Wroclaw University of Science And Technology

Faculty Of Mechanical Engineering

Automotive Engineering

Project

Piston

Students’
Name and Surname : Sami Onur Vural
Number : 263410

Supervisor : Dr inż. Krzysztof Widanka

 I. Description Of Piston

Piston is a part of a system which converts chemical energy to mechanic energy. Main duty of a
piston is turning crank shaft so converting linear motion to rotational movement. Mixture of fuel
and air combust in a cylinder and expanded gas push piston and thus the crank which linked by
piston turns.

There are two common methods to produce pistons. These ones are casting and forging. In forged
pistons , there are more molecules in the same area rather than casted piston. Thanks to this situation
forged pistons have more strenght and working hours. But after forging process machining is applied
more harder.
II. Specification Of Requirements

The piston together with the piston rings, form the combustion chamber with the cylinder head,
sealing the combustion gas. Then, it transfers combustion pressure to the rotating crankshaft
through the piston pin and connecting rod. Finally, in the two stroke engine particularly, the piston
itself works as the valve, exchanging gas. Also, pistons need to be mass-produced at low expense.

When exposed to a high-temperature gas,the piston must reciprocate at high speed along the
cylinder bore. Even a small engine can generate a high power output at an increased revolution
number. To generate high power output, the piston should be designed to be as light as possible
whilst retaining durability. Such lightweight designs increase the stress on the piston material.

In comparison with petrol engines, diesel engines generate power at relatively low rotation,
although a higher cylinder pressure is required. These engines use a piston with a centrally located
combustion bowl. This increased power has aised the piston head temperature to as much as 350
ᵒC at the combustion bowl edge. Compared to petrol engine pistons, diesels require a piston with a
much higher strength to withstand these high temperatures.

III. Material Investigation

Light aluminum alloy has been the most widely used material. A key issue was whether
aluminum, with a melting temperature as low as 660 ᵒC, could withstand hot combustion gas. We
will compare it with another materials in the next section.

Ashby chart is one of the first step of material selection. It is an useful tool because it give enable
to compare unnumberable materials during the consept design process. Also it is useful for
checking specific material properties whether or not appropriate for our design. An ashby plot
ensure to compoare two or more specification for a material or a group of material. For
comparing these traits , ashby charts are quite important.

For selected a material by using Ashby Chart ;

 We should know trait of material like density , yield tension

 Variables can be adjusted during the loading period such as applied force.
 Constraints such as, thickness of the beam, amount of deflection.
There are two main material groups are manufacturing in piston; These are Cast irons and
aluminium alloys ;

Cast İron : Cast iron is a group of iron-carbon alloys with a carbon content greater than %2.
Carbon (C) ranging from % 1.8-4 wt and silicon (Si) %1-3 wt are the main alloying elements of
cast iron. There are 4 types of cast iron. These ones are grey cast iron, white cast iron , malleable
cast iron and Ductile Cast iron. Cast iron is hard and brittle. Also it is very good in compression.
But it is non-malleable (i.e. it cannot be bent, stretched or hammered into shape) and more fusible
than steel.

Aluminium Alloys : Aluminium alloys are alloys in which aluminium (AI) is the predominant
metal. The typical alloying elements are copper , magnesium , manganese, silicon , tin and zinc.
Cast aluminium alloys yield cost-effective products due to the low melting point. Aluminum alloy
characteristics are high operating temperaturs , outstanding corrosion resistance , lightweight ,
very good strenth-to-weight ratio,excellent EMI and RFI shielding properties,excellent thermal
conductivity, high electrical conductivy, good finishing characteristics and full recyclability.
Aluminum castings improve automotive fuel efficiency by contributing to weight saving
requirements. Aluminium is used in a broad range of networking and infrastructure equipment in
the telecom and computing industries because RF filter boxes and housings require heat
dissipation. In handheld devices, aluminum castings provide EMI/RFI shielding,rigidity and
durability with minimal weight. Because of aluminum’s excellent electrical performance and
shielding properties,even in high temperature environments, die cast aluminum is ideal for
electronic connectors and housings.

It’s crucial efficiency and cost-effectiveness in material choose. Based on these knowings, a few
material were selected. The materials for manufacturing a piston

1. Carbon Steel
2. Cast Iron
3. Nickel Chronomium Alloy
4. Cast Aluminium
5. Aluminium Alloy which İnclude %4.6 Cu
 Material - Maximum Maximum Permissible Yield Stress
Properties Deformation Induced Stress N/mm2 N/mm2
(mm) Stress N/mm2
1 Carbon Steel 0,012788 156 210 420
2 Cast Iron 0,024735 156 175 350
3 Nickel 0,056724 158 170 340
Chronomium
Alloy
4 Cast 0,033759 248 190 380
Aluminium
5 Aluminium 0,035386 159 172,5 345
Alloy

IV. Index Method

Material performance index ,

n
γ = ∑ βi . α i
i =1

𝞫 = Scaled Property

𝜶 = Weightin Factor,

i = Summed over all the n relevant properties

For calculate material calculate index, initially we should detect weighting factor of these properties.

Property Maximum Maximum Permissible Yield Stress

Deformation Induced Stress Stress
Decisions 2 3 3 2
Weighting Factor 0,2 0,3 0,3 0,2
(𝜶)

Materials with higher maximum induced stress,permissible stress,yield stres are preferred for pistons
with the maximum value being 100. The following equation is used to measure their scaled values.

numerical value of property∗100

Scaled property=
maximum value∈the list
Because a lower maximum deformation is preferred for pistons. The lowest value is equal to 100 and
scaled values are determined using this equation

minimum value∈thelist∗100
Scaled property=
numerical value of property

Carbon Steel Cast Iron Ni Cr Alloy Cast Aluminium

Aluminium Alloy
Max Deform 100 51,7 22,5 37,88 36,14
Max Induced 62,9 62,9 63,7 100 64,1
Stress
Permissible 100 83,3 80,9 90,47 82,14
Stress
Yield Stress 100 83,3 80,9 90,47 82,14
Performance 90,725 70,3 62 79,7 66,13
Index

The performance index shows us only technological capability. But we should give importance only
costs and density.

γ
M=
ρ.c

C = Total cost of the material per unit weight

𝞀 = Density of the material

Material Carbon Steel Cast Iron Ni. Cr. Alloy Cast Al alloy
Aluminium
Performance 90,725 70,3 62 79,7 66,13
Index
Density 7,8 7,2 1,8 2,7 2,8
Costs 1 0,7 40 1,1 1,1
Figure of 11,63 13,9 0,86 26,835 21,47
Merit
Rank 4 3 5 1 2
Conclusion

There are cast aluminium and an alluminium alloy in 1st and 2nd ranks. Thanks to lower density and
production costs. Aluminium is preferred by Automotive Industry for manufacturing of pistons.
Although, carbon steel has best technological capability it has 4th rank because of it has highest
density.

References

https://www.sekizsilindir.com/

The science and technology of materials in automotive engines ( Hiroshi Yamagata)

Material selection for piston (Kumaraguru College of Technology)

A study on material selection of ic engine piston under static loads (M. Senthil Kumar,M. Suresh ,
P.Kumaravel, V.R. Srinivashan)

Material Selection in mechanical design (Michael F. Ashby)