International Journal of Research ISSN NO:2236-6124

MODELING ANDTHERMAL ANALYSIS OF

1M CHALAPATHI 2S.PRAVEEN KUMAR 1Department of Mechanical Engineering M-Tech Student (CAD/CAM) Chadalawada Ramanamma Eng. College.

2Department of Mechanical Engineering Assistant Professor (CAD/CAM) Chadalawada Ramanamma Eng. College. a swiveling gudgeon stick (US: wrist stick). This stick is mounted inside the motor : not in any ABSTRACT: In this investigation, Work is done to way like the steam motor, there is no cylinder or discover the Thermal stress distribution on various cross head (beside enormous two motor). Piston Materials utilized. In IC engine Piston is a the Trunk : most important element in engine element and complex part, so it is essential to keep up Piston in Trunk pistons are long relative to their diameter. good condition in order to attain good condition of They act both as a cylindrical and piston. the engine. Piston main fails due to mechanical and As the is angled for much of its thermal stress. rotation, there is also a side force that reacts along the So as to search out proper mechanical stress side of the piston against the cylinder wall. as well thermal distribution on Piston Materials are considered. In this analysis is work out on piston with Crosshead pistons different materials (AL-Si Alloys, AL-Mg-Si Alloys, Huge moderate speed Diesel motors may require and AlSiC alloy). The piston is modeled and analyze extra help for the side powers on the cylinder. These by using Computer aided design and Computer aided motors ordinarily utilize cross head cylinders. The engineering software. In this analysis I found that the fundamental cylinder has a substantial cylinder pole vonmisses stress, heat flux reduces in AlSiC stretching out downwards from the cylinder to what composite compared with otheraluminum alloys. is adequately a moment littler distance across INTRODUCTION: A piston is a element cylinder. Slipper pistons : of reciprocating engines, reciprocating pumps, gas compressors and pneumatic cylinders, etc. It is the reciprocating component that is contained by a cylinder and is made gas-tight by piston rings.

In an engine, the piston purpose is to transfer motion from expanding gas in the cylinder to the via a piston rod and/or connecting rod. In a pump, the function is modified and motion is transferred from the crankshaft to the piston for the purpose of compressing or ejecting the fluid in the container. In some engines, the piston also acts as A cylinder for an oil motor that has been decreased in a by covering and uncovering ports in the size and weight however much as could be expected. cylinder wall. In the extraordinary case, they are diminished to the cylinder crown, bolster for the cylinder rings, and Internal combustion engines : sufficiently only of the cylinder skirt staying to leave two terrains in order to stop the cylinder shaking in the drag.

Deflector pistons :

Figure 1 : Internal combustion engine piston, sectioned to show the gudgeon pin.

The connecting rod is associated with the cylinder by

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Two-stroke deflector piston Tunnels, mines, pit, cavities, and bore holes. Geological features like Joints, fissures fractures and INTRODUCTION TO FEM layers.

1.1 NEED FOR FEM Hydro Elasticity:

Numerous building issues dealt with today don't have Sloshing of liquids in flexible containers, shut type of Solution. For these issues, geometry of reservoir or darn interactions. the protest is sporadic or some of the time self- AlSi Material properties assertive. Prior to disregard the challenges in taking Sl No properties Value care of these genuine issues, rearranging suppositions were made. Numerical techniques, which give rough arrangement, appeared. These strategies can hold the 1 Young’s modulus 2.3×10 5 Mpa issue complexities, giving a superior arrangement. 2 Poisons ratio 0.24 GENERAL DESCRIPTION OF THE METHOD

3 In transitory the it all about of FEM is the cross 3 Density 2937 kg/m section of a biggest slice of the cake or practice by an set of subdivisions called finite elements. These 4 Thermal conductivity 197 W/m 0C graphic representation are thought-about inhume wired at joints, that are experienced as nodes or nodal 0 points. Simple functions are selected to mirror the 5 Specific heat 894 J/kg C selection or mutation of the distinct displacements completely each finite element. Such on a long shot functions are met with as driving out functions or driving out models. The long shot magnitudes of the Compositions of AlSi alloy 1 Cu ejection functions are the displacements at nodal 1.1% points. 2 Zn - 3 Mn BASIC CONCEPT OF FEM 0.2% 4 Fe “The most gracefulness of the FEM that separates it 0.3% from others is that the division of a given domain into 5 Mg 1.1% a collection of straightforward sub domains known as 6 Si finite elements. Any geometric form, that permits 12.5% computation of the solution or its approximation or 7 Ti provides necessary relations among the values of the - 8 Sn solution at selected points, known as nodes of the sub - domain, qualifies as a finite element. 9 Pb - 10 Ni REDUCING THE DESIGN AND 0.9% MANUFACTURING COSTS USING ANSYS 11 Al (FEA): Rest

The ANSYS program enables specialists to build PC models or exchange CAD models of structures, Al-Mg-Si Material properties items, segments, or frameworks, apply loads or other Sl No properties Value outline execution conditions and concentrate physical reactions, for example, feelings of anxiety, 1 Young’s modulus 0.7 ×10 5 Mpa temperature conveyance or the effect of lector attractive fields. 2 Poisons ratio 0.33

Rock Mechanics: 3 Density 2700 kg/m 3

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4 Thermal conductivity 200 W/m 0C 2 Poisons ratio 0.21 3 Density 2890 kg/m 3 5 Specific heat 898 J/kg 0C 4 Thermal conductivity 170 W/m 0C 0 5 Specific heat 808 J/kg C Compositions of Al-Mg-si 1 Aluminium: 97.9 to 99.3% Compositions of AlSiC-12 2 Chromium: Aluminum Alloy A 63 vol% 0.05% max 356.2 3 Copper: 0.1% max Silicon Carbide 37 vol% 4 Iron: 0.1 to 0.3% Compositions Aluminum Alloy A 356.2 5 Magnesium: 0.35 to 0.6% Aluminum, Al 91.2 - 93.1 % 6 Copper, Cu <= 0.10 % Manganese: 0.10% Iron, Fe 0.13 - 0.25 % 7 Silicon: 0.3 to 0.6% Magnesium, Mg 0.30 - 0.45 %

Manganese, Mn <= 0.05 % AlSiC-10 Material properties Other, each <= 0.05 % Sl No properties Value Other, total <= 0.15 % 1 Young’s modulus 1.67 ×10 5 Mpa Silicon, Si 6.5 - 7.5 % 2 Poisons ratio 0.251 Titanium, Ti <= 0.20 % 3 Density 2960 kg/m 3 Zinc, Zn <= 0.05 %

4 Thermal conductivity 190 W/m 0C MODELING 5 Specific heat 786 J/kg 0C 2.1. Piston Design The piston is designed according to the procedure and specification which are given in machine design Compositions of AlSiC-10 and data hand books. The dimensions are calculated Aluminum Alloy A 356.2 45 vol% in terms of SI Units. length, diameter of piston and Silicon Carbide 55 vol% hole, thicknesses, etc., parameters are taken into consideration Compositions Aluminum Alloy A 356.2 2.1.1. Design Considerations for a Piston Aluminum, Al 91.2 - 93.1 %  In designing a piston for an engine, the following points should be taken into Copper, Cu <= 0.10 % consideration: Iron, Fe 0.13 - 0.25 %  It should have enormous strength to withstand the high pressure. Magnesium, Mg 0.30 - 0.45 %  It should have minimum weight to withstand Manganese, Mn <= 0.05 % the inertia forces. Other, each <= 0.05 %  It should form effective oil sealing in the Other, total <= 0.15 % cylinder. Silicon, Si 6.5 - 7.5 %  It should provide sufficient bearing area to Titanium, Ti <= 0.20 % prevent undue wear.  It should have high speed reciprocation Zinc, Zn <= 0.05 % without noise.  It should be of sufficient rigid construction to withstand thermal and mechanical AlSiC-12 Material properties distortions. Sl No properties Value  It should have sufficient support for the 5 1 Young’s modulus 1.67 ×10 Mpa piston pin. 2.1.2 Piston Design specification

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a) Consider Diameter of Bore b) Width of the top land(b) c) Height of the piston(H) d) Distance from the front to the axis of piston pin(h 1) e) Diameter of thickness of piston pin(d) f) Distance from the front to the first channel(e) g) Wall thickness between channels(h n) h) Radial thickness of the piston ring (t r) i) Axial thickness of the piston ring (t ) a the complete three-dimensional model of

piston geometry was created using Ansys work bench Modeller. The part and is shown in figure 5.1.

MESHING OF PISTON

The piston shape is irregular, especially in the presence of various curved surfaces of inner cavity. Firstly, Automatic meshing method is used to mesh the model.Element used is 20 node Tetrahedron named soilid90 . The element size is taken as 5, then total number elements were 11475 and nodes were 19591 found in meshed model. The mesh grid is shown as figure below . Fig Piston Geometry

THEORETICAL CALCULATIONS

Structural

Sl .No Material Total Deflection (mm) 1 AlSi 0.04197 2 Al-Mg-Si 0.1304 3 AlSiC-10 0.057 4 AlSiC-12 0.05869 AlSi Table 1 Selected Dimensions of Design Specification of the piston

Ansys 3D Model

Thus, the dimensions for the piston are calculated and these are used for modelling the piston in Ansys work bench Modeller. Thus, a symmetric model is developed using the above dimensions. Piston was modelled using Ansys software which is shown in Figure 1. Fig(1); Vonmises stress of AlSi piston

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Fig(2); Total deformation of AlSi piston Fig(1); Vonmises stress of AlSiC -10piston Fig (1) and Fig (2) show the structural results of aluminium silicon Alloy piston influenced by gas pressure. Fig (1) show the distribution of Vonmises stresses induced within the piston body. The maximum values of equivalent stresses observed at centre portion of the piston crown is 89.929 Mpa. Fig (2) show the maximum deflection in the piston geometry due to the application of gas pressure is 0.042167 mm , which is observed at the

central portion of the piston crown. Fig(2); Total deformation of AlSiC-10 piston Al-Mg-Si

Fig (1) and Fig (2) show the structural results of AlSiC-10 Alloy piston influenced by gas pressure. Fig (1) show the distribution of Vonmises stresses induced within the piston body. The maximum values of equivalent stresses observed at centre portion of the piston crown is 90.749 Mpa . Fig (2) show the maximum deflection in the Fig(1); Vonmises stress of Al-Mg-Si piston piston geometry due to the application of gas pressure is 0.057958 mm , which is observed at the central portion of the piston crown. AlSiC-12

Fig(2); Total deformation of Al-Mg-Si piston

Fig (1) and Fig (2) show the structural results of Al-Mg-Si Alloy piston influenced by gas pressure. Fig (1) show the distribution of Vonmises Fig(1); Vonmises stress of AlSiC -12piston stresses induced within the piston body. The maximum values of equivalent stresses observed at centre portion of the piston crown is 96.739 Mpa . Fig (2) show the maximum deflection in the piston geometry due to the application of gas pressure is 0.13527 mm , which is observed at the central portion of the piston crown.

AlSic-10

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Fig(2); Total deformation of AlSiC-12 piston

Fig (1) and Fig (2) show the structural results of AlSiC-12 Alloy piston influenced by gas pressure. Fig (1) show the distribution of Vonmises stresses induced within the piston body. The maximum values of equivalent stresses observed at centre portion of the piston crown is 87.771 Mpa . Fig (2) show the maximum deflection in the piston geometry due to the application of gas pressure is 0.058328 mm , which is observed at the central portion of the piston crown. Maximum Heat flux of the piston crown S VONMISSES TOATAL NO MATERIAL STRESS ( DIFLECTION q= -k ……………………..From Fourier’s law MPa) (mm) 1 AlSi 89.929 0.042167 K= Thermal conductivity of piston 2 Al-MgSi 96.739 0.13527 material 3 AlSiC-10 90.749 0.057958 4 AlSic-12 87.771 0.058328 dT=Temperature gradient (T 2-T1)

dx=Thickness of the top land of the piston (t)

q= -k

T2= Temperature of the top surface of the piston crown.

T1=Temperature of the Bottom surface of the piston crown.

t = Thickness of the top land of the piston

CaseI Maximum Heat flux in AlSi Alloy Piston

q= -k

q = -197 ×

=3.788 x 10 6 W/m 2 MATERIAL TOATAL DEFLECTION S Ansys Theoretical Case-II Maximum Heat flux in Al-Mg-Si Alloy NO Piston 1 AlSi 0.042167 0.04197 2 Al-MgSi 0.13527 0.1304 q= -k 3 AlSiC-10 0.057958 0.057 4 AlSic-12 0.058328 0.05869 q = -200 ×

=3.846 x 10 6 W/m 2

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Case-II Maximum Heat flux in AlSiC-10 Alloy Fig (2) show the maximum total heat flux in Piston the piston geometry due to the application of gas temperature is 3.0227 MW/m 2, which is observed at q= -k the edge portion of the piston crown. Al-Mg-Si

q = -190 ×

=3.653 x 10 6 W/m 2

Case-II Maximum Heat flux in AlSiC-12 Alloy Piston

q= -k Fig(1); Temperature distribution for Al-Mg-Si piston q = -170 ×

=3.269 x 10 6 W/m 2

AlSi

Fig(2); Total heat flux for Al-Mg-Si piston

Fig (1) and Fig (2) show the Thermal results of aluminium silicon Alloy piston influenced by gas Temperature. Fig (1) show the distribution of Temperature

induced within the piston body. The maximum values of Temperature observed at top surface of the piston Fig(1); Temperature distribution for AlSi piston crown . Fig (2) show the maximum total heat flux in the piston geometry due to the application of gas temperature is 3.0375 MW/m 2, which is observed at the edge portion of the piston crown.

S No Material Total Heat flu (MW/m 2) 1 AlSi 3.0227

2 Al-Mg-Si 3.0375

3 AlSiC-10 3.0212 Fig(2); Total heat flux for AlSi piston 4 AlSiC-12 2.774 Fig (1) and Fig (2) show the Thermal results of aluminium silicon Alloy piston influenced by gas Temperature. Fig (1) show the distribution of Temperature induced within the piston body. The maximum values of Temperature observed at top surface of the piston crown .

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REFERANCES

• ”Thermal Analysis and Optimization of I.C. Engine Piston Using Finite Element Method” International Journal of Innovative Research in Science,Engineering and Technology. S.SrikanthReddy, Dr.B.SudheerPremKumar,Vol.2, Issue12, December 2013 . • “Piston Design and Analysis by CAE

Tools” Ghodake A. P.*, Patil K.N. IOSR Journal of Engineering (IOSRJEN) ISSN: 2250-3021 ISBN: 2878-8719 PP 33-36 Total heat Flux (MW/m 2) Sl No Material Theoretical Simulated • “Experimental Investigation and Analysis 1 AlSi 3.788 3.0227 of Piston by using Composite Materials ” 2 Al-MgSi 3.846 3.0375 R. RAVI RAJA MALARVANNAN1, P. VIGNESH.International Journal of 3 AlSiC-10 3.653 3.0212 Mechanical Engineering applications Research.Vol 04, Article-K100; 4 AlSic-12 3.269 2.774 • “Piston Strength Analysis Using FEM ” by Swati S Chougule*, Vinayak H The maximum heat flux was observed is 9.1716 Khatawate**International Journal of MW/m² . Maximum vonmisses stress was observed Engineering Research and Applications at top land of the piston is 89 Mpa and the maximum (IJERA) ISSN: 2248-9622. deflection of the piston due to gas pressure is 0.434 mm Conclusion: • “ Design, Analysis and Optimization of 1. From the analysis results of different Three Aluminium Piston Alloys Using material on piston is observed that FEA” by Ajay Raj Singh*, Dr. Pushpendra deformation, Vonmises stress, total heat flux Kumar Sharma. Journal of Engineering reduces in AlSiC composite compared to Al- Research and Applications ,ISSN : 2248- Si, Al-Mg-Si, Alloy. 9622, Vol. 4, Issue 1( Version 3, January 2. Theoretical calculation of the piston have 2014, pp.94-102. been done to get the influence of thermal load and mechanical load. • “Thermal Analysis And Optimization Of 3. The maximum Vonmises stress for heat flux I.C. Engine Piston Using finite Element total deforming reduced by increases Method” by A. R. Bhagat1, Y. M. Jibhakate composition of carbides in AlSiC Alloy. 2. International Journal of Modern 4. Results comparison between theoretical and Engineering Research (IJMER), Vol.2, analysis simulated done and found Issue.4, July-Aug 2012 pp-2919-2921. approximately same. 5. Results comparison was done with previous other papers which were taken as references. And almost approximate results were observed. Scope of feature works

• The work can be entered by using some more types of Aluminium alloys. • Different shapes of piston crown may be analysed. • Aluminium alloys may be coated with aluminium oxides for piston working at elevated temperature.

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