1DIESEL ENGINE PISTON - DESIGN ,THERMAL

ANALYSIS AND STRUCTURAL ANALYSIS

A SEMINAR REPORT
Submitted in the partial fulfilment for award of the requirement
For the award of

MASTER OF TECHNOLOGY I .SEMISTER

In

MECHANICAL ENGINEERING
(CAD/CAM)
By
MD.THANZEEL KOUSER (17474T6406)

UNDER THE ESTEEMED GUIDANCE OF

Dr. E. SURENDAR
Associate Professor
Dept. Of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEEERING

WARANGAL INSTITUTE OF TECHNOLOGY AND SCIENCE
WARANGAL-506342.
(Affiliated to Kakatiya University, Warangal)
2017
 WARANGAL INSTITUTE OF TECHNOLOGY AND SCIENCE
DEPARTMENT OF MECHANICAL ENGINEERING
WARANGAL-506342.

CERTIFICATE
This is to certify that this is the bonafide record of the seminar entitled “DIESEL ENGINE
PISTON-DESIGN, THERMAL ANALYSIS AND STRUCTURAL ANALYSIS’’ is being
submitted by, MD. THANZEEL KOUSER (1747T6406) in the partial fulfilment for the award of
the degree of Master of Technology I Semister in Mechanical Engineering (CAD/CAM) in the
Warangal Institute of Technology& Science (WITS), Warangal.

PROJECT GUIDE PROJECT CONVENOR

Dr. E. SURENDAR Mr. K. SHYAM KUMAR
ASSOCIATE PROFESSOR ASSISTANT PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING DEPT.OFMECHANICALENGINEERING,
WITS, WARANGAL. WITS, WARANGAL.

HEAD OF THE DEPARTMENT

Dr. E. SURENDER,
ASSOCIATE PROFESSOR,
DEPT. OF MECHANICAL ENGINEERING
WITS, WARANGAL.
 CONTENTS
ABSTRACT 1
CHAPTER-1 2
ITRODUCTION 3
PISTON 3

1.1 . PARTS OF PISTON 4

 The crown. 5
 The ring lands.
 Ring groove.
 Skirt.
 Wrist pin boss.
 Piston rings

1.3 . THERE ARE THREE TYPES OF PISTON CROWNS 5

 Dome top piston 5
 Blow top piston 6
 Flat top piston 7
 Flat top piston with valve head 8

1.4 PISTON MATERIALS 8

1.5 PROPERTIES OF PISTON 8

 Aluminum
 Grey cast iron
 Steel
1.6 METHOD OF MAKING PISTON 9
CHAPTER-2 10
2.1 CATIA 11
2.2 COMMANDS
2.3 DESIGN OF PISTON IN CATIA 12

LITERATURE 13

OBJECTIVES 14

REFERENCES 15
 ABSTRACT
A piston is a component of reciprocating engines, reciprocating pumps, gas
compressors and pneumatic cylinders, among other similar mechanisms. It is the moving component
that is contained by a cylinder and is made gas-tight by piston rings. Piston that transfer the combustive
gases power to the connecting rod. To improve the efficiency of the engine there is a need to study
about the piston. Pistons that are usually made up with alloy steels that show the grate resistant against
thermal loads and structural loads.

Piston is a moving component which is located in the cylinder and is made gas-tight by
piston rings. It is a vital component in an engine. In this present work a diesel pistons are made of
aluminium, cast iron, and steel material will be modelled in CATIA V5R17 and the same model will
be imported to ANSYS workbench and meshing will be done and further analysis will be carried out
in the same ANSYS Workbench. The type of analysis that I carry out here is on different types of
pistons and also by varying the mechanical design of the piston which will give thermal analysis and
structural analysis ,where the maximum temperature , total heat flux ,maximum stress by applying
average cycle temperature and adiabatic flame temperature and also some maximum stresses on the
piston .Here for carrying out the analysis three matirials are selected and out of those the material
which suits the best for the stipulated condition will be selected
CHAPTER-1
 INTRODUCTION
1.1PISTONS :
Piston is a component of a reciprocating engines, reciprocating pumps, gas compressor and
pneumatic cylinders, among other similar mechanisms. It is the moving component that is
contained by a cylinder and is made gas-tight by piston rings. In an engine, its purpose is to
transfer force from expanding gas in the cylinder to the crankshaft via a piston rod and/or
connecting rod. In a pump, the function is reversed and force is transferred from the crankshaft
to the piston for the purpose of compressing or ejecting the fluid in the cylinder. In some engines,
the piston lsoactsasa valve by covering and uncovering ports in the cylinder.

1.2 . PARTS OF PISTON :

 The crown.
 The ring lands.
 Ring groove.
 Skirt.
 Wrist pin boss.
 Piston rings
  THE CROWN :

The crown is the top surface (closest to the cylinder head) of the piston which is subjected to
tremendous forces and heat during normal engine operation

 RING LAND :

Rind lands are the reliefs cut into the side profile of the piston where the piston rings sit

 RING GROOVE :

Ring groove is a recessed area located around the perimeter of the piston that is used to retain a piston
ring

 SKIRT :

Skirt of piston is the portion of the piston clossest to the crank shaft that helps to aling the piston as it
moves in the cylinder bore

 WRIST PIN BOSS :

Wrist pin boss is a bore that connects the small end of the connecting rod to the piston by a wrist pin

 PISTON RINGS :
 Piston rings commonly used on small engines include the compression ring, wiper ring, and
Oil ring. A compression ring is the piston ring located in the ring groove closest to the piston

head. A wiper ring is the piston ring with a tapered face located in the ring groove between
the

compression ring and the oil ring. An oil ring is the piston ring located in the ring groove closest

to the crank case. The oil ring is used to wipe excess oil from the cylinder wall during piston
movement

 Piston rings seal the combustion chamber, transferring heat to the cylinder wall and controlling
oil consumption.
 A piston ring seals the combustion chamber through inherent and applied pressure. Inherent
 pressure is the internal spring force that expands a piston ring based on the design and
properties of the material used. Inherent pressure requires a significant force needed to
compress a piston
ring to a smaller diameter. Inherent pressure is determined by the uncompressed or free piston
ring gap.
 A piston pin bore is a through hole in the side of the piston perpendicular to piston travel that
receives the piston pin.
 A ring groove is a recessed area located around the perimeter of the piston that is used to retain
a piston ring.

1.3 . THERE ARE THREE TYPES OF PISTON CROWNS

 Dome top piston

 Blow top piston
 Flat top piston
 Flat top piston with valve head

 DOME TOP PISTON

The Dome Piston looks just like it sounds. Instead of a flat top It has a dome that looks like the top
of a dome stadium. Piston Dome refers to the amount of added volume on top of the piston compared
to a flat top piston. This added volume increases the Compression Ratio and therefore should increase
performance. However, depending on the shape of the combustion chamber in the head, highly domed
pistons can create slow burning, inefficient combustion chambers. The optimum trade off between
higher compression ratio and dome/combustion chamber shape can only be determined by trial -and -
error on a dyno.

Dome Pistons are also used in 2stroke engines, mostly to deflect the inlet charge up toward the spark
plug, and not let it flow directly to the exhaust ports.

Note: Performance Trends Engine Simulation Software does not work with 2stroke engines. But our
some of our tools can, such as the Compression Ratio Calculator and Engine Log Book. And our Dyno
Data mite systems have dyno testes hundreds of 2 and 4 stroke engine.
  BLOW TOP PISTON :

Bowl pistons typically are used to reduce compression ratio because of the added volume of the bowl
to the combustion volume. Because they reduce Compression Ratio, bowl pistons can be used in
Turbo Charged or Super Charged engines to help avoid detonation (spark knock) under boosted
conditions. The extreme bowl shown is used in diesel engines, where the bowl is used to confine the
diesel fuel spray for good, fast combustion. A piston bowl can do the same for a spark ignition engine
and make for a fast burning, compact combustion chamber.
  FLAT TOP PISTON :

The Flat Top Piston is just like it sounds; it has a flat top. These pistons are typically used in mass
produced engines. They are easy to manufacture and this keeps the cost of the engines low.
  Flat Top Piston with Valve Relief :

The Flat Top with Valve Relief is basically a Flat Top Piston but they have small amounts of material
removed to keep the valves from hitting the piston when the intake and exhaust valves are opening or
closing. This allows for higher compression ratios by allowing the piston to go higher in to the cylinder
head.

1.4.PISTON MATERIALS

 Aluminum
 Grey cast iron
 Steel

1.4.PROPERTIES OF MATERIALS :
 ALUMINUM :
 High thermal conductivity
 Less strength
 Ductility
 Hardness
 Lightness
  GREY CAST IRON:
 Hardness
 Tougthness
 Ductility
 Elasticity

 STEEL :
 Strength
 Toughness
 Ductility
 Weldability
 Durability

1.5 METHOD OF MAKING PISTON :

 THE ROD :

The piston begins as a nine foot long, solid aluminum rod. The reason aluminum is used is
that it's lightweight, rust-proof, and easy to cut. A saw then cuts the rod into smaller pieces at varied
lengths called slugs.

 THE PUNCH :

A punch press and dye are pre-heated while the slug moves through an oven, heating it to
the same temperature as the punch press. The slug is then removed from the oven, and placed into the
punch. The press applies 2,000 tons of pressure onto the slug, forging it into the basic shape of a piston.
This process generates a lot of heat, so the piston must be air cooled for one hour.

 THE OVEN :

After the forgings cool down, they go through an oven twice more. The first time is at a
higher temperature, to strengthen the metal. The second time is at a lower temperature to stabilize it.
  THE LATHE:

A lathe is then used to cut excess metal from the basic form of the piston, taking it closer
to its finished shape. Tiny holes are then drilled into the sides, to create the oil passages for the piston.
The same lathe then impresses three rings into the top of the piston. These rings, or grooves, help the
piston glide, and allow it to form an air-tight seal.

 THE WRIST PIN HOLES:

A large hole is then drilled through both sides of the piston. This is where the wrist pin will
go, which is used to attach the piston to the connecting rod during engine assembly.

 THE MILLING MACHINE:

A milling machine then shaves up to a couple of centimeters off of each side of the piston
where the large holes were drilled for the wrist pin insertion. This is to reduce the overall weight of
the piston. Another milling machine takes some more metal off of the area where the three rings were
formed earlier, bringing the piston one step closer to its final form.

 FINISHING THE JOB:

Another lathe shaves a few more milli meters off of the top, allowing the piston to expand
when heat builds up inside of it. Then a machine engraves model and production information. A human
worker then smooths out the sharp edges of the piston created during production. The holes created
for the wrist pin are then put through a machine which smooths them, allowing the wrist pin to fit
comfortably. Finally, the pistons sprayed by hot, deionized water, removing any lubricant or oil
gathered through the manufacturing process. After they're dry, they're ready for use.
 INTRODUCTION TO CAD/CAM/CAE
The modern world of design , development ,manufacturing so on ,in which we have
stepped can’t be imagined without interference of computer .the usage of computer is such that,
they have become an integral part of these fields. In the world market now the competition in
not only cost factor but also quality, consistency, availability, packing, stocking, delivery etc.so
are the requirements forcing industries to adopt modern technique rather local forcing the
industries to adopt better techniques like CAD/CAM/CAE, etc. The possible basic way to
industries is to have high quality products at low cost is by using the computer aided engineering
(CAE), computer aided manufacturing (CAM) set up . further many tools is been introduced to
simplify & serve the requirement CATIA, PRO-E, UG are some among many. This penertration
of technique concern has helped the manufacturers to

a) increase productivity

b) shortening the lead -time

c) minimize the prototyping expenses

d) improving quality

e)designing better products

CAD: Computer Aided Designing ( Technology to create ,modify, analyse or optimize the
design using computer.)

CAE: Computer Aided Engimeering ( Technology to analyse, simulate or study behaviour of

the cad model generated using computer.)

CAM: Computer Aided Manufacturing ( Technology to plan , manage or control the operation
in manufacturing using computer.)
Need for CAD,CAE & CAM

The usage of CAD CAE & CAM have changed the over look of the industries and
developed healthy & standard comprtition, as could achieve target in lean time and ultimately
the product reaches market in estimated time with better quality and consistency. in general
view, it has lead to fast approach and creative thinking

ADVANTAGES

 Cut off of the designing time

 Cut off of the editing time
 Cut off of the manufacturing time
 high & controlled quality
 reduction of process cost
 consistency
 maintenance of universal accessing data

DRAWBACKS

 requires skilled operators

 Initial setting & assumption consumes time
 Setting cost is more
 Over heads are high and
 Applicable if productions in high
 INTRODUCTION TO CATIA

2.1 CATIA

CATIA is a robust application the enables you to create rich and complex design. The
goals of the CATIA course are to teach you how to build parts and assemblies in CATIA ,and
how to make simple drawings of those parts and assemblies. This course focuses on the
fundamental skills and concepts that enable you to create solid foundation for your design

CATIA is a mechanical design software.it is a feature -based, parametric solid

modelling design Tool that takes advantage of the easy -to-learn windows graphics user
interface. You can create fully associative 3-D Solid models with or without constraints while
utilizing automatic or user-defined relations to capture design intent. To further clarify this
definition, the italic terms above will be further defined:

Feature -Based:

Like an assembly is made up of a number of individual part, a CATIA document is made up

of individual elements. These elements are called features. When creating a document, you
can add features such as pads, pockets, holes, fillets, chamfers, and drafts. As the features are
created, they are applied directly to the work piece. Features can be classified as sketched-
based or dress-up:

 Sketched-based features are based on a 2D sketch. Generally, the sketch is transformed into
a 3D solid by extruding, rotating, sweeping, or lofting.
 Dress-up features are features that are created directly on the solid model. Fillets and
chamfers are examples of this type feature.
PARAMETRIC:

The dimensions and relations used to create a feature are stored in the model. This enables
you to capture design intent, and to easily make changes to the model through these
parameters.

Driving dimensions are the dimensions used when creating a feature. They include the
dimensions associated with the sketch geometry, as well as those associated with the feature
itself. Consider, for example, a cylinder pad. The diameter of the pad is controlled by the
diameter of the sketched circle, and the height of the pad is controlled by the depth to which
the circle is extruded.

Relations include information such as parallelism, tangency, and concentricity. This type of
information is typically communicated on drawings using features control symbols. By
capturing this information in sketch, CATIA enables you to fully capture your design intent
up front.

SOLID MODELING

A solid model is the most complete type of geometric model used in CAD systems .It contains
all the wire frame and surface geometry necessary to fully describe the edges and faces of the
model .In addition to geometric information, solid models also convey their -topology ,which
relates the geometry together .For example, topology might include identifying which faces
(surfaces) meet at which edges (curves) . This intelligence makes adding features easier. For
example, if a model requires a fillet, you simply select an edge and specify a radius to create
it.

FULLY ASSOCIATIVE

A CATIA model is fully associative with the drawings and parts or assemblies that reference
it. changes to the model are automatically reflected in the associated drawings, parts, and/or
assemblies Likewise, changes in the context of the drawings or assembly are reflected back
in the model
 CONSTRAINTS

Geometric constraints (such as parallel, perpendicular, horizontal, vertical, concentric, and

coincident) establish relationships between features in your model by fixing their positions
with respect to one another. In addition, equations can be used to establish mathematical
relationships between parameters. By using constraints and equations, you can guarantee that
design concepts such as through holes and equal radii are captured and maintained.

CATIA USER INTERFACE

Below is the layout of the elements of the standard CATIA application .

A. Menu Commands
B. Specification Tree
C. Window of Active document
D. Filename and extension of current document
E. Icons to maximize/minimize and close window
F. Icon of the active workbench
G. Toolbars specific to the active workbench
H. Standard toolbar I.Compass
I. Geometry area

Different types of engineering drawings,

construction of solid models ,assemblies of so;id parts can be done using inventor. Different
types of files used are

1. Part files: .CAT part

2. Assembly files: .CAT product

WORK BENCHES

Workbenches contain various tools that may need to access during your part creation. You can
switch between any primary workbenches using the following two ways:

A. Use the start menu.

B. Click File > New to create a new document with a particular file type. The associated workbench
automatically launches.

The parts of the major assembly is treated as individual geometric model , which is modelled
individually in separate file . All the parts are previously planned and generated feature by feature to
construct full model

Generally all CAD models are generated in the same passion given bellow :

Enter CAD environment by clicking, later into parts designing mode to construct model.

Select plane as basic reference.

Enter sketcher mode .

In sketcher mode:

Tool used to create 2-d basic structure of part using line, circle etc

Tool used for editing of created geometry termed as operation

Tool used for dimensioning referencing. This helps creaing parametric relation.

Its external feature to view geometry in and out

Tool used to exit sketcher mode after creating geometry.

SKETCH BASED FEATURE:

Pad: On exit of sketcher mode the feature is to be padded (Adding material).

Pocket: On creation of basic structure further pocket has to be created ( removing material).

Revolve: around axis material is revolved ,the structure should has same profile around axis.

Rib: sweeping uniform profile along trajectory (adding material).

Slot: sweeping uniform profile along trajectory ( removing material).

Loft: sweeping non-uniform/uniform profile on different place along linear/non-linear trajectory.

Dress up features: its 3d creation of features creates chamfer, radius,draft,shell.

Transformation feat: its tool used to move geometry, mirror, pattern, scaling in 3d environmenton
creation of individual parts in separate files.

Assembly environment: In assembly environment the parts are recalled & constrained…

Product structure tool: to recall existing components already modelled.

Constraints: assembling respective parts by means of constraints.

Update: updating the made constraints

 Additional features are exploded view, snap shots, clash analysing numbering, bill of material
etc.
 Finally creating draft for individual parts & assembly with possible details.

The parts of the major assembly is treated as individual geometry model, which is modelled
individually in separate file. All the parts are previously planned & generated feature by feature to
construct full model.

Generally all CAD model are generated in the same passion given below:

Enter CAD environment by clicking, later into part designing mode to construct model.
 ANALYSIS OF PISTON

INTRODUCTION

In order to produce a product first one should design and the product should be manufactured,
once the product is produced it has to analyze. The analysis can be done by different aspects to ensure
the life and capacity of product. Analysis of product can be carried out when it is ideal condition or
modal condition and also when some loads are applied on it. Analysis is to be performed on various
materials which were used to make a product to know the withstanding capacity of those materials so
that we can select the material which is with low deformation, stress, strain at different loads.

In this project we have analysed the piston by applying forces and boundary conditions which
is called model analysis

2.2 .COMMANDS :

 SELECT :
Select plane as basic reference

 SKETCHER :

Enter the sketcher mode in sketcher mode

 PROFILE :

Tool used to create 2-D basic structure of part using line, circle, arc etc.

 OPERATIONS :

Tool used for editing of created geometry termed as operation.

 VIEW :

Its external feature to view geometry in & out

 CONSTRAINTS :

Tool used for dimensioning referencing. this helps in creating parametric relations.
2.3 . DESIGN OF PISTON IN CATIA
LITERATURE SURVEY

 Aluminum alloys are ready to cast by all common casting techniques (Budinski 2001).
 In order to improve the wear performance, a metalbased insert is reinforced with the base alloy.
Cast iron and steel inserts normally reinforced with the light weight alloy during the casting
process. To achieve the bonding between aluminum and cast iron, special patented processes
are used. The presence of dirt and oxide induces trouble to the bonding between insert and
alloy. The component was coated with a tin layer by dipping or electro plating and subsequent
heat treatments were carried
 Gravity die casting and the pressure casting methods are used for the Al-Fin process. A special
casting technique derived from the so called Al-Fin process is used in the manufacture of
piston by gravity die casting and squeeze casting method. Al-Fin process is also known as Al-
Fer process which is achieved by diffusion bond between the insert and aluminum alloy.
 Zone Ching Lin and Din yan chen (1995) studied on Cubic Boron Nitride (CBN) a sintered
product, turning and for higher productivity.
OBJECTIVES :

 The main objective is to design a piston by using software catia

 Static structural analysis and steady state thermal analysis is carried out by using software ansys

 Variation of rate maximum stress, maximum shear stress, maximum strain by keeping pressure
constant for different materials
 Variation of temperature distribution and heat flux by keeping constant maximum and
minimum temperatures for different materials
REFERENCES

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Influence on Secondary motion,International Journal of Engineering Research and Applications
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Performance, NADCA, 2009

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[13]. A Textbook on “Internal Combustion Engines” by V. Ganesan.

[14]. “Fundamentals of Internal Combustion Engines” by H.N.Gupta.

[15]. “Internal Combustion Engine Fundamentals” by John B.Heywood.

[16]. Mahdi Hamzehei, Manochehr Rashidi, “Determination of Piston and Cylinder Head Temperature
Distribution in a 4-Cylinder Gasoline Engine at Actual Process”.

[17]. Sachin Pente, Nitin Wankhade, Prasad Hatwalne, “Comparative investigation of vibration
analysis of VCR diesel engine for different types of grey cast iron”.

[18]. A. Krishna priya, A. Gopichand, V.S.Gangadhar, B.B.Vasanth, Y. Tejo Ram Charan, Arun Peri,
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