Fea of Two Engine Pistons Made of Aluminium Cast Alloy A390 and Ductile Iron 65-45-12 Under Service Conditions

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Fea of Two Engine Pistons Made of Aluminium Cast Alloy A390 and Ductile Iron 65-45-12 Under Service Conditions 5th International Conference on Mechanics and Materials in Design REF: A0319.0006 FEA OF TWO ENGINE PISTONS MADE OF ALUMINIUM CAST ALLOY A390 AND DUCTILE IRON 65-45-12 UNDER SERVICE CONDITIONS P. Carvalheira1, and P. Gonçalves Departamento de Engenharia Mecânica, Faculdade de Ciências e Tecnologia da Universidade Coimbra Coimbra, Portugal Email: (1)[email protected] SYNOPSIS As part of the design of a low fuel consumption internal combustion engine to be applied to our new vehicle XC20i (a prototype car for the European Eco-Shell Marathon), the aim of this work is to compare two different materials for the engine piston: Aluminium Alloy A390-T5 and Ductile Iron 65-45-12 using a Finite Element Analysis (FEA) and thus choose the best suited material. A number of FEA were carried out to predict the thermal and mechanical stresses in the piston and thus optimise its shape. The original design of the piston was fully analysed under wide open throttle (WOT) conditions at maximum design engine speed. Results showed three critical areas in the piston with high stresses and/or high temperatures. For each material, a parametric study of various design features/dimensions was conducted to make the design stronger and improve its safety. As a result of this work, we made a comparative study of some relevant parameters for each piston material. Despite low thermal expansion, thermal conductivity and high mechanical strength of Ductile Iron 65-45-12, its high density causes high inertial forces on the engine. Although the Aluminium Alloy A390- T5 has a larger thermal expansion, a larger thermal conductivity and a lower mechanical strength at high temperature than ductile iron, due to its lower density it was possible to design a piston meeting all the design requirements and weighting about 66 % less than Ductile Iron piston design. 1. INTRODUCTION The piston is the engine part that receives the energy from combustion and transmits it to the crankshaft. It must withstand heavy stresses under severe temperature conditions. The piston is considered the most critical component of an internal combustion engine and the prediction of the mechanical and thermal behaviour under service conditions requires great attention in the design phase. The material of the piston is chosen according to its mechanical strength, density, wear characteristics and thermal expansion properties. The design of the piston starts with the definition of the piston geometry using 3D CAD software. This 3D CAD geometric model is then imported to FEA software and analysed under the predicted service conditions before anything is made. That speeds up the design and testing process, reduces the lead time to create new pistons designs, and produces a better product. The idea behind finite analysis is to divide a model piston into a fixed finite number of elements. Computer software generates and predicts the overall stiffness of the entire piston. Analyzing the data it is possible predict Chapter III: Product Engineering & Development in Design 1 Porto-Portugal, 24-26 July 2006 how the piston will behave in a real engine and allows the engineer to see where the stresses and temperatures will be the greatest and how the piston will behave [1] About 50 percent of unburned hydrocarbon (HC) emissions from conventional four stroke SI engines can be attributed to flame quenching within the top ring crevice [2]. Crevice volume can be reduced by moving the ring closer to the crown, although the possibility of the ring failure due to exposure to high temperature is high. Other good alternative design solution to reduce the crevice volume is using tighter clearances between the piston and cylinder. Cast iron has the advantages of low thermal expansion and high temperature strength over aluminium alloys allowing the reduction of the clearances between the piston and cylinder. Also, the lower thermal conductivity of the cast iron causes more of heat energy produced in combustion to be put into useful work, rather than wasted in the cooling system. The larger weight of the ductile iron piston increases the inertial forces created by the rapid change in piston direction. On the other side, the aluminium alloy has a high strength-to-weight ratio but also larger thermal conductivity and larger thermal expansion. Both materials in analysis have different characteristics with some positive and negative aspects. The FEA carried out for these two different materials predict the thermal and mechanical stress under operating conditions. Detailed comparative thermal and mechanical stress analyses are presented together as well as sensitivity reports of some piston geometrical parameters. With these results we can make a robust component and make a more rational selection tool for the material of the piston. 2. CHARACTERIZATION OF MATERIALS The materials chosen for our study are two metallic alloys usually used as substrate material for internal combustion engine pistons. 2.1 ALUMINIUM A390-T5 A unique combination of properties makes aluminium one of our most versatile engineering and construction materials. Besides its lower density, it has high resistance to corrosion under the majority of service conditions. A wide range of mechanical characteristics, or tempers, are available in aluminium alloys through various combinations of cold work and heat treatments. Aluminium and its alloys lose part of their strength at elevated temperatures, although some alloys retain good strength at temperatures from 200-260 ºC [5]. Aluminium Alloy A390 is a hypereutectic alloy for which silicon is the main alloying element. The low thermal expansion coefficient is exploited for pistons, the high hardness of silicon particles for wear resistance. [6] The hypereutectic alloys pistons features increased fatigue strength, lower thermal conductivity, increased scuff resistance, lower friction, and better wear properties than pistons made with other alloys. Increasing fatigue strength allows for pistons with thinner wall sections and lower weight. Lower thermal conductivity allows more of the heat energy produced in combustion to be converted to useful work, rather than wasted in the engine cooling system [7]. Table 1 shows the composition by weight percent of each component of Aluminium A390- T5. 2 Editors: J.F. Silva Gomes and Shaker A. Meguid 5th International Conference on Mechanics and Materials in Design Table 1. Composition of Aluminium A390-T5 [8]. Component Percent of weight Al 74.4-79.6 Cu 4-5 Fe Max 1.3 Mg 0.45-0.65 Mn Max 0.1 Si 16-18 Others -- Table 2 shows relevant mechanical and thermal properties of the Aluminium A390-T5 for the FEA. Table 2. Relevant mechanical and thermal properties of Aluminium A390-T5 [8] for the FEA. Poisson Ratio 0.33 Modulus of Elasticity /GPa 81.2 Density at 20ºC / (kg/m3) 2730 Thermal Conductivity at 25ºC /(W/m K) 134 Thermal Expansion Coefficient (100-300ºC)/(1/ºC) 18.0E-06 - 22.5E-06 Specific Heat Capacity at 100ºC /(J/kg K) 963 Ultimate Tensile Strength at 25ºC /MPa 280 Yield Tensile Strength at 25ºC /MPa 240 Fatigue Tensile Strength (5e8 cycles R.R Moore Test) /MPa 110 The evolution with temperature of yield tensile strength is shown on Table 3. Table 3. Evolution of yield tensile strength with temperature for Aluminium A390-T5 [8]. Temperature /ºC Yield Strength /MPa 25 240 95 225 150 195 205 160 260 85 Due to the lack of information of fatigue tensile strength with temperature, we used the same ratio of fatigue tensile strength to yield tensile strength at ambient temperature to obtain the fatigue tensile strength at each temperature. Fig. 1 shows the approximation made. Chapter III: Product Engineering & Development in Design 3 Porto-Portugal, 24-26 July 2006 300 250 200 150 Stress /MPa 100 50 0 20 60 100 140 180 220 260 Temperature /ºC Yield Tensile Strength /MPa Fatigue Tensile Strength (Approximation)/MPa Fig.1. Evolution of tensile yield strength and fatigue strength (approximation) with temperature for Aluminium A390-T5. 2.2 DUCTILE IRON 65-45-12 Ductile iron 65-45-12 is a high silicon ductile iron intended for use at high temperatures or when a part is subjected to thermal cycling. The ferritic structure remains stable so that no significant transformation takes place minimizing stresses that lead to cracks and distortion of the finished part. The composition of ductile iron 65-45-12 is presented on Table 4. Table 4. Composition of ductile iron 65-45-12 in percentage of weight of each element. Element Percentage Carbon 3.45 – 3.75 Silicon 3.25 – 4.00 Manganese 0.15 – 0.35 Sulphur 0.025 Phosphorus 0.05 Relevant mechanical and thermal properties of ductile iron 65-45-12 for the FEA are shown on Table 5 [9]. 4 Editors: J.F. Silva Gomes and Shaker A. Meguid 5th International Conference on Mechanics and Materials in Design Table 5. Relevant mechanical and thermal properties of ductile iron 65-45-12 for the FEA. [9] Poisson Ratio 0.33 Modulus of Elasticity /GPa 168 Density /(kg/m3) 7100 Thermal Conductivity /(W/m K) 36 Thermal Expansion Coefficient /(1/ºC) 12.8 E-6 Specific Heat Capacity at 100ºC/(J/kg K) 494 Ultimate Tensile Strength at 25ºC /MPa 448 Yield Tensile Strength at 25ºC /MPa 310 Elongation at rupture /% 12 Fatigue Tensile Strength /MPa (50% of the ultimate tensile strength) /MPa 224 Due to the lack of data for ductile iron 65-45-12 to predict the evolution of the fatigue strength limit (R = -1) with temperature of ductile iron 65-45-12 we considered at each temperature the same ratio between the fatigue strength limit (R = -1) and the ultimate tensile strength. The ratio considered was 50 %. Fig. 2 shows the results of the assumptions made to find the evolution of fatigue strength limit with temperature.
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