Thermo-Structural Analysis of Piston in Compression

Ignition Engine
Mukul Shrivastava1*, L. Lakshmana Rao2, Mohammad. Sameer3, Medavarapu
Jeevana4, Venkata Sasi Priya Reddi5
1,2,3,4,5
Department of Mechanical Engineering, Vardhaman College of Engineering, Hyderabad-501218, India

*Corresponding author email: mukul@vardhaman.org

Abstract. The piston is one of the most important component in the internal combustion engine. The main function
of the piston is to transfer the generated thermal energy by burning of air-fuel mixture to crank shaft. Due to
continuous working thermal loads and thermal stresses act on the piston resulting in decreased life. In order to
minimize piston failures, in present work 4 types of pistons are modeled using CATIA V5 3d modeling software.
The structural and thermal analysis are done by using ANSYS software. Values of the thermal stresses, heat flux,
total deformation and temperatures of different piston models are compared thereby proposing the preferred shape.

INTRODUCTION
In present times fossil fuel scarcity is leading to the importance of fuel saving and fuel efficiency. Also the life of
engine palys an important part. Both the factors are hugely effected by the stresses generated in the piston. The
piston is one of the important component in internal combustion engine. The main function of the piston is convert
the thermal energy produced to reciprocating motion. The burnt air-fuel moves till the top of the piston. The thermal
energy produced in combustion chamber is converted into mechanical energy by using the reciprocating motion of
piston and then converted into rotary motion with the help of connecting rod and crankshaft of engine. Earlier works
have been done in the area of engine coating [1], for different materials [2], different materials with coatings [3,4,5],
piston crown design [6], analytical study [7], coating thickness and roughness effects [8], cast iron (coated and non-
coated) piston [9], using thermal barrier coating [10], effect of thermal boundary conditions [11] and comparing Al
and Zr for material effect [12]. The pistons are available in different geometries [13]. According to application
different piston models can be used for various materials of the piston.

Most of the published work discussed about piston materials, coating material and their thermal performance
only [14,15]. Structural performance is not done in most of the published work. Temperature differences between
the Engine Head and the Piston Cylinder have a major role in inducing thermal stresses and hence is important in
predicting the life of an Internal combustion engine. Present work focuses on the thermal and structural evaluation
of different piston heads [16]. Present work involves modeling of four types of pistons by using CATIA. Further
investigation is carried out for the maximum Thermal stress developed due to rise in temperature and pressure using
structural linear analysis in Ansys. On Comparing all the values model which is suitable at high speed working
conditions is proposed.
DESIGN CONSIDERATION
As discussed earlier present work focuses on analyzing four different types of piston with respect to thermal and
structural stresses. The types of piston considered are i) Flat type piston ii) Cup type piston iii) Dome type piston
and iv) Bowl type piston as shown in Figure 1

Flat type piston Cup type piston Dome type piston Bowl type piston
 Figure 1: Different types of piston considered for thermal and structural analysis

The model developed were meshed as shown in Figure 2. Hexahedral meshing is used for all the four types.

Flat type piston

Cup type piston

Bowl type piston

Dome type piston

Figure 2: Full and cut section model with meshing in various types of piston under study

METHODOLOGY

In present work modelling of all the pistons is done by using Catia V5 according to theoretical calculations.
Further piston models are imported into the ANYSIS software, elements used were hexahydral type. All the
boundary
conditions are given according to the theoretical calculations. The material used for the piston in is AL4032.
Methodology for modelling and analysis of the piston.
1. Create 3D models of the four types of piston.
2. Export the solid models in Ansys workbench.
3. Apply the boundary conditions for the piston models.
4. Analysis done according to requirements of the project.

GOVERNING PARAMETERS
During the analysis of the piston the governing parameters considered are i) Type of piston (as discussed earlier ii)
Temperature iii) Heat transfer coefficient and iv) Pressure. Taking the mentioned governing parameters, the study is
done for thermal and structural stresses. The piston head is the top of the piston, due to the expansion of hot gases
the thermal load act on the top of piston. In present work applied temperature is kept at 1132.9 0C. The heat transfer
due to convection mode from the side walls of the piston takes place at atmospheric temperature 298.15 k and the
heat transfer coefficient is taken as 3200 w/mm 2k, for steady state thermal analysis. The thermal conditions are
applied to all the pistons. The pressure applied on the piston is taken as 6.5Mpa, friction less support to the side
walls of the piston is provided here and to constant body temperature condition is used. Imported body
temperature boundary condition is applied on the piston. After applying boundary conditions structural analysis
[19,20] is performed in Ansys work bench. In finite element method we can perform thermal and structural analysis
[17,18] of 4 different types of pistons by using Ansys work bench. In this analysis, we get accurate results according
to our requirements.

RESULTS

The governing parameters and boundary conditions applied (as mentioned earlier) results in the thermal stresses and
structural stresses. The key results to be observed includes i) Temperature variation ii) Heat flux variation iii) Stress
variation and iv) Deformation. All the stated parameters are plotted and tabulated for their quantitative values.
Various results obtained are shown in following figures.
Flat type Cup type Dome type Bowl type

Figure 3: Temperature variation in various types of piston

Flat type Cup type Dome type Bowl type

Figure 4: Heat flux variation in various types of piston

 Cup type
Flat type

Do
me type Bowl type

Figure 5: Stress variation in various types of piston

Flat type Cup type

Dome type Bowl type

Figure 6: Deformation in various types of piston

Based on the simulation results obtained various values like temperature, heat flux, stress and deformation are
extracted from simulation results and are tabulated as shown in Table 1 below

Table 1: Parametric variation for various types of piston

Temperature variation Heat flux variation

Piston type Minimum Maximum Piston Minimum heat Maximum heat

temperature(K) temperature(K) type flux(w/mm2) flux (w/mm2)

Flat 172.29 1132.9 Flat 7.4125 x 10-6 176.52

Cup 173.01 1132.9 Cup 1.0137 x 10-4 161.28

Dome 173.1 1132.9 Dome 1.7262 x 10-5 150.64

Bowl 172.28 1132.9 Bowl 1.953 x 10-4 153.43

Stress variation Deformation

Piston type Minimum stress Maximum stress Piston Minimum Maximum

(Mpa) (Mpa) type deformation(mm) deformation(mm)

Flat 0.2523 80.11 Flat 1.72 x 10-6 0.02

Cup 0.22794 214.25 Cup 2.8421 x 10-5 0.20

Dome 0.12404 80.248 Dome 4.8352 x 10-5 0.01

Bowl 0.23345 163.1 Bowl 6.3295 x 10-5 0.09

Figure 7: Effect of piston type on the maximum stress obtained in a piston

 DISCUSSION

The simulation results are plotted and tabulated as shown in earlier section. Figure 3 shows the
temperature contours obtained for different types of piston. It is observed that effect of piston
shape on the temperature profile is not pronounced.
Figure 4 shows a comparison of heat flux obtained for various types of piston. It can be seen
that flat type piston has more heat flux followed by cup type where the values remain almost same
for dome and bowl type.
Stress contours for different types of piston is shown in Figure 5. It is observed that maximum
stress is almost same and lesser for flat and dome type. Bowl type has increased maximum stress
and the value is largest for cup type.
Deformation obtained under stresses is shown in form of deformation contours in Figure 6. It is
observed that Flat and dome type has lesser and almost same deformation. Deformation in cup and
bowl type is found to be more.
Table 1 represents the quantitative value of maximum / minimum temperature, heat flux,
maximum stress and maximum deformation for all the types of piston. A close observation shows
a negligible variation in the minimum temperature with 172.28 K for bowl type and 173.1 K for
dome. It can be concluded that the type of piston is not having any substantial effect on the
minimum temperature obtained.
Further from the data it is seen that type of piston is having pronounced effect on the heat flux
with 176.52 w/mm2 for flat type and 150.64 w/mm 2 for dome type. It can be seen that flat type has
maximum heat flux resulting in faster dissipation of heat.
Maximum stress is also substantially effected by the type of piston. Maximum stress is almost
same for flat and dome type (80.11 and 80.248 Mpa) whereas the stress is maximum for cup type
(241.25 Mpa). Thus the maximum stress obtained is lesser in flat and dome type.
Also maximum deformation obtained is considerably effected by the type of piston.
Deformation is minimum for flat and dome type (0.02 and 0.01 mm respectively) and maximum
for cup type (0.2 mm).

CONCLUSION

After performing thermal and structural analysis by using Aluminum alloy. Among the four types
of pistons, flat and dome type pistons give the low stress and deformation values compared to the
remaining pistons which are noted above. From all the above tables it can be concluded that the
flat and dome type pistons give stresses equal to 80.11 and 80.24 Mpa respectively, which are
preferable than other two types. Likewise, in structural analysis also flat and dome type pistons
give lower deformation values equal to 0.02 mm and 0.01 mm respectively. From the above
information, we can conclude that flat and dome type pistons are preferable as compared to other
pistons.

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