Structural and Thermal Analysis of a C.I. Engine Piston of Different Materials Using FEM Technique

Authors:

Puran Singh (Manav Rachna International University, Faridabad)

Dr. Debashis Pramanik (Manav Rachna International University, Faridabad)

Keywords: Piston, thermal load, structural load, combustion.

Abstract:

Internal combustion engines have been, and will remain for the foreseeable future, a vital and active area of engineering education and research. Most of the researches in internal combustion engines are operating performance and fuel performance oriented. Almost all of the components in an internal combustion engines are subjected to thermal loads. Every mechanical component is designed for a particular structural and thermal strength. Piston seizure and cylinder block melting are typical problems when thermal and structural loads on the components exceeds the design strengths. Piston is a cylindrical component fitted into the cylinder and forms the moving boundary of the combustion system. It fits perfectly into the cylinder providing gas tight space with the help of piston rings and lubricant. These pistons are made of three different types of materials Alloy steel-1040, aluminium alloy-6061 and cast iron. Structural and thermal analysis will be carried out on problem made up of these materials using simulation software ANSYS. The peak surface temperature of the piston material when there is no cooling is about 1980oC against 518 oC when cooling was provided in an aluminium piston. Peak stress in the piston due to combustion pressure 118 N/mm2 Typical internal combustion engines leave about 30% of the combustion energy to the cooling water. The boundary conditions are combustion gas temperature of 2000 oC [3] with a convection heat transfer coefficient of 1500W/m2K. This FEM study can be extended to engine valves, heads, bearing analysis, and fuel injection systems etc.

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