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    Sahil Acharya
    The document summarizes the design, static analysis, and thermal analysis of a piston using ANSYS. It describes the objectives of analyzing and optimizing the piston geometry and material. The piston design is modeled in SOLIDWORKS. Grey cast iron material is selected based on its thermal and stress properties. Boundary conditions like pressure, temperature, and supports are applied. Static analysis shows maximum von-Mises stress of 103.67 MPa and deformation of 0.0018522 mm. Thermal analysis finds highest temperature of 500°C at the top surface. In conclusion, grey cast iron is found suitable but other materials like aluminum composites could better withstand heat.

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    Concept Paper Full

    Uploaded by

    Sahil Acharya
    31 views11 pages
    The document summarizes the design, static analysis, and thermal analysis of a piston using ANSYS. It describes the objectives of analyzing and optimizing the piston geometry and material. The piston design is modeled in SOLIDWORKS. Grey cast iron material is selected based on its thermal and stress properties. Boundary conditions like pressure, temperature, and supports are applied. Static analysis shows maximum von-Mises stress of 103.67 MPa and deformation of 0.0018522 mm. Thermal analysis finds highest temperature of 500°C at the top surface. In conclusion, grey cast iron is found suitable but other materials like aluminum composites could better withstand heat.

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    The document summarizes the design, static analysis, and thermal analysis of a piston using ANSYS. It describes the objectives of analyzing and optimizing the piston geometry and material. The piston design is modeled in SOLIDWORKS. Grey cast iron material is selected based on its thermal and stress properties. Boundary conditions like pressure, temperature, and supports are applied. Static analysis shows maximum von-Mises stress of 103.67 MPa and deformation of 0.0018522 mm. Thermal analysis finds highest temperature of 500°C at the top surface. In conclusion, grey cast iron is found suitable but other materials like aluminum composites could better withstand heat.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    31 views11 pages

    Concept Paper Full

    Uploaded by

    Sahil Acharya
    The document summarizes the design, static analysis, and thermal analysis of a piston using ANSYS. It describes the objectives of analyzing and optimizing the piston geometry and material. The piston design is modeled in SOLIDWORKS. Grey cast iron material is selected based on its thermal and stress properties. Boundary conditions like pressure, temperature, and supports are applied. Static analysis shows maximum von-Mises stress of 103.67 MPa and deformation of 0.0018522 mm. Thermal analysis finds highest temperature of 500°C at the top surface. In conclusion, grey cast iron is found suitable but other materials like aluminum composites could better withstand heat.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 11

    KATHMANDU UNIVERSITY

    SCHOOL OF ENGINEERING

    DEPARTMENT OF MECHANICAL ENGINEERING

    CONCEPT NOTES ON

    DESIGN, STATIC AND THERMAL ANALYSIS OF A PISTON USING


    ANSYS

    SUBMITTED BY SUBMITTED TO
    Sahil Acharya Ranjit Shrestha, PhD
    Roll number: 31 DOME
    ME II (Hydropower) Kathmandu University

    MAY 2O2
    INTRODUCTION

    Background

    Engine pistons are one in all the foremost difficult components among all automotive and
    completely different trade field components. We knew an engine was known as the heart of a
    motor vehicle as like the piston may be viewed as the most vital part of an engine. There are
    several explorations works suggesting, for engine pistons, new geometries, materials and
    producing ways, and this development has veteran with a non-stop amendment within the course
    of the foremost recent decades and needed complete examination of the tiniest delicate
    components. Despite all of those studies, there are an infinite of broken pistons. Damage parts
    have distinctive beginning points and are largely sporting, temperature, and weakness connected.
    The exhaustion connected piston damages assume overriding preponderating half for the
    foremost half in lightweight of thermal and mechanical fatigue, either at area or at hot
    temperature.

    Fig 1: Component of piston head

    The design of the piston is carried out using SOLIDWORKS software, thermal and stress
    analysis is performed using Finite Element Analysis (FEA). The Grey Cast Iron material is
    selected based on thermal and stress analysis results. The analysis results are used to optimize the
    piston geometry of cast iron. In this project the piston plays a major role in the performance of
    the engine performance, materials of the piston are made up of impacts the strength of the piston.
    In this project the piston become optimized after the reducing the material of the piston, the mass
    and volume of the piston become reduced. The deformation also increased after the optimization
    which is responsible for the stress distribution on the piston head or piston crown. This project
    describes the stress distribution and thermal stresses of Grey Cast iron piston by using finite
    element method (FEM). The results predict the maximum stress and critical region on grey cast
    iron pistons using FEA. Static and thermal stress analysis are performed by using ANSYS 2022.

    Objective

    The main objective of this project is to find out and suggest optimum material for piston. The
    project includes the following steps:

    1. A piston head is designed using the ANSYS Workbench.


    2. To find out and suggest optimum material for piston based on quality and economy
    considering material weight and dimensional issues at the same time
    3. FE analysis of the geometry for various loading and boundary condition is done as
    I. Gas pressure at top of Piston = 5MPa
    II. Temperature at the top of the piston = 500°C
    III. Heat transfer Co-efficient = 950 W/m2 °C
    IV. Frictionless support
    V. Material properties is described by Grey cast iron

    Component of Piston

    The main components of the piston as shown in fig [1] are as follows:

    • Piston Crown- which carries gas pressure


    • Skirt-which acts as a bearing against the side thrust of Connecting rod
    • Piston Pin- Piston pins are used to connect the piston to the connecting rod. These
    pins are made from hardened steel alloy and have a finely polished surface. Most
    piston pins are hollow, to reduce weight
    • Piston Rings- which seal the annular space between the cylinder wall and piston
    and scrap off the surplus oil on the cylinder.
    Methodology and Timelines

    Fig 2: work flow chart

    The above shown steps are followed for completion of the project. Beginning from a brief
    literature review, then moving on to design of the connecting rod on SOLIDWORKS.
    Available specifications will be used to design the model. ANSYS will be used to analyse the
    Piston head deformation under pressure and thermal analysis.

    Table 1: Gantt chart


    DESIGN
    The piston head is designed using SOLIDWORKS 2022 on the basis of following
    specification:

    Fig 2: Specification

    Fig 3: Model of piston head

    Fig 4: model of piston


    ANALYSIS

    Finite Element Method (FEM)

    Finite Element Method (FEM) is a computer-based numerical technique for calculating the Strength and
    behaviour of engineering structures. It can be used to calculate deflection, stress, vibration, Buckling
    behaviours and many other phenomena. In the finite element method, a structure is broken down into many
    small simple blocks or elements. The behaviour of an individual element can be described with a relatively
    simple set of equations. Just as the set of elements would be joined together to build the whole structure,
    the equation describing the behaviours of the individual elements are joined into an extremely large set
    of equations that describe the behaviour of the whole structure.

    Definition of Material

    Fig 5: Material defined for Grey Cast Iron

    Meshing

    In order to analyse the model by FEM meshing of the model must be done. The mesh is then generated
    using the software.

    Fig 6: Meshing the Model


    Boundary Conditions

    Frictionless Support at Piston Pin Location

    Piston is connected to the connecting rod with the help of piston pin in such a way that it allows
    linear sliding of piston inside the cylinder and also allows to freely rotate. This boundary
    condition is achieved by using Frictionless support at the location of the piston pin and outer
    surface of piston ring.

    Fig 7: Frictionless Support

    Pressure

    Combustion of gases in the combustion chamber exerts pressure on the head of the piston during
    power stroke. The pressure force will be taken as boundary condition in structural analysis.

    Pressure acting on the piston = 5 Mpa

    Fig 8: Pressure on Piston


    Temperature

    Along the axis of the piston, the temperature distribution is symmetrical. The temperature of the
    piston top surface is relatively high, especially at the centre and the edge of the combustion
    chamber, meanwhile the temperature of piston skirt is relatively low. The maximum surface
    temperature of the piston is assumed as 500°C.

    Fig 9: Temperature Distribution

    REASULT

    The model is solved after applying the pressure and results are obtained for Von-Mises stress and
    structural deformation which are shown below. Here in the figure below we can see that the total
    deformation was found to be 0.0018522 mm and the maximum stress value obtained was 103.67 Mpa.
    Also, we can see the temperature distribution is maximum at top i.e. 500.and total heat flux is 6.6732

    Fig 10: Total Deformation


    Fig 11: Equivalent stress

    Fig 12: Temperature Distribution

    Fig 13 : Total Heat Flux


    CONCLUSION

    We can conclude from above picture is that Grey Cast iron has greater deformation and stress
    resistance an well as it has low tolerance in temperature (thermal behaviour). So, Grey cast iron is
    list suitable material for piston as its cannot withstand the heat and piston breaks easily. So ,other
    material like aluminium ,composite material etc is preferable.

    The following conclusions can be drawn after the analysis.


    a. The structural deformation is least at the piston pin holes and maximum at the top surface.
    b. The stress concentration is highest at piston pin holes.
    c. The temperature of the piston is maximum at the upper surface.

    REFERENCE
    • DESIGN AND ANALYSIS OF THE PISTON USING THREE MATERIALS Goriparthi
    S N Phanindra kumar1, Murari indrani2, Nagababu Gungati
    • THERMAL & STATIC ANALYSIS ON IC ENGINE PISTON USING FEA
    1Thirakavinod Kumar, 2 B. Ravisekhar
    • Design and Analysis of Piston Using Composite Material Molla Shehanaz1 ,
    Dr.G.Shankariah

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