Boundary Conditions and steps involved in performing

piston FEA

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Step 1: Temperature Analysis:
•Mean Gas Temperature and Mean HTC has been applied

•Conrod ,Pin was completely

decoupled
• HTC and Bulk Temperatures
were applied to all the zones

Results Explored from this analysis are

Temperature distribution
To calculate FOS, we will take the nodal temperatures from this analysis.
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 Step 2: Thermal Analysis :

Nodal temperature results from step1

were read in structural analysis to
find free expansion of the piston and
also to find thermal stresses in the
piston. No load and no constraints
are applied in this analysis

To calculate FOS, we will take the Principal stresses (Thermal) from this analysis.

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 Step 3: Thermal+Mechanical analysis with contact
Cylinder Pressure
(Crown, Top Land and 1st Ring Groove)

Ring Carrier / Piston

Interaction
(Bonded Contact )

Piston / Pin
Pin / Conrod
Interaction
(Frictionless Contact
between pin & pin boss Thermal
between pin & conrod bush) Boundary Conditions read
nodal temperature results from
step1

Acceleration
constrained in vertical direction
Note: Piston-Liner interaction is not considered for Thermal+Mechanical analysis
Results Explored from this analysis are
a)Normal & Hoop Stress in Pin Bore b) Hoop Stress in Bowl Edge and Bowl Base
To calculate FOS, we will take the Principal stresses ( for Thermal+Mechanical) from this analysis.

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 Steps involved in Calculating FOS in Ansys Workbench

Step.1. Temperature Distribution analysis (Slide no 2)

Step 2. Thermal + Mechanical Analysis (Slide no 4)

Step 3. Thermal analysis (Slide no 3)

Step 4. Solution Combination ( Step2-Step3 )

Using inbuilt fatigue tool FOS can be calculated, with

following settings.

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Fatigue tool Settings Material properties: Alternating
stress vs. cycles

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 FOS Results:

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 FOS Results:

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 FOS Results

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