Chapter 23

Development of a Preliminary Approach

for Automatic CAD Model Generation
of the IC Engine Piston

Nikhil Tuljapurkar, Gurunandan Jamalpur, Shubham Agarwal,

and Jayakiran Reddy Esanakula

Abstract The traditional CAD modeling approaches for IC engine pistons are
tedious because of the complexity in geometry and design calculation. A little
change in size or shape of IC engine assembly will cause an extensive chain
reaction in calculating the associate modifications because of different interrelated
plan issues. Therefore, the CAD model of the piston should be changed in order to
match the modification(s) of the IC engine. The CAD modeling techniques, like
parametric modeling, offer the answers for these issues. This paper presents a
framework for generating the CAD model of an IC engine piston by using
SolidWorks. A dedicated GUI was developed in the CAD software for helping the
design engineers to feed the input data. The presented framework uses the reuse of
the design information.

23.1 Introduction

Automotive industries, shipbuilding, aerospace industries, industrial, and architec-

tural designs are some of the fields where computer-aided design (CAD) is
extensively used as a tool. The comprehensive engineering method of 3D models
and/or 2D sketches of physical parts is commonly done with CAD and is also used
throughout engineering applications. Hence, this requires customization, so that
their effectiveness can be enhanced. The lack of skilled professionals available for
CAD modeling and the complexity of design make modeling a time-consuming
process. Alternate processes are being researched by the companies and the
professionals too. Customizing and improving CAD/CAM effectiveness and effi-
ciency are the need of today’s generation. A knowledge-based system (KBS) for

Nikhil Tuljapurkar, Gurunandan Jamalpur and Shubham Agarwal contribute equally to this
work.

N. Tuljapurkar
G. Jamalpur
S. Agarwal
J. R. Esanakula (&)

Department of Mechanical Engineering, Sreenidhi Institute of Science and Technology,
Hyderabad, Telangana 501301, India

© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2022 227
A. N. R. Reddy et al. (eds.), Intelligent Manufacturing and Energy Sustainability,
Smart Innovation, Systems and Technologies 265,
https://doi.org/10.1007/978-981-16-6482-3_23
228 N. Tuljapurkar et al.

engineering and design is important for fulfilling this requirement. The problem
statement/task can be regenerated in no time when compared to humans with the
usage of parametric modeling. The dimension-driven parametric modeling tech-
nique allows for automated reuse of existing design processed based on engineering
analysis.

23.1.1 IC Engine Piston

The piston is one of the important components of internal combustion (IC) engine.
It is the traveling part enclosed inside a cylinder and sealed by piston rings. Mostly
it is used in reciprocating engines, reciprocating pumps, gas compressors, hydraulic
cylinders, and pneumatic cylinders. The objective of the piston and/or connecting
rod in an engine is to pass force from the expanding gas in the cylinder to the
crankshaft. Usually, the aluminum alloy piston is used for passenger vehicles, and
steel or cast-iron pistons are used for commercial vehicles. Figure 23.1 shows the
cut section of the IC engine piston.
The CAD modeling of the IC engine piston is an elaborate and time-consuming
process, and the specifications are constantly changing according to the power or IC
engine needs. Hence, automized modeling is very much essential. This can be

Fig. 23.1 Cut section of the

IC engine piston [1]
23 Development of a Preliminary Approach for Automatic … 229

achieved by the parametric modeling technique which is an advanced modeling

technique of the CAD. Many researchers suggested that by using specialized
methods such as KBS, one can reduce the time of modeling. Even though it is an
evolving discipline, the automatic generation of a knowledge-based engineering
(KBE) framework based on general knowledge will have the most drastic effects.
This paper proposes a KBS for developing the CAD model of the IC engine piston
to reduce CAD modeling time.

23.1.2 Knowledge-Based Engineering (KBE)

The blend of CAD techniques and artificial intelligence (AI) technologies is well
represented by an engineering method called KBE. This provides advantages for
customized or various design automation solutions [2–4]. The objective of the KBE
system is to capture the product and process its information/data. It also involves
simulating the engineering design process system and then uses the model to
automate all or part of it. The internal representation of the product design process
is the computer-generated product model. It includes information on both the
product and the processes used to make the part. The focus is to provide complete
product representational information which is captured in the product model.

23.1.3 SolidWorks API

The application programming interface (API) is a mechanism that allows various

programs to communicate with one another. It is accomplished by embedding a
programming language code within another application. Hundreds of functions are
included in the API and can be accessed via Visual Basic for Applications (VBA),
VB.NET, Visual C#, Visual C++ 6.0, and Visual C++/CLI. These functions give
direct access to SolidWorks features like drawing a line, adding an existing part into
a part text, and checking a surface’s parameters. By writing special scripts, it is
possible to automate the modeling and assembly of components using the
SolidWorks API. SolidWorks API is a hierarchical tree-like framework that
encompasses all of the program’s features [5–7].

23.1.4 Visual Basic Language

Microsoft first introduced Visual Basic (VB) in 1991 as a third-generation pro-

gramming language. It is a beginner-friendly programming language that allows us
to quickly create graphical user interface (GUI) windows applications. Furthermore,
VB is an effective engine for creating macros in all Microsoft applications.
230 N. Tuljapurkar et al.

As a result, VB has evolved into a versatile method for creating various pro-
gramming codes for a variety of applications, including SolidWorks. Programmers
will use ActiveX dynamic connection libraries (ActiveX DLLs) to connect VB with
various Windows applications [8]. It also can add additional menus, tools, and
toolbars to the application’s environment.

23.1.5 Macros

A macro is a rule or pattern in computer science that specifies how a certain input
sequence should be mapped to an output sequence according to a given process. To
boost the design automation process, engagement with the model environment is
critical. CAD systems have API interfaces that enable users to communicate with
the model environment using macros and with the need for data sharing through
technologies from different disciplines to solve real-world problems. In certain
instances, a complex algorithm must be implemented to execute an efficient cal-
culation that is not available in commercial applications. It also helps to use a
computational algorithm to generate geometrical entities and operations [9].

23.1.6 Parametric Modeling Techniques

One of the most advanced CAD modeling approaches is the parametric modeling
technique which provides approaches to traditional 2D drawings. It enables the
reuse of preexisting procedures to carry out quick design changes based on engi-
neering rules that are already in place [10].

23.2 Literature Review

Macro programming can be blended with parametric modeling techniques for one’s
use to generate effortless and accurate solid shape modeling [4]. As these tools are
of great help to minimize the complexities that come up during the time of mod-
eling, these can be used widely for producing CAD-enabled modeling [3].
Moreover, these tools facilitate the automation of CAD modeling, particularly for
already existing tasks that can be automated and simplified with the help of a
predefined algorithm/code [5]. A system was built for developing various parts of
automobile chassis, cylindrical, and seed plate by Liu et al. [11], Luo et al. [12], and
Dun et al. [13], respectively, wherein they used SolidWorks as a basis for devel-
oping CAD model and developing tool such as Virtual Basic (VB) were used.
Modeling the tools and products using parametric modeling techniques were pre-
sented by Myung et al. [14]. These techniques facilitated the reduction of the CAD
23 Development of a Preliminary Approach for Automatic … 231

modeling time and led to a faster rate of production. A new process was shown by
Yangshou et al. [15] for generating the dynamic CAD models for performing
structural analysis on it. Similarly, Kumar et al. [16], Dheeraj et al. [17], and
Jayakiran et al. [18–21] developed a framework for optimized design on the
SolidWorks platform which uses the knowledge-based system for CAD modeling.
A form of artificial intelligence (AI) technique known as knowledge-based
system was designed to collect human expert knowledge to promote decision
making. This form of computer software helps to increase the probability of gen-
erating sustainable modeling and simulation software within the given inputs and
specifications [22–25]. Even though much effort was put into developing parametric
modeling of materials, little effort was put into IC engine pistons. As a result, the
authors assume that in the current market and research environment, a dedicated
automated CAD modeling system for producing an IC engine piston is necessary.
To conclude, a lot of significant contribution was made toward the CAD modeling
and manufacturing using the parametric modeling techniques to reduce the time for
modeling and also lead to faster production rates with desired inputs. With the use
of VB as a development tool, SolidWorks can generate the CAD model. Analyzing
geometrical information which is available in the predefined text data, an automated
CAD model can be acquired.

23.3 Methodology for Modeling and Automation

Most commercial CAD software today is aimed at developing part models of

components using a traditional approach and accepting input data in text format
related to the model. Besides, a computer program [5, 13] can be used to feed this
text input. This method was used to feed the input data in this article. This software
can be written in a variety of programming languages, including VBA, C++, Lisp,
and others [19]. VBA is regarded as the most practical of these languages. The
programming editor in SolidWorks CAD applications is VBA. As a result, the
authors chose SolidWorks as the CAD program for designing the proposed method
to produce an automatic CAD model of an IC engine piston. Additionally, macro
code is used to generate the CAD model of the IC engine piston since it allows for
the automated creation of the CAD model. The novelty of the proposed system is
the blending of the macro code into a parametric modeling technique, and the
system is powered with the dedicated KBS. As this proposed system is a prelim-
inary approach, the developed KBS works only for the IC engine piston. From the
literature, it is found that no researcher has worked on developing a KBS which
works on blending the macro code with a parametric modeling technique.
Additionally, it is also understood from the literature that no researchers tried to
develop a KBS for developing the CAD model of the IC engine piston. Hence, the
proposed approach is the novel one in addressing the development of a KBS for
generating the CAD modeling of the IC engine piston.
232 N. Tuljapurkar et al.

23.3.1 Generating Graphical User Interface

The user can create and develop their GUI with the support of VB in SolidWorks.
Figure 23.2 is the GUI that was created for the generation of the CAD model of the
IC engine piston. Figure 23.3 shows the button that was created for the generation
of the CAD model of the IC engine piston. The GUI was developed in such a way
that it should be able to collect the required data from the user and should transfer
the same inputs to the logical algorithm for performing the design calculations.

23.3.2 Program Development for Design Calculations

To compute the design calculation of the IC engine piston, a logical computing

algorithm was developed. Calculating the appropriate dimensions manually using
typical empirical methods is difficult and time consuming. So, the developed logical
computing algorithm helps in design calculation. Computer software for design
calculations is being developed in an attempt to address this complexity. This
computer program performs all the detailed designs and computes geometrical
dimensions of the IC engine piston. The program’s output data will be transmitted
to the SolidWorks software, which will produce a CAD model based on the
computed geometrical parameters. As a result, design and modeling tasks are
automated. Figure 23.4 shows the process flowchart of the proposed system.

Fig. 23.2 GUI for the piston

23 Development of a Preliminary Approach for Automatic … 233

Fig. 23.3 Button for CAD model generation of the piston

Start

Collection of the design

inputs through GUI

Enough data No
obtained?

Yes

Proposed KBS geathers all the standards, empirical relation and procedure for
design calculation based on the input data with the help of the knowledge-base

Critical geometrical dimensions of the IC engine piston

will be obtained as a output from proposed KBS

Display the results on GUI

for user reference

Proposed system generates the CAD model of all the components of the
IC engine piston and assemble them on SolidWorks using macro code

End

Fig. 23.4 Process flowchart of the proposed system

234 N. Tuljapurkar et al.

Table 23.1 Sample inputs Parameter Input data (mm)

for the proposed system
Bore 300
Skirt length 262
Axial thickness of piston ring 8

23.4 Results

A sample result that was generated by the developed KBS is shown in this
section. Generally, 220–345 h are required if the complete design calculations and
the CAD modeling are done manually for the IC engine piston [20]. But with the
help of the proposed approach, the total time required for the complete modeling
process is 13 s when it was executed on SolidWorks 2020. When compared to
the traditionally generated CAD models, the proposed approach produces the
same CAD model with very close dimensional accuracy. The sample input data
for the proposed system is given in Table 23.1. Based on these inputs, the
proposed system has generated the IC engine piston, piston pin, piston rings, and
IC engine piston assembly which are shown in Figs. 23.5, 23.6, 23.7, and 23.8,
respectively.

Fig. 23.5 IC engine piston

23 Development of a Preliminary Approach for Automatic … 235

Fig. 23.6 Piston pin

Fig. 23.7 Piston ring

Fig. 23.8 CAD model of the

IC engine piston assembly

23.5 Conclusion

A KBS for generating a CAD model is proposed in the paper. This technique reuses
the design procedure with the help of parametric modeling technology. This design
procedure and parametric modeling technique can be used on any computer which
has access to SolidWorks making CAD modeling a user-friendly tool and handy to
use. This system has also proved to run faster and generate a CAD model of an IC
engine piston in comparison with the traditional approaches.
236 N. Tuljapurkar et al.

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