International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 11 Issue: 05 | May 2024
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p-ISSN: 2395-0072
Topology Optimization for Higher Thermal Efficiency and Resisting Higher Mechanical Load of the Piston Narayanan S1, Sivaganesh A2, Vignesh V3, Gokulakumar K4, Syed Alam M5, Prithish Kanna S6 1Head of the Department, Department of Mechanical Engineering, Rajiv Gandhi College of Engineering &
Technology, Puducherry, India
2,3,4,5,6Student, Department of Mechanical Engineering, Rajiv Gandhi College of Engineering & Technology,
Puducherry, India ---------------------------------------------------------------------***---------------------------------------------------------------------1.2 Design and Analysis Abstract - This paper describes the comparative study of pistons made of three different materials by using Finite Element Method (FEM) and attempts to increase the properties of piston used in Supercars. The parameters used for the analysis are pressure, temperature and many other material properties of piston. The specifications used for the study of these pistons belong to four stroke six cylinder engine of Toyota GR Supra 2998cc. This project represents the procedure for analytical design of Al2618, Al4032 and Ti-3Al-8V-6Cr-4Mo-4Zr alloy piston. The dimensions are obtained and a 3-D CAD model on Solid Works (2022) is prepared. Static structural and thermal stress analyses are performed by using ANSYS 2023R1. The results predict the maximum stress, strain, total deformation and heat flux on the pistons using FEA. The best material is then selected on basis of these results and a comparison is made with the titanium alloy to find out whether the titanium alloy is better than aluminium alloy.
The main objective of piston design is to predict the pressure and temperature distribution on the body of piston. Most of the car pistons are made up of aluminium alloy which has better thermal expansion coefficient. Also, to improve mechanical efficiency and reduce inertia force in high-speed machines, the weight of the piston also plays a major role. Finite Element Analysis Finite element analysis is a computerized method for predicting how a piston reacts to real-world forces, vibration and heat. It is used to reduce the number of physical prototypes, experiments and optimize components in their design to develop better products. Finite element analysis shows whether a product will break, wear out or work as it was designed. FEA works by breaking down a real object into a large number of finite elements (Meshing). FEA helps predict the behaviour of products affected by many physical effects including stress, strain, deformation, temperature, heat transfer etc.
Key Words: Alloys, Pistons, Al2618, Al4032, Ti-3Al-8V6Cr-4Mo-4Zr, Stress, Deformation, Analysis
1. INTRODUCTION 1.1 Engine Piston
There are lots of research works proposing for engine pistons, new geometries, materials and this evolution has undergone with a continuous improvement over the years and required thorough examination of the smallest details.
Engine pistons are the most complex and important part of an engine. The function of the piston is making the crankshaft rotation by using pressure generated in combustion chamber. Piston works in higher temperature, higher pressure, more speed and less lubrication conditions. Piston works with cyclic gas pressure and the inertial forces and this condition may cause the fatigue damage of piston such as side wear, head cracks etc.
2. PROBLEM DEFINITION Aluminium alloys are used in the pistons of supercars. The operating pressure and temperatures are very high in such cars and this material struggles to sustain and work in such conditions. That so we introducing titanium alloy piston. The objective of the present work is to design and analyse piston made of Al2618, Al4032 and Ti-3Al-8V-6Cr4Mo-4Zr alloys, compare the analysis results, find the best material amongst them and choosing that the titanium alloy is a suitable option.
Piston in an IC engine must had the following characteristics:
Strength to resisting gas pressure Must have minimum weight Must be able to reciprocate with less noise Must have required bearing area to prevent wear Must disperse the heat generated during combustion Must have good resistance to distortion under heavy forces and high temperature.
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