IC Engine Piston Design and Analysis Using Catia-Ansys Software

June 29, 2024 Roberto Magalhães

IC Engine Piston Design and Analysis Using Catia-Ansys Software

Abstract:

This project mainly deals with the design, analysis and manufacturing of piston. The piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders, among other similar mechanisms. In an engine, its purpose is to transfer force from the expanding gas in the cylinder to the crankshaft via a piston rod and/or connecting rod. Here, the piston is designed, analyzed and the manufacturing process has been studied.

Piston temperature has considerable influence on the efficiency, emission and performance of the SI engine. The aim of the investigation is to measure the transient temperature of the piston at various points on the piston from cold start to stationary condition and compare it with the results of finite element analysis.

In this project, the piston is modeled and assembled with the help of CATIA software and the component is meshed and analysis is done in ANSYS software and the thermal and static behavior is studied and the results are tabulated. The various stresses acting on the piston under various loading conditions were studied.

In the presented thesis, work was carried out in the following aspects to cover research gaps and present results based on systematic studies:

1) Temperature distribution and heat flow through the piston of an engine.

2) FEA analysis of the piston to measure the temperature at points where it is not possible to know in practice and observe the heat flow inside the piston.

INTRODUCTION

The modern trend is to develop IC engines with higher power capacity. One of the design criteria is the effort to reduce the weight of the structures and thus reduce fuel consumption. This was made possible by the improved engine design. These improvements include the increased use of lightweight materials such as advanced ultra-high tensile strength steels, aluminum and magnesium alloys, polymers and carbon fiber reinforced composite materials. Integrating lighter materials is especially important if more complex parts can be manufactured as a single unit. Over the next 10 to 20 years, a further 20 to 40% reduction in total weight appears possible without sacrificing safety. Cuddy et al (1997) reported that for every 10% reduction in vehicle weight, an improvement in fuel consumption of 6–8% is expected. Improved engine design requires optimized engine components. Therefore, sophisticated tools are needed to analyze engine components. The engine piston is one of the most analyzed components among all automotive or other components.

industry field components. The engine can be called the heart of an automobile and the piston can be considered the most important part of an engine.

DESIGN PROCEDURE:

Computer-aided design or CAD has a very broad meaning and can be defined as the use of computers in creating, modifying, analyzing and optimizing a design. CAE (Computer Aided Engineering) is referred to computers in engineering analysis such as stress/strain analysis, heat transfer and flow. It is said that CAD/CAE has more potential to radically increase productivity than any development since electricity. CAD/CAE build quality shape concept

to the final product. Instead of introducing quality control during final inspection, it helps to develop a process in which quality is present throughout the product's life cycle. CAD/CAE can eliminate the need for prototypes. But prototypes are needed that can be used to confirm and predict performance and other characteristics. CAD/CAE is employed in various industries such as manufacturing, automotive, aerospace, foundry, mold making, plastic

electronics and other general-purpose industries. CAD/CAE systems can be broadly divided into low-cost, medium-cost and high-cost systems.