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DESIGN AND FAILURE ANALYSIS OF PISTON

Abstract

Recent advancement of technology leads to complex decision in the Engineering

field. Thus this paper entails the design and analysis of an IC engine piston using
two different aluminum materials that are competitive in market. Piston plays a
main role in energy conversation. Failure of piston due to various thermal and
mechanical stresses is common and so expensive to replace. The specifications
used for this work is related to four stroke single cylinder engine of Hero Karizma
ZMR motorcycle. Design of the piston is carried out using SOLIDWORKS
software, thermal and stress analysis is performed using Finite Element Analysis
(FEA).The best aluminum alloy material is selected based on thermal and stress
analysis results. The analysis results are used to optimize piston geometry of best
aluminum alloy.
KEYWORDS: Piston, Solid works, thermal, stress analysis.

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DESIGN AND FAILURE ANALYSIS OF PISTON

CONTENT

1. INTRODUCTION

2. LITERATURE SURVEY

3. PROBLEM STATEMENT

4. OBJECTIVES

5. WORKING PRINCIPLE

6. COMPONENT OF THE SYSTEM

7. CAD MODEL

8. ADVANTAGES

9. LIMITATION

10. APPLICATIONS

11. CONCLUSION

12. REFRENCES

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DESIGN AND FAILURE ANALYSIS OF PISTON

▸INTRODUCTION:

A piston is a component of reciprocating IC engines. It is the moving component

with in a cylinder and is made of gas-tight by piston rings. In an engine, piston is
used to transfer force from expanding gas in the cylinder to the crankshaft via a
piston rod. Piston endures the cyclic gas pressure and the inertial forces at work,
and this working condition may cause the fatigue damage of the piston, such as
piston side wear, piston head cracks and so on. So there is a need to optimize the
design of piston by considering various parameters in this project the parameters
selected are analysis of piston by applying pressure force acting at the top of the
piston and thermal analysis of piston at various temperatures at the top of the
piston in various strokes. This analysis could be useful for design engineers for
modification of piston at the time of design.

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DESIGN AND FAILURE ANALYSIS OF PISTON

▸LITERATURE SURVEY:

A.w. Roberts and a. Harrison has explained a review of design trends

associated with long overland conveyors is presented indicating the
influence of economic and technical considerations in the design
methodology. Aspects of conveyor dynamics are discussed and research
and development work concerned with specific subjects including belt
drum friction, rolling resistance and bulk solid and conveyor belt
interaction. A test rig for examining stability between bulk solids and
conveyor belts during transportation is described.

Sunderesh S. Heragu and Banu Ekren [2] has explained Material handling
systems consist of discrete or continuous resources to move entities from one
location to another. They are more common in manufacturing systems
compared to service systems. Material movement occurs everywhere in a
factory or warehouse—before, during, and after processing. Apple (1977)
notes that material handling can account for up to 80 percent of production
activity. Although material movement does not add value in the
manufacturing process, half of the company’s operation costs are material
handling costs (Meyers 1993).

Aniket A Jag taps teal [3] in the process or manufacturing industry, raw
materials need to be transported from one manufacturing stage to another.
Material handling equipment are designed such that they facilitate easy,
cheap, fast and safe loading and unloading with least human interference. FOR
instance, belt conveyor system can be employed for easy handling of
materials beyond human capacity in terms of weight and height. This paper
discusses the design calculations and considerations of belt conveyor system
for biomass wood using 3 rolls idlers, in terms of size, length, capacity and
speed, roller diameter, power and tension, idler spacing, type of drive unit,
diameter, location and arrangement of pulley, angle and axis of rotation,

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SYSTEM

▸PROBLEM STATEMENT:

Throughout the world bulk materials handling operations perform a key

function in a great number and variety of industries. While the nature of the
handling tasks and scale of operations vary from one floor to anotherand
according to the industrial and economic base, the relative costs of
transporting bulk materials are, in the majority of cases, quite significant. It is
important, therefore, that handling systems be designed and operated witha
view to achieving maximum efficiency and reliability with flexible material
handling. The aim of this project is to redesign existing conveyor system by
designing the critical parts (pulley, belt, gear and Frame), to minimize the
overall weight of the assembly and to save considerable amount of material.

▸OBJECTIVES:
1. Analytical design of piston using Hero Karizma ZMR specifications. 2.
Obtaining design of piston using Solid works 2013 and then imported in ansys
15.0 3. Meshing of design model using ANSYS 15. 4. Analysis of piston by stress
analysis and thermal analysis method. 5. Comparing the performance of two
aluminum alloy piston under structural and thermal analysis process. 6.
Identification of the suitable aluminum alloy material for manufacturing of the
piston under specified conditions.
▸Working Principle

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As the conveyor convey the material from start to end. In our project two
conveyor belts are used. Perpendicular to each other & a rotating conveyor is
installed in between them as shown in Fig. 1. First material flows through the
one conveyor and the then after it pass on the rotating conveyor then that
conveyor rotates in 90degree and pass on another conveyor.

▸Component of the System:

 Conveyor belt
 Pulley
 DC motors
 Shaft
 Bevel gears
 Rotating plate

A. Conveyor belt:

Fig. 2 conveyor belt

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 DESIGN AND FABRICATION OF CONVEYOR
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* Pulley:

Fig. 3 Pulley

*DC
motors:

Fig. 3 DC motor

*Shaft

Fig. 4 bevel gear

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▸CAD MODEL:
Rotating conveyor:

▸ADVANTAGES:
The 90 degree conveyor system for material handling has all abundant and
outstanding advantage of this equipment in any material handling industry
with minimum knowledge about the operation of equipment is very limited
time.
 Low manufacturing cost of the equipment.
 Easy to handle.
 Less weight.
 Compact in size.
 Cost of checking the error is less.
 All kinds of material can the
handled. Even a lay man can work
in it.

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▸LIMITATIONS:
 Continuous or periodic monitoring of belt is necessary.
 Heat affects the material of belt.

▸APPLICATIONS:
 Can be applied in gear manufacturing unit.
 Used in automobile industry
 Used in airport.
 Also used in stone crushing industry.
 Used in both small scale industries as well as the large scale industries
Outcome can be utilized properly to a great executed in mechanical field as
well as the automobile field.
Also used in
Warehouses In coal
industry
Food and packaging industry.

▸CONCLUSION:

The piston plays a major role in the performance of the engine performance,
materials of the piston is made up of impacts the strength of the piston. The
maximum stress intensity is on the bottom surface of the piston crown in both the
materials, as it is expected. The maximum displacement is absorbed at the top of
the piston of 4032 and A2618. The highest value of maximum temperature found
in piston is due to thermal conductivity of the materials and the total maximum
heat flux is absorbed in both the piston materials. Results comparison between two
alloys is found approximately same. Thus further research can be carried with the
advance materials and different designing, analysis tools.

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▸REFRENCE:
1. “Thermal analysis of aluminum alloy piston” by B.A.Devan1, G.
Ravinder Reddy2 International Journal of Emerging Trends in Engineering
Research (IJETER), vol. 3 no6, ISSN 2347-3983. Pages: 511 -515 (2015)
2. Ajay Raj Singh, Dr. Pushpendra Kumar Sharma, “Design, Analysis and
Optimization of Three Aluminum Piston Alloys Using FEA” Int. Journal
of Engineering Research and Applications, ISSN : 2248-9622, Vol. 4, Issue
1 Version 3, January 2014, pp.94-102 3. “Thermal Stress Analysis of a
Speculative IC Engine piston using CAE Tools” by Hitesh pandey1 , Avin
chandrakar2 , PM Bhagwat3 , int. journal of Engineering Research and
Applications (ijera), ISSN :2248-9622, vol.4, issue 11(version-
5),November 2014,pp.60-64 4. “Design Analysis and Optimization of
Piston Using CAE Tools” by Vaibhav v. mukkawar1 , Nitin d.bhusale2 .
babasahebnaik college of engg, pusad-445204 5. Isam Jasim Jaber and
Ajeet Kumar Rai, Design and Analysis of IC Engine Piston and Piston-
Ring Using CATIA and ANSYS Software, IJMET, Vol.5, 2014 6.
”Thermal Analysis and Optimization of I.C. Engine Piston Using Finite
Element Method”InternationalJournal of Innovative Research in Science
Engineeringand Technology.
S.SrikanthReddy,Dr.B.SudheerPremKumar,Vol.2, Issue12,
December2013. 7. “Thermal Analysis and Optimization of I.C. Engine
Piston Using finite Element Method”by A. R.Bhagat1, Y. M. Jibhakate 2.
International Journal of Modern Engineering Research (IJMER), Vol.2,
Issue.4,July-Aug 2012 pp-2919-2921. 8. K Venkateswara rao1 , Baswaraj
Hasu2 , “Modeling, Analysis and Optimizatoin of Diesel Engine Piston”,
IJREAT , volume 2, Issue 1, 2014, ISSN: 2320-8791 9. Aditya Kumar
Gupta1 , Vinay Kumar Tripathi2 , “Design Analysis and Optimization of
Internal Combustion Engine Piston Using CAE tools ANSYS” ijera.com,
ISSN: 2248-9622, vol.4, Issue 11(version -5), November 2014

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