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Abstract
Due to the inherent nature of combustion in the Cylinder of a Conventional Internal combustion engine, stress variation as well as
a certain temperature distribution sets up in the entire piston. Analysis of piston is required because of its shape and it is
subjected to both structural and thermal loads. In the present study, piston of a two stroke spark ignition internal combustion
engine having maximum power of 6.5 kW at 5500 RPM, has been designed and analysed. The piston made up of Aluminium 4032
alloy is designed by conventional approach and then both thermal and transient structural analysis have been carried out.The
piston has been modeled in CATIA and analysed using ANSYS Workbench. In order to improve the design of piston, two
alternative designs have been considered by providing openings at the skirt region of the piston. The analysis showed that this
modification improved the thermal performance of the piston. An alternative design with large openings at the skirt region
showed the best thermal performance.
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Volume: 03 Issue: 06 | Jun-2014, Available @ http://www.ijret.org 642
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
aluminum used [8]. However, adding silicon to pistons sufficient bearing area to prevent undue wear. The strength
makes them more brittle and thus making the piston more of the piston pin should be sufficient against shear failure.
susceptible to cracking if the engine experiences pre-ignition The piston is designed based on both strength and thermal
or detonation. considerations. Preliminary dimensions of piston have been
determined using the strength and thermal based design
Table 1: Specification of single cylinder 2 stroke petrol approach [9]. This has resulted in piston diameter of 56 mm,
engine piston length of 60 mm and piston pin diameter of 15 mm.
Displacement volume 145.45cc The design considers three piston rings. The model of the
Clearance volume ~30cc designed piton is shown in Fig. 1.
assuming no failure of the components and uniform angular radiation. Radiative contribution is more significant in
velocity of the crank. Using the piston motion equation, the compression-ignition engines than in spark-ignition engines,
variation of acceleration w.r.t. crank angle can be found out. due to the formation of highly radiative soot particles during
Distribution of acceleration on piston crown is shown in Fig. combustion. Assuming the flow of the combustion gases to
2. be over a flat plate, the correlation of convection used, based
on fully turbulent flow over flat plate is shown in eq- (2).
0.8 0.33
𝑁𝑢 = 0.037 𝑅𝑒 𝑃𝑟 - (2)
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Volume: 03 Issue: 06 | Jun-2014, Available @ http://www.ijret.org 644
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
Table 5(a): Comparison of Thermal analysis results of alternative designs and preliminary design
Design Mass Maximum temperature Temperature variation in the Variation of
(kg) attained(oC) gudgeon pin region (oC) temperature in the
skirt(oC)
Preliminary Design 0.21 357 Negligible 180-230
Alternative -1 0.207 335 Negligible 180-230
Alterative - 2 0.19 339 Negligible 180-230
Table 5(b): Comparison of structural analysis results of alternative designs and preliminary designs
Design Mass Maximum stress Maximum deflection Minimum defection
(kg) (MPa) (mm) (mm)
The analysis results in terms of von Mises stress, thermal aspects of design rather the structural aspects. In
deformation and temperature distribution for both the present case, the maximum temperature at the piston
Alternative design 1 and Alternative design 2 are shown in crown was reduced to prevent subsequent crystallization of
Fig. 5 and Fig. 6 respectively. The results show a decrease the surface of the piston. A further detailed investigation
in piston temperature compared to the preliminary design. into the temperature variation at the gudgeon pin region as
On the basis of the preliminary data compiled and well as at the skirt, shows minor changes in variation in the
subsequent thermal and structural analysis shows that, two designs.
reduction in the skirt of the piston significantly improve the
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Volume: 03 Issue: 06 | Jun-2014, Available @ http://www.ijret.org 646
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
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Volume: 03 Issue: 06 | Jun-2014, Available @ http://www.ijret.org 647
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163 | pISSN: 2321-7308
REFERENCES
[1]. P Gudimetal and C V Gopinath, Finite Element
Analysis of Reverse Engineered Internal Combustion
Engine Piston, Asian International Journal of Science and
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2(4) 2009, 85-92.
[2]. Ch. V Rajan, P.V. K Murthy, M.V.S Murali Krishna
and G.M. Prasada Rao, Design Analysis and Optimization
of piston using Catia and Ansys,International Journal of
Innovative Research in Science and Engineering, Issn 2319
-5665(January 2013, Issue 2 Volume1)
[3]. CA F Parra,Heat Transfer Investigations in a Modern
Diesel Engine, A thesis submitted for the degree of Doctor
of Philosophy,University of Bath, Department of
Mechanical Engineering,February 2008.
[4]. CY Jeong, Effect of Alloying Elements on High
Temperature Mechanical Properties for Piston Alloy,
Department of Nuclear and Energy System Engineering,
Dongguk University.
[5]. T.T.Mon, M.M.Noor, K.Kadirgama, R A.Bakar
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[6]. I O Toppo, CFD Analysis of combustion characteristics
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[7]. V V. Kuppast, S.N.Kurbet, H.D.Umeshkumar an B C,
Adarsh,Thermal Analysis of Piston for the
Influence on Secondary motion,International Journal of
Engineering Research and Applications (IJERA);3 (3),
May-Jun 2013
[8]. D. Apelian, Worldwide Report, Aluminum Cast Alloys:
Enabling Tools for Improved Performance, NADCA, 2009
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Volume: 03 Issue: 06 | Jun-2014, Available @ http://www.ijret.org 648