International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
Thermal Analysis of Different Piston Head
Profiles by Using FEM
[Link] krishna1, [Link] Naidu2, [Link] Kumar3
1
Mtech Scholar, Mechanical Engineering Dept, Visakha Institute of Engineering and Technology
2,3
Assistant Professor, Mechanical Dept, Visakha Institute of Engineering and Technology, VSKP.
Abstract
The objective of this research work is to optimize the stress variations at the top of the piston in real
engine conditions. During this pressure analysis on the examined surface of the piston, the thermal
behavior is examined. The operating gas pressure, temperature and piston material functions are used as
investigation functions. The analyzes carried out showed that the upper part of the piston could be
damaged or broken due to the temperature caused by the working conditions, as the replacement of
damaged or non-functioning parts is very expensive and usually difficult to obtain. Concave and convex
piston profile designed in Solid Work 2023, used to design the piston geometry and for FEM analysis to
optimize the thermal behavior of the used ANSYS R23.0 piston. Aluminum alloy and gray cast iron
material for piston construction. Stress and displacement are analyzed for the piston by applying
pressure to it in the structural analysis. By observing the results of the analysis, we can decide whether
the piston we are designing is safe or not under the applied load conditions. Heat flow and thermal
temperature distribution are analyzed using piston surface temperatures in thermal analysis.
Keywords: Concave, convex piston, Solid, ANSYS R23.0, Aluminum Alloy, Thermal analysis, FEM.
1. Introduction
Nowadays, automotive components are in high demand due to the increasing use of automobiles. The
increase in demand is due to the improved performance and lower cost of these components. R&D and
test engineers must develop critical components as quickly as possible to minimize time to market for
new products. This requires understanding new technologies and rapidly adopting new product
developments. A piston is a component of reciprocating internal combustion engines. The piston
converts the energy of the expanding gases into mechanical energy. The piston slides in the cylinder
liner or sleeve. Pistons are generally made of aluminum alloys or cast iron. To prevent combustion gases
from passing the piston and minimize friction, each piston is surrounded by several metal rings. These
rings act as a seal between the piston and the cylinder wall and also reduce friction by minimizing the
contact area between the piston and the cylinder wall. The piston design must be rigid enough to prevent
mechanical and thermal deformation and must have sufficient bearing surface to prevent excessive wear.
The piston was designed with resistance and temperature considerations in mind. The strength of the pin
must be sufficient to resist shear fracture. During combustion, the piston undergoes deformation, and the
energy stored in it is a crucial factor in the performance and failure conditions of a piston under static
load. The production of Von Misses yield stress can be formulated as Von Misses stress or equivalent
tensile stress; A scalar stress value can be calculated from the stress tensor.
IJFMR230611430 Volume 5, Issue 6, November-December 2023 1
International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
a) Fundamental of Piston
A piston is a cylindrical metal element that moves back and forth within the cylinder and applies force to
the fluid in the cylinder. The pistons have outer rings that prevent oil from entering the combustion
chamber and fuel and air from escaping from the oil. Most pistons mounted in a cylinder are equipped
with piston rings. There are typically two spring-loaded compression rings that act as a seal between the
piston and the cylinder wall, as well as one or more oil control rings below the compression rings. The
top of the piston may be flat, curved or otherwise shaped. Pistons can be made by forging or casting
processes. The piston profile is usually rounded but can vary. Figure 1 shows the structure of the piston
engine. The piston is the main element of a piston machine and pneumatic-hydraulic systems.
Figure 1: Schematic Diagram of Piston
2. Piston Design
The piston is designed according to the procedure and specification which are given in machine
design and data reference books.
Figure 2: Drawings of the Piston
3. Finite Element Analysis
To perform a finite element study of the piston when gas pressure is applied to it, a structural study is
performed using ANSYS Workbench R23.0. In this phase the examination of the piston is static and
IJFMR230611430 Volume 5, Issue 6, November-December 2023 2
International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
linear. When small changes in stiffness occur, there is no change in the direction of loading, the
materials remain in the linear flexible region, and deformations and mineral stresses appear. The piston
model is designed in Solid Work 2023 and saved in this file as *.igs, then imported into ANSYS
Workbench.
The experimental piston model was analyzed by ANSYS, which is linked to the commercially used
engineering simulation software package, providing a comprehensive assembly that expands the entire
variety of physics and gives the right to use in almost various fields of engineering applications requiring
a design method. The software package uses its own tools to put a virtual product through a rigorous
testing process, such as testing a piston model under various loading conditions, before it becomes an
extraordinary object.
4. Material properties of piston material
Piston analysis performed by using Aluminum alloy and Grey cast iron alloy as the piston material.
Composition of Aluminum alloy and Grey cast iron alloy grade is shown in Table 2.
5. Results and Discussion
a) Analyzing the model in ANSYS:
After designing the model in solid work, IGS FILE has been converted to IGES format. This
configuration allows the design to be compatible in the ANSYS software. After importing the design in
ANSYS, the process of analysis begins
Figure 3: Design Model of Concave and convex profile piston
Figure 4: Meshed view of piston models
IJFMR230611430 Volume 5, Issue 6, November-December 2023 3
International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
b) Meshing the model:
Mathematically, the piston model to be examined is decomposed into a network of finite-dimensional
elements of simple shape. It is assumed that the displacement difference within each component is
calculated using simple polynomial profile functions and nodal displacements. Strain and stress
equations are created using unknown nodal displacements. From there, the balance equations are
assembled into a matrix form that can be easily programmed.
c) Boundary conditions for analysis of S.I. engine piston using ANSYS
After the piston is meshed, we need to apply the suitable boundary condition under which the thermal
Analysis will be performed
Figure 5: Piston with Convex Head profile
Figure 6: Piston with Concave Head profile
d) Static Analysis results of Piston
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International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
6. Thermal Analysis of Piston Using ANSYS
Thermal analysis is a set of methods used to calculate the variation of a physical property of a material
as a function of temperature. The most commonly used methods are those that calculate changes in mass
or energy of a material model. The figures show the temperature curve between different piston heights
in steady state conditions and the applied boundary conditions are shown. Maximum temperatures at the
summit.
After solution processing, the contours of total strain and equivalent elastic strain are recorded in the
static structural analysis. On the other hand, in the transient thermal analysis, the temperature and total
heat flux were present. These structural and thermal analysis results are obtained for concave (cup) and
convex (dome) pistons.
a) Piston profile with concave head with Aluminium Materials
Figure 7: Thermal Analysis of Aluminium alloy piston with concave head profile
b) Piston profile with concave head with Grey cast iron Material
Figure 8: Thermal Analysis of Grey cast iron piston with concave head profile
IJFMR230611430 Volume 5, Issue 6, November-December 2023 5
International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
c) Piston profile with Convex head with Aluminum Material
Figure 9: Thermal Analysis of Aluminium alloy piston with convex head profile
d) Piston profile with Convex head with Grey cast iron Material
Figure 10: Thermal Analysis of Grey cast iron piston with convex head profile
Figure 11: Comparison of Heat flux b/w concave and convex piston profile
IJFMR230611430 Volume 5, Issue 6, November-December 2023 6
International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
Figure 12: Comparison of Temperature variations on Top surface of piston
7. Conclusion
The piston plays an important role in engine performance; The piston material is made by changing the
resistance of the piston. As expected, for both materials the highest force intensity is recorded in the
elastic band. It got the maximum displacement on top of the aluminum alloy and gray cast iron piston.
The higher maximum force in the piston temperature is due to the thermal conductivity of the material,
and the maximum heat flux is absorbed in both piston materials. Therefore, in-depth research can be
carried out using advanced materials and various analysis methods and tools. In the designs for which
the analyzes are performed, the total stresses and strains observed in the concave-shaped piston are
greater than those observed in the convex-shaped piston. This demonstrates the use of hollow or copper-
shaped pistons in internal combustion engines using diesel in furnaces and large engines.
From the above study it is concluded that the total heat flux in the aluminum alloy hollow piston was
10.64W/mm2 and the minimum temperature on the surface of the hollow piston was 154.390°C. In this
analysis, it is concluded that the hollow piston type has better thermal properties. Therefore, the
experimental results show that the hollow piston head has better thermal properties to design the piston
according to the thermal conditions of the material. The analysis performed is presented in Ansys
Analysis R23.0. These results are based on the finite element method. Therefore, a more in-depth
investigation can be carried out using advanced materials and various analysis methods and tools.
8. REFERENCES
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International Journal for Multidisciplinary Research (IJFMR)
E-ISSN: 2582-2160 ● Website: [Link] ● Email: editor@[Link]
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