Design and Analysis of IC Engine Piston, Piston Rings and Connecting Rod 1 2 3 4 5 6 G

ISSN 2348–2370 Vol.10,Issue.04, April-2018, Pages:0342-0347

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Design And Analysis of IC Engine Piston, Piston Rings and Connecting Rod 1 2 3 4 5 6 G. MANUSHA , G. KAVYA , K. S. J. SADHANA , NASEER AHMED , SD. INTHIYAZ , T. HARISH BABU Dept of Mechanical Engineering, SVITS, Mahbubnagar, Telangana, India.

Abstract: This project mainly deals with the design and expanding gas in the cylinder to the crankshaft via a piston analysis of I.C engine piston, piston rings and connecting rod and/or connecting rod. rod. Piston is a component of reciprocating engines, reciprocating pumps, gas compressors and pneumatic A. Piston cylinders among other similar mechanisms. In an engine, its A piston is a component of reciprocating engines, purpose is to transfer force from expanding gas in the reciprocating pumps, gas compressors and pneumatic cylinder to the crankshaft via a piston rod or connecting rod. cylinders, among other similar mechanisms. For this project, there are two basic requirements. The first requirement is to design of a model of I.C engine piston, piston rings and connecting rod. The second requirement is to analyze of I.C engine piston, piston rings and connecting rod by the method, such as following a track, which consists of straight lines and curves. These systems are done by modeling software’s like CatiaV5, and analysis is done by Ansys software. Specifications of a product are detailed in terms of the product size, speed range, weight and power consumption. Here the piston is designed; analyzed and has been studied. Piston temperature has considerable influence on efficiency, emission, performance of the engine. Purpose of the investigation is measurement of piston transient temperature at several points on the piston, from cold start to steady condition and comparison with the results of finite It is the moving component that is contained by element analysis. Even though the program worked well, a cylinder and is made gas-tight by piston rings. In an there were some errors that were identified after testing, engine, its purpose is to transfer force from expanding gas resulting in increased performance. In this project work has in the cylinder to the crankshaft via a piston rod and/ been taken up on the following aspects to cover the research or connecting rod. In a pump, the function is reversed and gaps to present the results based on the systematic force is transferred from the crankshaft to the piston for the studies. Temperature distribution and heat flow through the purpose of compressing or ejecting the fluid in the cylinder. piston of the engine, FEA analysis of the piston to measure In some engines, the piston also acts as a valve by covering temperature at the points where it is not possible to find out and uncovering ports in the cylinder wall. The petrol enters practically and to observe the heat flow inside the piston. inside the cylinder and the piston moves upwards and the spark plug produces spark and the petrol is set on fire and it Keywords: IC Engine Piston, Piston Rings, FEA. produces an energy that pushes the piston downwards.

I. INTRODUCTION B. Piston ring Automobile components are in great demand these days A piston ring is a split ring that fits into a groove on the because of increased use of automobiles. The increased outer diameter of a piston in a reciprocating engine such as demand is due to improved performance and reduced cost of an internal combustion engine or steam engine. The three these components. R&D and testing engineers should main functions of piston rings in reciprocating engines are: develop critical components in shortest possible time to 1. Sealing the combustion chamber so that there is minimize launch time for new products. This necessitates minimal loss of gases to the crank case. understanding of new technologies and quick absorption in 2. Improving heat transfer from the piston to the development of new products. A piston is a component the cylinder wall. of reciprocating IC-engines. It is the moving component that 3. Regulating engine oil consumption by scraping oil from is contained by a cylinder and is made gas-tight by piston the cylinder walls back to the sump. rings. In an engine, its purpose is to transfer force from

An internal combustion engine is acted upon by the C. Connecting rod pressure of the expanding combustion gases in In a reciprocating piston engine, the connecting rod the combustion chamber space at the top of the cylinder. connects the piston to the crank or crankshaft. Together with the crank, they form a simple mechanism that converts This force then acts downwards through the connecting reciprocating motion into rotating motion. Connecting rods rod and onto the crankshaft. The connecting rod is attached to the piston by a swiveling gudgeon pin (US: wrist pin). may also convert rotating motion into reciprocating motion. This pin is mounted within the piston: unlike the steam Historically, before the development of engines, they were engine, there is no piston rod or crosshead (except big two first used in this way. stroke engines).

As a connecting rod is rigid, it may transmit either a push or a pull and so the rod may rotate the crank through both halves of a revolution, i.e. piston pushing and piston pulling. Earlier mechanisms, such as chains, could only pull. In a few two-stroke engines the connecting rod is only required Gas sealing is achieved by the use of piston rings. These to push. are a number of narrow iron rings, fitted loosely into II. LITERATURE REVIEW grooves in the piston, just below the crown. The rings are There is a vast amount of literature related to Finite split at a point in the rim, allowing them to press against the Element Analysis of shape optimization of connecting rod. cylinder with a light spring pressure. Two types of ring are The literature review presented here considers the major used: the upper rings have solid faces and provide gas development in implementation of FEA. The main objective sealing; lower rings have narrow edges and a U-shaped of this study was to explore opportunities for a I.C engine profile, to act as oil scrapers. There are many proprietary piston, piston rings and connecting rod. Typically, an and detail design features associated with piston rings. Oil optimum solution is the minimum or maximum possible control rings typically are of three types: value the objective function could achieve under a defined 1. single piece cast iron set of constraints. The weight of the I.C engine piston, 2. helical spring backed cast iron or steel piston rings and connecting rod has little influence on the 3. multi piece steel final component. As a result, in this optimization problem the cost and the weight were dealt with separately. The The earliest evidence for a connecting rod appears in the structural factors considered for weight reduction during the late 3rd century AD Roman Hierapolis saw mill. It also buckling load factor, stresses under the loads, bending appears in two 6th century Eastern Roman saw mills stiffness, and axial stiffness. Cost reduction is achieved by excavated at Ephesus and Gerasa. The crank and connecting using C-70 steel, which is fracture crack able. It eliminates rod mechanism of these Roman water mills converted the sawing and machining of the rod and cap mating faces and rotary motion of the waterwheel into the linear movement of is believed to reduce the production cost by 25%. the saw blades. International Journal of Advanced Technology and Innovative Research Volume. 10, IssueNo.03, March-2018, Pages: 0342-0347 Design And Analysis of IC Engine Piston, Piston Rings and Connecting Rod II. PRINCIPLE OF I.C ENGINE PISTON, PISTON wear on the piston. The pistons are short cylindrical parts RINGS AND CONNECTING ROD which seal one end of the cylinder from the high pressure of An internal combustion engine (ICE) is a heat engine the compressed air and combustion products and slide where the combustion of a fuel occurs with an oxidizer continuously within it while the engine is in operation. The (usually air) in a combustion that is an integral part of the top wall of the piston is termed its crown and is typically working fluid flow circuit. In an internal combustion engine flat or concave. Some two-stroke engines use pistons with the expansion of the high-temperature and high-pressure a deflector head. Pistons are open at the bottom and hollow gases produced by combustion apply direct force to some except for an integral reinforcement structure (the piston component of the engine. The force is applied typically web). When an engine is working the gas pressure in the to pistons, turbine blades, rotor or a nozzle. This force combustion chamber exerts a force on the piston crown moves the component over a distance, transforming which is transferred through its web to a gudgeon pin. Each chemical energy into useful mechanical energy. The first piston has rings fitted around its circumference that mostly commercially successful internal combustion engine was prevent the gases from leaking into the crankcase or the oil created by Étienne Lenoir around 1859 and the first modern into the combustion chamber. A ventilation system drives internal combustion engine was created in 1876 by Nicolaus the small amount of gas that escape past the pistons during Otto (see Otto engine). The term internal combustion normal operation (the blow-by gases) out of the crankcase engine usually refers to an engine in which combustion is so that it does not accumulate contaminating the oil and intermittent, such as the more familiar four-stroke and two- creating corrosion. In two-stroke gasoline engines the stroke piston engines, along with variants, such as the six- crankcase is part of the air–fuel path and due to the stroke piston engine and the Wankel rotary engine. A continuous flow of it they do not need a separate crankcase second class of internal combustion engines use continuous ventilation system. combustion: gas turbines, jet engines and most rocket engines, each of which are internal combustion engines on IV. DESIGN METHODLOGY OF I.C ENGINE the same principle as previously described. Firearms are PISTON, PISTON RINGS AND CONNECTING ROD also a form of internal combustion engine. The concept of CATIA V5 is to digitally include the complete process of product development, comprising the A. Reciprocating engines first draft, the Design, the layout and at last the production The base of a reciprocating internal combustion engine is and the assembly. The workbench Mechanical Design is to the engine block, which is typically made of cast iron or be addressed in the Context of this CAE training course. aluminum. The engine block contains the cylinders. In engines with more than one cylinder they are usually arranged either in 1 row (straight engine) or 2 rows (boxer engine or V engine); 3 rows are occasionally used (W engine) in contemporary engines, and other engine configurations are possible and have been used. Single cylinder engines are common for motorcycles and in small engines of machinery. Water-cooled engines contain passages in the engine block where cooling fluid circulates (the water jacket).

Some small engines are air-cooled, and instead of having a water jacket the cylinder block has fins protruding away from it to cool by directly transferring heat to the air. The cylinder walls are usually finished by honing to obtain a cross hatch, which is better able to retain the oil. A too rough surface would quickly harm the engine by excessive Fig4. 1. Home Page of CatiaV5. International Journal of Advanced Technology and Innovative Research Volume. 10, IssueNo.03, March-2018, Pages: 0342-0347 G. MANUSHA, G. KAVYA, K. S. J. SADHANA, NASEER AHMED, SD. INTHIYAZ, T. HARISH BABU CATIA can be applied to a wide variety of industries, V. ANALYSIS OF I.C ENGINE PISTON, PISTON from aerospace and defense, automotive, and industrial RINGS AND CONNECTING ROD equipment, to high tech, shipbuilding, consumer goods, A. Procedure for FE Analysis Using ANSYS: plant design, consumer packaged goods, life sciences, The analysis of the Skirt, Air cushion, cabin, blower fan, architecture and construction, process power and petroleum, pulleys, v-belt is done using ANSYS. For compete assembly and services. CATIAV4,CATIAV5, Pro/ Engineer, NX is not required, motor and attached system is to carried out (formerly Unigraphics), and Solid Works are the dominant by applying moments at the rotation location along which systems. axis we need to mention. Fixing location is bottom legs of assembly of the craft. A. Modeling of I.C engine piston, piston rings and connecting rod in CATIA V5 B. Preprocessor This I.C engine piston, piston rings and connecting In this stage the following steps were executed: rod is designed using CATIA V5 software. This software Import file in ANSYS window: used in automobile, aerospace, consumer goods, heavy File Menu > Import> STEP > Click ok for the popped up engineering etc. it is very powerful software for designing dialog box > Click complicated 3d models, applications of CATIA Version 5 Browse" and choose the file saved from CATIAV5R19 > like part design, assembly design. Click ok to import the file

Fig5.1: Importing file in Ansys.

C. Meshed View of I.C engine piston, piston rings and connecting rod components Fig4.2. Model design of I.C engine piston, piston rings These components are modeled with tetra elements and and connecting rod in CATIA-V5. shown as above and assembled with adjacent components.

Few components are solved using Rotational Force Analysis for checking the stress and displacements while rotating.

After completing the meshing of each assembly components next is to do analysis based on the OEM (Original Equipment of Manufacturer) application. So all Fig4.3. Model arrangement of I.C engine piston, piston the models which are rotated along which axis that we need rings and connecting rod mechanism in CATIA-V5. to mention in the Analysis software to get accurate results as International Journal of Advanced Technology and Innovative Research Volume. 10, IssueNo.03, March-2018, Pages: 0342-0347 Design And Analysis of IC Engine Piston, Piston Rings and Connecting Rod per the original component. Some of the components are needed to be solved using static analysis. Load is applied and fixing at the bottom key location of engine, was validated. Validation The material and geometric properties are listed.

VI. DISCUSSION ON ANALYSYS RESULT A. Results of Displacement analysis:

Fig6.4. Final Stress of Piston.

VII. CONCLUSION Piston skirt may appear deformation at work, which usually causes crack on the upper end of piston head. Due to the deformation, the greatest stress concentration is caused on the upper end of piston, the situation becomes more serious when the stiffness of the piston is not enough, and the crack generally appeared at the point A which may gradually extend and even cause splitting along the piston Fig6.1. Displacement of Piston. vertical. The stress distribution on the piston mainly depends on the deformation of piston. Therefore, in order to reduce the stress concentration, the piston crown should have enough stiffness to reduce the deformation. A highly nonlinear model for the dynamic behavior is considered. A parametric study to investigate the influence of the control parameters on the dynamic response is conducted. The control parameters that influence the transient response are found to be dimensionless equation is developed to predict the settling time of the response. Based on the developed equation, the Optimum values of the control parameters are obtained. As shown in above figures the displacements of the components is meshed and solved using Ansys and displacement is very less. This is showing us that clearly each component in assembly is having minor displacement. 1. The optimal mathematical model which includes deformation of piston crown and quality of piston and piston skirt. Fig6.2. Stress of Piston. 2. The FEA is carried out for standard piston model used

in diesel engine and the result of analysis indicate that the maximum stress has changed from 85 Mpa. to 55 Mpa. And biggest deformation has been reduced from 0.051762 mm to 0.025884 mm.

The value which is very less compared to yield value of given materials; this is below the yield point. The final result positive manner .There is no problem while in Final assembly design; without failure. For proving that above analysis is carried out for applying displacements and rotational force analysis.

VIII. REFERENCES [1]Shuoguo Zhao, Design the piston of Internal Combustion Engine by PRO\ENGEER,EMEIT-2012. [2] Isam Jasim Jaber and Ajeet Kumar Rai, Design and Analysis of IC Engine Piston and Piston-Ring Using Fig6.3: Final Displacement of Piston CATIA and ANSYS Software, IJMET. International Journal of Advanced Technology and Innovative Research Volume. 10, IssueNo.03, March-2018, Pages: 0342-0347 G. MANUSHA, G. KAVYA, K. S. J. SADHANA, NASEER AHMED, SD. INTHIYAZ, T. HARISH BABU [3] Ch. Venkata Rajan ,P.V.K. Murthy, M.V.S. Muraly Krishna, G.M. Prasada Rao, Design Analysis and Optimization Of Piston using CATIA and ANSYS, International Journal of Innovative Research in Engineering & Science Vol.1 , January 2013. [4] Kesarapu Sandeep Reddy, K.R. Senthil Kumar, P R Jeyakrishnam , Study on Stability of Honeycomb Structured Piston, IJERA. [5] Al-Beiruti, Dr.Basim M. Al Quraishi & Isam Ezzulddinyousif, Thermal effects on Diesel Engine Piston and Piston Compression Rings, Eng. & Tech Journal Vol. 27, 2009. [6] Ekeren Buyukkaya, Thermal analysis of functionally graded coating AlSi alloy and steel pistons, Surface & Coatings Technology 202 (2008).

Author's Profile G. Manusha B.Tech student in the Mechanical Engineering from Sri Visvesvaraya institute of technology and science, MBNR.

G. Kavya B.Tech student in the Mechanical Engineering from Sri Visvesvaraya institute of technology and science, MBNR.

K.S.J. Sadhana B.Tech student in the Mechanical Engineering from Sri Visvesvaraya institute of technology and science, MBNR.

Naseer Ahmed B.Tech student in the Mechanical Engineering from Sri Visvesvaraya institute of technology and science, MBNR.

Sd Inthiyaz B.Tech student in the Mechanical Engineering from Sri Visvesvaraya institute of technology and science, MBNR.

T. Harish Babu, Asst. Professor Mechanical Engineering from Sri Visvesvaraya institute of technology and science, MBNR.

International Journal of Advanced Technology and Innovative Research Volume. 10, IssueNo.03, March-2018, Pages: 0342-0347