INTERNATIONAL JOURNAL FOR RESEARCH & DEVELOPMENT IN
TECHNOLOGY
Design and Analysis of the Piston For Four Different
Materials by Using Catia and AnsysSoftwares
__________________________________________________________________________________________
Shaik.Moulali1,Ch.Raviteja2,L.Nagaraju3,N.Suneel Kumar4
1,2,3
Department of Mech, 4Department of Mech, Assistant Professor, Gandhiji Institute of Science and Technology, India
Abstract – In IC engines maximum parts are functioning
with high variations in the properties such as pressure,
temperature and thermal stresses incurred by the momentum
at higher rates. These higher variations lead to reduce the
engine’s life which is uneconomical. By studying these
variations in detail, it was observed happening due to rapid
changes in the properties of Piston. The various efficiencies
of an IC engine are influencing by the Piston speed. The
functioning method of piston is more significant in deciding
the remaining properties.Inthis criteria, the role of Piston
design to be viewed with attention. The modeling of Piston
design from various aspects is more informative and
advantageous. The main objective of this work is to
investigate and analyze the stress distribution of Piston. Four
different materials (A2618 material, A4032material,
AluminumFlyash alumina and AMC225XE material) are
selected in manufacturing the Pistons to study of structural
and thermal analysis from various aspects in detail and
depth.In the systematic analysis and study of Piston specific
properties the pressure and temperatures applied on the
surface of the Piston are 1.5MPa and 4000C. At this stage
the properties of these four materials analysed for better
material to be selected by the systematic modeling, analysis
and behavioral study. The design of piston carried out by
using Solid works software, Static and thermal analysis by
using Finite Element Analysis (FEA).
I. INTRODUCTION
A piston is a component of reciprocating IC engine. It is the
moving component with in a cylinder and is made of gas-tight
by piston rings. In an engine, piston is used to transfer force
from expanding gas in the cylinder to the crankshaft via piston
rod. Piston endures the cyclic gas pressure and the inertial
forces at work. In this project the parameters selected are
analysis of piston by applying pressure force acting at the top
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Volume-9,Issue-3(Mar-18)
ISSN (O) :- 2349-3585
of the piston and thermal analysis of piston at various
temperatures at the top of the piston in various strokes. This
analysis could be useful for design engineers for modification
of piston at the time of design. There are significant research
works proposing, for engine pistons designs, new geometries,
materials and manufacturing techniques, and this evolution
has undergone with a continuous improvement over the last
decades and required thorough examination of the smallest
details. Engine pistons are one of the complex components
and its damage mechanisms have different origins and are
mainly wear, temperature, and fatigue related. Among the
fatigue damages, thermal fatigue and mechanical fatigue,
either at room or at high temperature, play a prominent role.
For mechanical fatigue analysis we have considered vibration
analysis of the piston and used finite element method ANSYS
15.0. The piston is a „heart‟ of an automobile engine. It‟s one
of the key components of the engine and it‟s working the hard
condition. The function of the piston is bearing the gas
pressure and making the crankshaft rotation through the piston
pin. The instantaneous temperature can be up to 2500K.
Because of the high temperature and the poor cooling
condition, the temperature of the top of the piston can reach
600~700K when the piston working in the engine and the
temperature distribution is uneven
A.Piston
A single piston free-piston engine is shown in Fig. 1. This
engine essentially consists of three parts a combustion
cylinder, a load device, and a rebound device to store the
energy required to compress the next cylinder charge. In the
engine shown in the figure the hydraulic cylinder serves as
both load and rebound device, whereas in other designs these
may be two individual devices, The rebound device may give
the opportunity to accurately control the amount of energy put
into the compression process and thereby regulating the
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Paper Title:-Design and Analysis of the Piston For Four Different Materials by Using Catia and AnsysSoftwares
compression ratio and stroke length.
Fig 1.Single piston hydraulic free-piston engine
B. Dual Piston
The dual piston (or dual combustion chamber) configuration,
shown in Fig 2, has been topic for much of the recent research
in free-piston engine technology. A number of dual piston
designs have been proposed and a few prototypes have
emerged both with hydraulic and electric power output. The
dual piston engine configuration eliminates the need for a
rebound device, as the (at any time) working piston provides
the work to drive the compression process in the other
cylinder. This allows a simple and more compact device with
higher power to weight ratio.
Fig.2.Hydraulic dual piston free-piston engine
C. Opposed Piston
An opposed piston free-piston engine essentially consists of
two single piston units with a common combustion chamber.
Each piston requires a rebound device, and a load device may
be coupled to one or both of the pistons. Figure 3 shows an
opposed piston free-piston engine, with a mechanical piston
synchronization mechanism.
Fig 3.Opposed piston free-piston engine with piston
synchronization mechanism
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D.Gas Generators
The only „load‟ for the engine itself is that to supercharge the
intake air, the output work is taken out entirely from the power
turbine. Free-piston gas generators were used in some large-
scale marine and stationary power plants in the mid-20th
century, and attempts were made to use this principle in
automotive applications. Figure 4 illustrates an opposed piston
free-piston gas generator plant.
Fig.4. Illustration of a free-piston gas generator
II.ALUMINA
Introduction to Aluminum -Fly ash-Alumina Composite:
Engine Piston is most complex part compared to other
components in an automobile sector. Still lot of research
works have been conducting on piston regarding material
composition, geometry and manufacturing technique. And
hence to avoid this case pistons are made up of cast aluminum
alloy matrix with the combination of reinforcements in
different weight percentage. For better results here I am
replacing conventional piston material LM13- TF with new
composite [Al6061 +Al2O3 + FLY ASH]. The addition of Fly
ash and Alumina reinforcement particles to the Aluminum
matrix improves the tensile strength, compressive strength and
hardness behaviour
Fig: 5 Al6061 +Al2O3 + FLY ASH
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Paper Title:-Design and Analysis of the Piston For Four Different Materials by Using Catia and AnsysSoftwares

TF with new composite [Al6061 +Al2O3 + FLY ASH]. The do = outer diameter of piston pin (mm)
addition of Fly ash and Alumina reinforcement particles to the Mechanical efficiency of the engine (η) = 70 %.
Aluminum matrix improves the tensile strength, compressive Η = Brake power (B.P)/ Indicating power (I.P)
Strength and hardness behavior. Therefore, I.P = B.P /η
Material properties: = 14.9/0.9
Density: 2.7gm/Cc = 16.55 KW
Elastic Modulus: 68.9gpa Also, I.P = P x A x L x N /2
Yield Strength: 276mpa I.P = P x π D2/4x L x N / 2
Ultiate Tensile Strength: 330mpa Substituting the values we have,
Fatigue Strength: 96.5mpa
Poissons Ratio: 0.33 16.55×1000 = ×(0.0662)×

METHODOLOGY P=1.3566 Mpa

Let, IP = indicated power produced inside the cylinder (W) Maximum Pressure = Pmax=10 × P

N = engine speed (rpm) = 10 × 1.356

L = length of stroke (mm) = 13.56 Mpa

A = cross-section area of cylinder (mm2) PROCEDURE FOR DESIGN OF PISTON

mp = mass of the piston (Kg)

V = volume of the piston (mm3) tH =
tH = thickness of piston head (mm) Where: p is the maximum gas pressure (Mpa)
D = cylinder bore (mm) D is the bore diameter (mm)
Pmax = maximum gas pressure or explosion pressure (MPa) 𝛔t is the permissible stress (Mpa)
σt = allowable tensile strength (MPa)
σut = ultimate tensile strength (MPa) t1=D×
K = thermal conductivity (W/m K) Where Pw is the Pressure of fuel on cylinder wall
Tc = temperature at the centre of the piston head (K) (0.025N/mm2-0.042N/mm2)
Te = temperature at the edge of the piston head (K) t2 = 0.7t1 to t1
HCV = Higher Calorific Value of fuel (KJ/Kg) = 48000 Or
KJ/Kg
BP = brake power of the engine per cylinder (KW) t2 =
C = ratio of heat absorbed by the piston to the total heat Where: nr is the number of rings
developed in the cylinder = 5% b1 = tH to 1.2 tH
t1= radial thickness of ring (mm) b2 = 0.7t2 to t2
Pw = allowable radial pressure on cylinder wall (N/mm2) = t3 = 0.03×D+t1─4.9
0.025 Mpa 1s = (0.6D to 0.8D)
σp = permissible tensile strength for ring material (N/mm2) = do = (0.28D to 0.38D)
110 N/mm2 The geometric values considered design of piston in solid
t2 = axial thickness of piston ring (mm) works 2013
b1 = width of top lands (mm) Table 1: Geometric values
b2 = width of ring lands (mm) S.NO DIMENSIONS SIZE(
mm)
t3 = thickness of piston barrel at the open end (mm)
1 Cylinder bore(D) 65.5
ls = length of skirt (mm) 2 Thickness of the piston head (tH) 8.03

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Paper Title:-Design and Analysis of the Piston For Four Different Materials by Using Catia and AnsysSoftwares
3 Radial thickness of ring (t1) 1.710
4 Axial thickness of ring (t2) 2.183
5 Width of top land (b1) 8.03
6 Width of other land (b2) 2.183
7 Maximum thickness of barrel (t3) 8.575
8 Length of the skirt (1s) 39.3
9 Piston pin diameter (do) 18.34
III CATIA V5R20
CATIA (Computer Aided Three Dimensional Interactive
Application). As a new user of this software package, you will
join hands with thousands of users of this high-end
CAD/CAM/CAE tool worldwide. If you are already familiar
with the previous releases, you can upgrade your designing
skills with the tremendous improvement in this latest release.
CATIA V5, developed by Dassault Systems, France, is a
completely re-engineered, Next-generation family of
CAD/CAM/CAE software solutions for Product Lifecycle
Management. Through its exceptionally easy-to-use and state-
of-the-art user interface.
CATIA V5 provides three basic platforms:P1, P2, and P3.
P1 is for small and medium-sized process-oriented companies
that wish to grow toward the large scale digitized product
definition.
P2 is for the advanced design engineering companies that
require product, process, and resource modeling.
P3 is for the high-end design applications and is basically for
Automotive and Aerospace Industry, where high quality
surfacing or Class-A surfacing is used. The subject of
interpretability offered by CATIA V5 includes receiving
legacy data from the other CAD systems and even between its
own product data management modules.
IV. Geometric Constraints
Geometric constraints are the logical operations performed on
the sketched elements to define their size and position with
respect to the other elements. These are two methods to apply
geometric constraints, automatic and manual. While drawing
the sketch, some constraints are automatically applied to it.
For applying constraints manually, you need to invoke the
constraints defined in dialog box tool and select the
appropriate check box.
Distance: This constraint is used to apply a distance
dimension between any two selected entities.
Length: This constraint is used to apply a linear dimension to
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the selected line.
Angle: This constraint is used to apply an angular dimension
between any two selected lines.
Radius / Diameter: This constraint is used to apply a radius
or diameter dimension to the selected circular entity.
Semi major axis: This constraint is used to apply a dimension
to the major axis of the selected ellipse.
Semi minor axis: This constraint is used to apply a dimension
to the minor axis of the selected ellipse.
Symmetry: This constraint is used to force the selected
sketched entities symmetrical about an axis. A line segment
can be used as an axis.
Midpoint: This constraint forces a selected point to be placed
on the midpoint of the selected line.
Equidistant point: This constraint forces a selected point to
be placed at an equal distance from any two preselected
points.
Fix: This constraint is used to fix a selected entity in terms of
its position with respect to the coordinate system of the current
sketch.
Coincidence: This constraint is used to make two points, two
lines, a point and a line, or a point and a curve coincident.
Concentricity: This constraint is used to make two circles,
arc, an arc and a circle, a point and a circle, or a point and an
arc concentric.
Tangency: This constraint is used to force the selected line
segment or curve to become tangent to another curve.
Parallelism: The parallelism constraint is used to force any
two selected line segments to become parallel to each other.
The selected line segments can be axes also.
Perpendicular: The perpendicular constraint is used to force
any two selected line segments to become perpendicular to
each other. The selected line segments can be axes also.
Horizontal: The horizontal constraint forces the selected line
segment to become horizontal.
Vertical: The vertical constraint forces the selected line
segment to become vertical.
Assembly Constraints: The constraints in the assembly
design work bench are the logical operations performed to
restrict the degrees of freedom of a component and to define
its precise location and position with respect to the other
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Paper Title:-Design and Analysis of the Piston For Four Different Materials by Using Catia and AnsysSoftwares
components in the assembly. The constraints in this
workbench are discussed next.
Coincidence: This constraint is used to force two selected
entities to coincide with each other. The Selected entities can
be central axes of circular components, two adjacent or
opposite Faces or two adjacent planes.
Contact: This constraint is used to force two selected faces to
maintain contact with each other.
Offset: This constraint is used to place two different selected
faces, planes, or central axes at a distance with respect to each
other.
Angle: This constraint is used to place two selected entities at
an angle with respect to each other. These entities can be the
central axes of circular components, two faces, two planes, or
a combination of an axis and a face, a plane and a face, or an
axis and a plane.
Fix: This constraint fixes the position of the selected part in
the 3D space.
Fix Together: This constraint fixes the position of two
different selected parts with respect to each other.
Quick: The quick constraint tool is used to apply the most
appropriate constraint to the elements in the current selection
set. You can set the priority depending on which CATIAV5
will perform the constraint selection
Part Body: The Part Body is the default body in the part
design workbench. All solid related features, such as pad,
pocket, shaft, and so on are placed inside it. Other bodies that
will be inserted under the part design work bench will be
named as Body.2, Body.3, and so on.
Geometrical Set: The geometrical set is defined as a body
that includes the newly created planes, surfaces, wireframe
elements, and reference elements.
Wireframe: The wireframe construction elements aid in
creating surfaces. They generally consist of points, lines, and
arcs, and are used as substitutes of entities drawn in the
sketcher workbench.
Surface: Surfaces are geometric features which have no
thickness. They are used to create complex shapes that are
difficult to make using solid features. After creating a surface,
you can assign a thickness to it to convert it into a solid body.
Feature: A feature is defined as a basic building block of a
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solid model. The combination of various features results in a
complete model. In the part design work bench of CATIA V5,
the features are of the following four types:
• Sketch-Based Features
• Dress-Up Features
• Transformation Features
• Surface-Based Feature
Reframe on: Sometimes, a feature, a body, or a sketch may not
be visible in the available space of the geometry area. The
reframe on option is available in the contextual menu is used
to view the particular selection in the available display space.
Centre Graph: The centre graph option available in the
contextual menu is used to bring the selected feature, body, or
sketch in the Specification tree to the middle left portion of the
geometry area
V. Design Procedure in Catia
Create the half piston profile in sketcher workbench next go to
exist work bench (part design) now go to the sketched based
features and go to shaft option apply angle 360 after create the
planes offset to x y planes create the circles and apply pocket
around the up to surface now go to mirror option apply mirror
finally as shown the figure 6 below
Fig: 6 Piston Final Output
V.RESULTS
The constructed piston in catia is analyzed using ANSYS 15.0
and the results are depicted below. Combustion of gases in the
combustion chamber exerts pressure on the head of the piston
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Paper Title:-Design and Analysis of the Piston For Four Different Materials by Using Catia and AnsysSoftwares
during power stroke. Fixed support has given at surface of
pinhole. Because the piston will move from top dead center to
bottom dead center with the help of fixed support at pinhole.
Fig 7.Total deformation
Fig 8. Heat flux
Graph.2 Stresses Between Four Materials
Graph 3 Heat Flux Between Four Materials
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VI. CONCLUSION
The piston plays a major role in the performance of the engine
performance, materials of the piston is made up of impacts the
strength of the piston. we are selected three materials, A4032,
A2618, AMC225XE, ALUMINIUM FLYASH ALUMINA
and we finally find our von-misses stress, deformation and
heat flux, and we created Maximum pressure load at the top
surface of the piston crown 13.56 Map on three materials, and
we created Temperature at the top surface of the piston crown
15000 C According to the results obtained from Ansys
AMC225XE material for piston is selected. In the analysis
deformations, stresses and heat flux. AMC225XE is having
low deformation and high heat flux properties compare to
other 3 materials. As per above results piston with
AMC225XE is having high heat flux value than traditional
materials. As per analysis values AMC225XE is having good
value so we can use AMC225XE.
ACKNOWLEDGMENT
I express my sincere gratitude to Mr.N.Suneel Kumar,
Department of Mech , GIST college, India and also thanks to
for continuous guidance and other Professors of Department
of Mechanical Engineering, GIST, India for extending their
help & support in giving technical ideas about the paper
without which I would not come up with this paper.
REFERENCES
1.“Thermal analysis of aluminum alloy piston” by
B.A.Devan1, G. Reminder Reddy2 International Journal of
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Piston Alloys Using FEA” Ajay Raj Singh, Dr.Pushpendra
Kumar Sharma, Int. Journal of Engineering Research and
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January 2014, pp.94-102

3. “Thermal Stress Analysis of a Speculative IC Engine piston
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