A

Internship Report
On

“Finite Element Stress Analysis of a Piston-Cylinder

Assembly of an IC Engine using Ansys”
Undergone at
Aerial Delivery Research and Development Establishment, Agra
(Duration: 20/7/23 – 21/8/23)
Submitted to
Department of Mechanical Engineering
Hindustan College of Science and technology, Farah, Mathura
By
Piyush Lavania
7th Semester, Mechanical Engineerng
(Roll Number: 2000640400008)
 DECLARATION

I hereby declare that this internship report on “Finite Element Stress

Analysis of a Piston-Cylinder Assembly of an IC Engine” undergone at
ADRDE, Agra being submitted is uniquely prepared by me after the
completion of one month work in this organization.

I also confirm that, the report is only prepared for my academic requirement
and not for any other purpose.

Piyush Lavania

(2000640400008)

a
 ACKNOWLEDGEMENT

It gives me a great sense of pleasure to present my internship report. I

would like to express my sincere gratitude to Anup Raj, Scientist “D”, Aerial
Delivery Research and Development Establishment, Agra for his invaluable
support and guidance throughout my internship. His mentorship has been
instrumental in shaping my professional growth.

I also take the opportunity to acknowledge the contribution of Dr. Puneet

Mangla, Head, Department of Mechanical Engineering, Hindustan College
of Science and Technology for providing me with the opportunity to
undertake this internship at Aerial Delivery Research and Development
Establishment, Agra. His belief in me and his encouragement have been
truly inspiring.

I extend my heartfelt thanks to all my colleagues and friends for their

unwavering motivation and support during this internship journey. Their
encouragement has played at significant role in my success.

Thank you all for being an integral part of my internship experience.

Piyush Lavania

(2000640400008)

b
 ABSTRACT

The piston-cylinder assembly has been analyzed to investigate the

stresses, strain and deformation under static loading conditions. The finite
element structural analysis shows the material strength and pressure
differential requirements and areas where material can be optimized in
weight and strength. Graphic output from the analysis shows the deformed
shapes and the stress distribution. The theoretical formulas and finite
element analysis are used to estimate the structural analysis and other
design related parameters of the piston-cylinder assembly. Finally, the
stresses, strain and deformation has been identified.

The findings of this research contribute to the understanding of piston-

cylinder assembly design and analysis. The comparison of theoretical
results and Ansys simulation enables a comprehensive evaluation of
piston-cylinder assembly’s behavior. The results and methodologies
presented in this report serve as a foundation for further research and
development in the field of piston-cylinder assembly design.

c
 LIST OF FIGURES

Figure 1. Internal Combustion Engine Page No.1

Figure 2. Working of 4-stroke IC engine Page No.6

Figure 3. Piston Measurements 1 Page No.12

Figure 4. Piston Measurements 2 Page No.12

Figure 5. Piston Page No.13

Figure 6. Connecting Rod Measurements 1 Page No.13

Figure 7. Connecting Rod Measurements 2 Page No.14

Figure 8. Connecting Rod Page No.14

Figure 9. Pin Page No.15

Figure 10. Upper Case Measurements 1 Page No.15

Figure 11. Upper Case Page No.16

Figure 12. Lower Case Measurements 1 Page No.16

Figure 13. Lower Case Measurements 2 Page No.17

Figure 14. Lower Case Page No.17

Figure 15. Crankshaft Measurements 1 Page No.18

Figure 16. Crankshaft Measurements 2 Page No.18

Figure 17. Crankshaft Measurements 3 Page No.19

Figure 18. Assembly Page No.19

Figure 19. Ansys Workbench Page No.20

Figure 20. Model in Ansys Page No.21

d
Figure 21. Model Mesh Page No.22

Figure 22. Mesh Details Page No.22

Figure 23. Pressure Application on Model Page No.23

Figure 24. Force Application on Model Page No.23

Figure 25. Fixing the Model Page No.24

Figure 26. Total Deformation Page No.25

Figure 27. Normal Stress Page No.26

Figure 28. Shear Stress Page No.27

Figure 29. Equivalent Stress Page No.28

Figure 30. Equivalent Elastic Strain Page No.29

e
 LIST OF TABLES

Table 1. Total Deformation Table Page No.25

Table 2. Normal Stress Table Page No.26

Table 3. Shear Stress Table Page No.27

Table 4. Equivalent Stress Table Page No.28

Table 5. Equivalent Elastic Strain Table Page No.29

f
 TABLE OF CONTENT

DECLARATION a

ACKNOWLEDGEMENT b

ABSTRACT c

LIST OF FIGURES d

LIST OF TABLES f

TABLE OF CONTENT g

NOMENCLATURE h

1. Introduction Page No.1

1.1) Motivation of the Project Page No.1

1.2) IC Engine Page No.1
1.3) Classification of IC Engine Page No.2
1.4) Working of IC Engine Page No.4
1.5) Components of IC engine Page No.6
1.6) Finite Element Analysis Method Page No.9

2. Methodology Page No.12

2.1) Design and description of the model Page No.12

2.2) Simulation in Ansys Page No.20
3) Result and discussion Page No.25

3.1) Simulation Results Page No.25

4) Conclusion Page No.30

g
 NOMENCLATURE

l = Deformation

P = Pressure

l = Length

E = Young’s Modulus of Elasticity

F = Load

A = Area where load is applied

 = Normal Stress

S = Shear Stress

AC = Cross-sectional Area

E = Equivalent Stress

E = Equivalent Elastic Strain

h
1. Introduction:

1.1) Motivation of the Project:

Engines, the heartbeats of modern machinery and vehicles, are intricate
marvels of engineering that propel our world forward. These mechanical
powerhouses harness various forms of energy to generate motion, perform
work, and drive countless applications. While providing power, engines are
subjected to various types of loads of different magnitudes in different
parts. To avoid failure of these devices, proper stress-strain analysis needs
to be done. In this report, finite element analysis is done through Ansys
software and the results are compared with theoretical results. For this
report, two type of loads i.e. pressure and downward load is taken into
consideration and static structural analysis of piston- cylinder assembly of
an IC engine is done.

1.2) IC Engine:

An internal combustion engine (IC engine) is a marvel of engineering that

powers many of the vehicles and machinery we rely on daily. It operates on
the fundamental principle of converting chemical energy, typically in the
form of gasoline or diesel, into mechanical energy through controlled
explosions within its combustion chambers. These explosions drive pistons,
which in turn generate rotational motion that powers the vehicle or
equipment. They have played a pivotal role in shaping modern
transportation and industry, enabling the efficient movement of people and
goods across the globe while continuously evolving to meet demands for
performance, efficiency, and environmental considerations.

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 Figure 1. Internal Combustion Engine

1.3) Classification of IC Engine:

Internal Combustion (IC) engines are widely used in various applications,

ranging from automobiles and motorcycles to industrial machinery and
power generators. These engines are classified based on several criteria,
including their cycle, fuel type, arrangement, and application. Let's delve
into the details of the classification of IC engines:

A. Based on Cycle:

IC engines operate on different cycles, which describe the sequence of

events that occur within the engine during one complete working cycle. The
two primary cycles are:

- Otto Cycle (Spark Ignition): This cycle is used in gasoline (petrol) engines.
It consists of four processes: intake, compression, power, and exhaust. A
spark plug ignites the air-fuel mixture at the end of the compression stroke.

- Diesel Cycle (Compression Ignition): This cycle is used in diesel engines.

Similar to the Otto cycle, it comprises four processes: intake, compression,
power, and exhaust. However, in diesel engines, air alone is compressed
to a high temperature and pressure, and then fuel is injected into the
combustion chamber, igniting due to the high temperature of the
compressed air.

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B. Based on Fuel Type:

IC engines can be classified according to the type of fuel they use:

- Gasoline (Petrol) Engines: These engines run on gasoline and use spark
plugs to ignite the air-fuel mixture.

- Diesel Engines: Diesel engines use diesel fuel and rely on high
compression to ignite the air-fuel mixture without spark plugs.

- Gas Engines: These engines use natural gas or other gaseous fuels as
their primary fuel source. They are often used in applications where natural
gas is abundant.

C. Based on Arrangement:

IC engines can be categorized based on how their cylinders are arranged:

- Inline Engine: In this arrangement, cylinders are arranged in a straight

line. Inline engines are often used in smaller vehicles and have a more
compact design.

- V-Type Engine: Cylinders are arranged in two banks at an angle to each

other, resembling the letter "V." V-type engines are common in both cars
and larger vehicles due to their ability to accommodate more cylinders.

- Flat or Boxer Engine: In this arrangement, cylinders are horizontally

opposed, with two banks of cylinders facing each other. This design
provides a lower center of gravity and smoother operation.

D. Based on Application:

IC engines are also classified based on the application they are designed
for:

- Automotive Engines: These are engines used in automobiles, including

cars, trucks, and buses. They are further categorized based on their size
and power output.

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- Marine Engines: Designed for use in ships and boats, marine engines are
built to withstand the harsh conditions of marine environments.

- Aircraft Engines: These engines are designed to power airplanes and are
optimized for high power-to-weight ratios and efficient operation at high
altitudes.

- Industrial Engines: Used in various industrial applications, such as power

generation, construction equipment, and agricultural machinery.

In addition to these classifications, IC engines can also be differentiated by

factors such as cooling methods (air-cooled or water-cooled) and number
of strokes (two-stroke or four-stroke). IC engine technology continues to
evolve, with advancements in efficiency, emissions reduction, and
alternative fuels playing a significant role in shaping the industry.

1.4) Working of IC Engine:

Let's focus on the most common type of IC engine: the four-stroke spark-
ignition (gasoline) engine, also known as the Otto cycle engine.

Working of a Four-Stroke Spark-Ignition IC Engine:

A. Intake Stroke:

- The piston starts at the top of its cylinder (top dead center or TDC).

- The intake valve opens, and the piston moves down the cylinder (moves
towards bottom dead center or BDC).

- The intake valve allows a mixture of air and fuel to enter the cylinder
from the intake manifold.

B. Compression Stroke:

- Both the intake and exhaust valves are closed.

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 - The piston moves back up the cylinder, compressing the air-fuel
mixture.

- The compression increases the pressure and temperature of the

mixture.

C. Power Stroke:

- At the end of the compression stroke, a spark plug ignites the

compressed air-fuel mixture.

- The ignited mixture rapidly burns, creating a high-pressure, expanding

gas.

- This expansion forces the piston down the cylinder, generating

mechanical power.

- The energy from the power stroke is transferred to the crankshaft

through the connecting rod, converting linear motion into rotary motion.

D. Exhaust Stroke:

- After the power stroke, the exhaust valve opens, and the piston moves
up the cylinder.

- The rising piston pushes the burnt exhaust gases out of the cylinder and
into the exhaust manifold.

- The cycle is completed, and the engine is ready for the next intake
stroke.

Figure 2. Working of 4-stroke IC engine

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Keep in mind that the actual engine is more complex, with additional
components like camshafts, timing belts, and various sensors controlling
the fuel injection and ignition timing. Also, this description is based on a
four-stroke cycle; two-stroke engines have a different cycle involving fewer
strokes for each power cycle.

1.5) Components of IC engine:

Internal Combustion (IC) engines are composed of various components,
each serving a specific role in the operation of the engine. Let's delve into
the details of the major components of an IC engine:

A. Cylinder Block:

- The cylinder block forms the main structure of the engine. It houses the
cylinders where the combustion process takes place.

- It also contains passages for coolant circulation to maintain optimal

operating temperature.

B. Cylinder Head:

- The cylinder head is attached to the top of the cylinder block.

- It contains intake and exhaust ports, spark plugs (in gasoline engines),
and valves that control the flow of air and exhaust gases in and out of the
cylinders.

C. Pistons:

- Pistons are cylindrical components that move within the cylinders.

- They are connected to the crankshaft via connecting rods and convert
the pressure generated by the combustion process into mechanical motion.

D. Connecting Rods:

- Connecting rods connect the pistons to the crankshaft.

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 - They transmit the reciprocating motion of the pistons into rotary motion
of the crankshaft.

E. Crankshaft:

- The crankshaft is a rotating shaft that converts the linear motion of the
pistons into rotary motion.

- It is connected to the wheels in vehicles to provide propulsion.

F. Camshaft:

- The camshaft controls the opening and closing of the engine's intake
and exhaust valves.

- It is driven by the crankshaft and has lobes or cams that actuate the
valves through a series of mechanisms (pushrods, rocker arms, or directly).

G. Valves:

- Valves control the flow of air and exhaust gases in and out of the
combustion chamber.

- Intake valves allow fresh air (and fuel in gasoline engines) to enter the
cylinder, and exhaust valves allow burned gases to exit.

H. Piston Rings:

- Piston rings are placed around the pistons and help seal the combustion
chamber.

- They prevent the escape of combustion gases and ensure efficient

compression and power strokes.

I. A gudgeon pin:

- Also known as a piston pin or wrist pin is a crucial component in an

internal combustion engine.

- It connects the piston to the connecting rod, allowing the piston to move
within the cylinder while transmitting the force generated during combustion
to the connecting rod.
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1.6) Finite Element Analysis Method:
Finite Element Analysis (FEA) is a powerful numerical method used in
engineering and applied sciences to solve complex physical problems. It's
a simulation technique that divides a complex geometry or physical domain
into smaller, simpler elements, allowing engineers and researchers to
analyze how the system behaves under various conditions. FEA is widely
used for structural analysis, heat transfer, fluid flow, electromagnetics, and
more. Detailed overview of the Finite Element Analysis method:

A. Problem Formulation:

- The first step is to define the problem you want to analyze. This includes
specifying the geometry, material properties, boundary conditions, and the
type of analysis required (structural, thermal, etc.).

B. Discretization:

- The continuous geometry is divided into smaller discrete elements.

These elements can be triangles or quadrilaterals in 2D or tetrahedrons or
hexahedrons in 3D. Each element is defined by a set of nodes, and the
behavior within an element is approximated using mathematical
interpolation functions.

C. Element Types:

- Different types of elements are used based on the nature of the

problem. For example, truss elements are used for structural analysis,
while heat transfer problems might use heat conduction elements.

D. Mesh Generation:

- The process of creating the discrete mesh from the continuous

geometry is called mesh generation. A fine mesh is needed in areas of high
stress gradients or rapid changes in the solution, while coarser meshes are
sufficient in less critical regions.

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E. Governing Equations:

- For each element, governing equations based on the physics of the

problem (e.g., equilibrium equations for structural analysis) are formulated.
These equations relate the unknown variables (such as displacements,
temperatures) to known quantities (such as loads, boundary conditions).

F. Assembly:

- The equations for all elements are assembled into a global system of
equations that represents the behavior of the entire structure or system.
This system of equations is often large and sparse.

G. Solution:

- The global system of equations is solved using numerical techniques,

often iterative methods. The solution provides the values of the unknown
variables (displacements, stresses, temperatures, etc.) at the nodes of the
mesh.

H. Post-Processing:

- Once the solution is obtained, post-processing is performed to extract

meaningful information. This could involve generating contour plots of
stress distribution, displacement vectors, temperature profiles, and other
relevant quantities.

I. Validation and Iteration:

- The results obtained from FEA need to be validated against

experimental data or known analytical solutions. If discrepancies are found,
the model may need refinement, and the analysis process may need to be
iterated.

Finite Element Analysis offers several advantages, such as the ability to

study complex geometries, predict system behavior under various
conditions, optimize designs, and reduce the need for physical prototypes.
However, it requires careful consideration of modeling assumptions, mesh
quality, and solution convergence to ensure accurate results.

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The final design of piston is shown below:

Figure 5. Piston

B) Connecting rod:

Various dimensions of connecting rod are shown in below figures:

Figure 6. Connecting Rod Measurements 1

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