements

Many FEA program also equipped with the capability to use multiple materials
within the structure such as:

1. Isotropic, Identical throughout

2. Orthotropic, Identical at 90 degrees
3. General anisotropic, Different throughout

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TYPE OF ENGINEERING ANALYSIS :

STUCTURAL analysis consists of linear and non-linear models. Linear

models use simple parameters and assume that material is not plastically
deformed. Non- linear models consist of stressing the materials past its elastic
capacities. The stresses in material then vary with amount of deformation as
in.

VIBRATIONAL analysis is used to test a material against random

vibrations, shock and impact. Each of these incidents may act on the natural
vibrational frequency of material which in turn may cause resonance and
subsequent failure.

FATIGUE analysis helps designers to predict the life of the materials or

structure by showing the effects of cyclic loading on the specimen. Such
analysis can show the areas where crack propagation is most likely occur.
Failure due to fatigue may also show the damage tolerance of the material.

HEAT TRANSFER models the conductivity or the dynamics of thermal

fluid or the material of the structure. This may consists of steady state or
transient heat transfer. Steady state transfer refers to constant thermal
properties in the material that yields linear heat diffusion.

RESULTS OF FINITE ELEMENT ANALYSIS :

FEA has become a solution of task of predicting failure due to unknown

stresses by showing problem areas in a material and allowing designers to see
all the theoretical stresses within. This method of product design and testing
is far superior to manufacturing cost which would accrue if each sample was
actually built and tested. In practice, a finite element analysis usually consists
of three principal stresses.

1. PREPROCESSING: The user constructs a model of a part to be analyzed

in which the geometry is divided into number of discrete sub region of
element,” Connected at discrete point called nodes”. Certain of these nodes
will have fixed displacements, and other will have prescribed loads. These
models can be extremely time consuming to prepare , an commercial codes
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via with one another to have the most user friendly graphical “pre-processor”
to assist in this rather tedious chore. Some of these pre-processors can over
lay a mess on a pre-existing CAD file, So that finite element analysis can be
done conveniently as part of the computerised drafting-and-design process.
2. ANALYSIS: The data set prepared by the pre-processor is used as an
input to the finite element code itself, which constructs and solves a system
of linear or non-linear algebraic equations.

Where, u and f are displacements and extremely applied forces at the nodal
points. One of FEA’s principle advantages is that many problem types can be
addressed with the same code, merely by specifying the appropriate types
from the library.

3. POSTPROCESSING: In the earlier days of finite elements analysis, the

user would pore through reuse of numbers generated by the pore, Listing
displacem1ents and stresses at discrete positions within the model. It is easy
to miss important trends and hot spots this way, and modern codes used
graphical displays to assist in visualization the results. A typical
postprocessor display overlays coloured contours representing stress level on
the model, showing a fulfilled picture similar to that of photo elastic or moiré
experimental results.

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INTRODUCTION TO HYPERMESH
Altair Engineering Inc. is an American multifunctional information
technology company headquartered in Troy, Michigan. They provide product
design and engineering solutions, enterprise services and cloud computing. Altair
was founded by James R Scapa, George Christ, and Mark Kistner in 1985. As of
2017, the company has more than 2000 employees in 71 offices across 24
countries.[2]
Altair Engineering is the creator of the HyperWorks suite of CAE software
products.
Altair is divided into three business divisions: Product Design (PD), HyperWorks
CAE Software (HW), and PBS Works (PBS)
The principal product offerings from Altair's Commercial Software division is its
HyperWorks line of software, including:

 OptiStruct - Structural Analysis Solver (linear and non-linear); solution for

structural design and optimization
 RADIOSS - Structural Analysis Solver (highly non-linear problems under
dynamic loadings); an industry standard for automotive crash and impact
analysis
 MotionView - Solver-neutral Multi-body Pre-processor
 MotionSolve - Multi-body Solver; an integrated solution to analyze and
optimize multi-body system performance
 HyperXtrude - Metal & Polymer Extrusion Solver; an advanced solver for
manufacturing process simulations and validations
 HyperForm - Metal Forming Solver
 HyperMesh, HyperCrash, Simlab, HyperView, HyperGraph - CAE Pre & Post
Processing
 HyperStudy - Design of Experiments and Multi-disciplinary Design
Optimization
 HyperMath - Mathematical Analysis Environment
 AcuSolve - General-purpose Finite Element Based CFD Solver
 FEKO - 3D Electromagnetic Solver
The CAE data and process management solutions

 Altair Data Manager

 Altair Process Manager

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The Enterprise Computing division develops and manages:

 PBS Professional software, developed from OpenPBS.

Subsidiaries of Altair Engineering

 ilumisys - produces LED lighting products[4][5]

Altair Owned Companies

 solidThinking - industrial design software

 HiQube - business intelligence software
 Altair ProductDesign - product innovation consulting
 Carriots - Development platform for Internet of Things based application

HISTORY
Altair was established in 1985. In 1990, Hyper Mesh was released. In 1994, Altair
receives Industry Week’s "Technology of the Year" award for OptiStruct.
During the 2008 economy crisis, Altair started a program to offer free training on
its product for unemployed persons in Michigan.
In September 2010, Altair purchased a 136,000-square-foot (12,600 m2) Annex
Facility in Troy, to initially house Altair’s subsidiary ilumisys, Inc.
In September 2011, Altair ProductDesign unveiled BUSolution, a hybrid hydraulic
bus.

STATIC ANALYSIS:
A static analysis calculates the effects of steady loading conditions on a
structure, while ignoring inertia and damping effects, such as those caused by time
varying loads. A static analysis can however, include steady inertia loads (such as
gravity and rotational velocity), and time varying loads that can be approximately
as static equivalent loads (such as the static equivalent wind and seismic loads
commonly defined in many building codes).

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PROCEDURE FOR ANALYSIS

STEP 1: GEOMETRY &MODEL

Import – assembly file of STEP.format
Model--edit

STEP 2: MESH
GENERATE MESH

STEP 3: STATIC STRUCTURAL _FIXED SUPPORTS

Apply- fixed supports- on side holes.

STEP 4: STATIC STRUCTURAL _FORCE

Apply –fixed supports- force – on piston top surface

STEP 5: SOLUTION
Solve
1. Displacement
2. Vonmises stresses

STATIC ANALYSIS
MESHING: Import the file in step.format and apply mesh in tetramesh

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SUPPORTS ALONG WITH THE FORCE APPLIED

DISPLACEMENT

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VONMISESSTRESSES

RESULTS

Static Analysis:

In Hypermesh we have applied a force of 20N and got the results as

follows:
Deformation : 1.077e-03m

Von misses stress : Minimum-2.295e-0.4pa.

Maximum-5.540e+00pa.

REFERENCES:
https://www.solidworks.com/
https://altairhyperworks.com/
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