In order to analyze the phenomenon of bolt preload when piston of low speed diesel engine is assembled and maximum explosion pressure and temperature during piston working impact on piston’s strength and fatigue life, Coupled analysis of mechanical stress and thermal stress on the piston of 5S60 low-speed diesel engine have been done, and the fatigue life of the piston on the alternating load condition was calculated. Firstly, the FEM-model which consists of 10-node tetrahedral meshes was built for the piston by using Hypermesh software with arranging different density of element quality which was guaranteed with the mesh parameters. Secondly, after setting the boundary conditions, the thermal stress, the mechanical stress and the coupling stress of the piston were calculated by using Abaqus software. Finally, the fatigue life of the piston on the alternating load condition was calculated by using nSoft software. The results indicate that the fatigue damage is easily occurred on the side of the surrounding area of the threaded holes, and that position should be made an especially consideration for design.
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Static and Thermal Analysis of Piston and Piston Rings
M.Srinadh1, K Rajasekhara Babu2
1 M.Tech Student, Mechanical Engineering Dept, Bapatla Engineering Co llege, A.P, India
2 Assistanat Professor, Mechanical Engineering Dept, Bapatla Engineering Co lle ge, A.P, India
Abstract
A piston is a component of reciprocating engines, reciprocating pumps, compressors and pneumatic cylinders, among
other similar mechanisms It is the moving component that is contained by a cylinder and is made gas-tight by piston rings The piston transforms the energy of the expanding gasses into mechanical energy The piston rides in the cylinder liner or sleeve Pistons are commonly made of aluminum or cast iron alloys The present project to designed a piston for 1300cc diesel engine car and tak en 3 different profile rings A 2D drawing is created from the calculations The piston and piston rings are modeled using Pro/Engineer software, The stress and displacement are analyzed for the piston and piston rings by applying pressure on it in Structural analysis By observing the analysis results, we can decide whether our designed piston is safe or not under applied load conditions The thermal flux, thermal temperature distribution is analyzed by applying temperatures on the piston surface in Thermal analysis
The structural and thermal analysis were also done on the piston and piston rings model using Cast iron, Aluminum Alloy A360 and Zamak By comparing both the material analysis and decided which material is better for manufactur ing
of Piston and piston rings Structural and Thermal analysis were also performed in ANSYS software
Key Words: piston, piston rings, Struct ural analysis, thermal analysis, ANSYS
-*** -1 INTRODUCTION TO PISTON
The piston transforms the energy of the expanding gasses
into mechanical energy The piston rides in the cylinder
liner or sleeve Pistons are commonly made of alu minum
or cast iron alloys To prevent the combustion gasses
fro m bypassing the piston and to keep friction to a
minimu m, each piston has several metal rings around it
These rings function as the seal between the piston and
the cylinder wall and also act to reduce friction by
minimizing the contact area between the piston and the
cylinder wall The rings are usually made of cast iron and
coated with chrome or mo lybdenum Most diesel engine
pistons have several rings, usually 2 to 5, with each ring
performing a distinct function The top ring(s) acts
prima rily as the pressure seal The intermediate ring(s)
acts as a wiper ring to re move and control the amount of
oil film on the cylinder wa lls The bottom ring(s) is an
oiler ring and ensures that a supply of lubricatin g oil is
evenly deposited on the cylinder wa lls
Ashwani Ku mar et al [1] The ma in objective of this
research work is to investigate and analyze the stress
distribution of piston at actual engine condition
M.afzaa lma lik et a l [2] The piston top ring in an
automotive ring piston system plays a very crucial role
during the engine start up and norma l operating
conditions
1.1 PISTON RINGS
Piston rings are used on pistons to maintain gastight seals
between the pistons and cylinders, to aid in cooling the
piston, and to control cylinder-wa ll lubrication About
one-third of the heat absorbed by the piston passes
through the rings to the cylinder wall Piston rings are
often complicated in design, are heat treated in various ways, and are plated with other metals Piston rings are
of two distinct classificat ions: compression rings and oil control rings
1.2 MATERIALS FOR THE PISTON
Cast Iron, Aluminu m Alloy and Cast Steel etc are the common materia ls used for piston of an Internal
Co mbustion Engine Cast Iron p istons are not suitable for high speed engines due its more weight These pistons have greater strength and resistance to wear
The Aluminum A lloy Piston is lighter in weight and enables much lower running temperatures due to its higher thermal conductivity The coeffic ient of e xpansion
of this type of piston is about 20% less than that of pure alu minu m piston but higher than that of cast iron piston and cylinder wa ll To avoid seizure because of higher
e xpansion than cylinder wall, more piston clearance required to be provided It results in piston slap after the engine is started but still warming up and tends to separate the crown fro m the skirt of the piston
2 MODELING 2.1 Design Calculations
Density of diesel = 820 to 950 kg/cm at 15˚c = 0.00095 kg/c m³
Density = 0.00000095 kg/ mm³ Diesel C10H22 to C15H28 = C15 H28 Molecular weight of C15H28 =208g/ mole Mass =density × volu me
m = 0.00000095× 312000
m =0.2964 kg
R = 8.3143 J/ mo l K
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PV = m R T
P = 10.936 N/ mm²
Piston He ad
Gas pressure p = 10.936 N/ mm²
Outside dia meter of p iston = 69.6 mm
σt = bending tensile stress = 35-40MPa for cast iron
Temperature at the centre of the piston head Tc = 425˚c
to 450˚c
Temperature at the edge of the piston head Te = 200˚c to
225˚c
Tc – Te = 220˚c for cast iron
Thickness of the ribs = to
= 5.25 (or) 7.875 mm
Piston Ring
Radia l thic kness of the ring
t1 = D ×
Pw = pressure of gas on the cylinder wa ll
Pw = 0.025 to 0.042 N/ mm²
σt = 85 MPa to 110MPa for CI rings
t1 =69.6 × = 2.35mm
a xia l thic kness t2 = D/10nR
nR = no of rings = 3
t2 = =2.32mm
or t2 = 0.7 t1 to t1 = 1.645 to 2.35 mm
Width of top land b1 = th to 1.2 th =15.75 to 18.9 mm
The width of other ring land (distance between the ring
grooves)
b2 = 0.75t2 to t2 =1.74 to 2.32 mm
The gap between the free ends of the ring = 3.5t1 to 4t1
= 8.225 to 9.4 mm
Piston Barrel (Cylindrica l portion of the Piston)
Thickness of piston barrel
t3 = radia l depth of piston ring groove
b = t1+0.4 =2.75mm
t3 = 0.03× 69.6+2.75+4.5 = 9.338mm
The piston wall thickness towards the open end
t4 =0.25t3 to 0.35t3
t4 = 3.2683mm
1 Piston Skirt
Ma ximu m gas load on the piston
P= p ×
P= ma ximu m gas pressure
P= 10.936 ×
P= 41585.951 N
Ma ximu m side thrust on the cylinder
R= = 4158.5951N
Length of the piston skirt L= 0.65D to 0.8D = 55.68 mm Length of ring section = 7× b2=16.24 Total length of the piston
L = length of the skirt +length of the ring section +top land
=55.68+16.24+18.9 = 90.82mm
d0 = outside dia meter of the piston pin
l1 =length of the piston pin in the bush of the small end of the connecting rod
= 0.45D = 0.45× 69.6
l1= 31.32mm Load on the piston due to gas pressure
p = 41585.951N Load on the piston pin due to bearing pressure or bearing load = bearing pressure × bearing area
P= × d0 × l1 = bearing pressure at the small end of the connecting rod bushing
d0 = Bearing pressure of tin bronze =50MPa The mean d ia meter of the piston bosses = 1.4 d0 = 37.17mm
2.2 2D DRAWINGS OF THE PISTON
Fig 2.1 2D Drawing of the piston
Fig.2.2 showing the piston profile in Pro/E in step2
3 ANALYSIS
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Static Analysis Used to determine d isplacements,
stresses, etc under static loading conditions Both linear
and nonlinear static analyses, Nonlinearit ies can include
plasticity, stress stiffening, large deflection, la rge strain,
hyper elasticity, contact surfaces, and creep
A thermal analysis calculates the temperature
distribution and related therma l quantities in a system or
component Typical therma l quantities of interest are:
The temperature distributions
The amount of heat lost or gained
Thermal gradients
Thermal flu xes
3.1 MATERIAL PROPERTIES
Cast iron:
Density -7.81 g/cm3
Ultimate Tensile strength -900 MPa
Yield tensile strength -600 MPa
Modulus of elasticity -150 GPa
Specific heat -506J/kg-K
Thermal conductivity -45W/m-K
Aluminum A360:
Density -2.65 g/cm3
Ultimate Tensile strength -300MPa
Yield tensile strength -180MPa
Modulus of elasticity -71GPa
Specific heat -963J/kg-K
Thermal conductivity -113W/m-K
ZAMAK:
Density -6.60 g/cm3
Ultimate Tensile strength -240MPa
Modulus of elasticity -96 GPa
Specific heat -420J/kg-K
Thermal conductivity -113W/m-K
3.2 BOUNDARY CONDITIONS:
a) Temperature on piston head
b) Convection on total body
c) Pressure on piston head
d) Constrained at piston pin holes
4 RESULTS AND DISCUSSION
Structural And Thermal Analysis Of Piston
PIS TON
Fig 4.1 p iston model
MES HING
Fig 4.2 meshed model of p iston Fig 4.2 shows the meshed model De fault s olid bric k ele ment was used to mesh the components The shown mesh method was called tetra hydra mesh
MATERIAL: CAS T IRON TOTAL DEFORMATION
Fig 4.3 deformation with cast iron Fro m fig 4.3 it shows the total deformation of the p iston
is 0.00349mm
ELAS TIC STRAIN
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Fig 4.4 strain with cast iron
EQUIVALENT VON-MIS ES STRESS
Fig 4.5 Distribution of von-mises stress
Fro m fig it can be found that the equivalent von -mises
stress is 97Mpa
TEMPERATUR E
Fig 4.6 Te mpe rature distribution with cast iron
Fro m the fig te mperature distribution of the piston is
determined The ma ximu m te mperature is at the top of
the piston is 450 0C
TOTAL HEAT FLUX
Fig 4.7 Total heat flu x distribution Fro m fig 4.7it can be found that the ma ximu m heat flu x
is 8.3W/ mm2and the minimu m heat flu x is 1.02e -6
W/mm2
By taking properties of Alu minu m and ZAMAK materia ls to piston head the analysis performed and results are plotted
STRUCTARAL AND THERMAL ANALYS IS OF RECTANGULARFACE RING
MATERIAL:CASTIRON TOTAL DEFORMATION
Fig 4.8 Deformation with cast ironFro m fig 4.8 the total deformat ion of the model can be determined The ma ximu m and minimu m values are found to be MAX: 0.000768mm and MIN: 0.0000538mm
ELAS TIC STRAIN
Fig 4.9 strain with cast iron
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Fro m fig the strain values for cast iron model can be
determined It can be observed that the ma ximu m and
minimu m va lues are MAX : 0.0008263 and min imu m
values are MIN: 1.00e-4
EQUIVALENT VON-MIS ES STRESS
Fig 4.10 Distribution of von-mises stress
Fro m fig the stress values of cas t iron can be determined
It can be observed that the ma ximu m and minimu m
values of stress are MAX: 90 Mpa and 11.06 Mpa
TEMPERATUR E
Fig 4.11 Te mperature d istribution with
fro m the fig the te mperature distribution for cast iron can
be determined It can be found that the ma ximu m value
of temperature occurs at the top of the ring of 320 0C
TOTAL HEAT FLUX
Fig 4.12 Total heat flu x distribution
Fro m the fig total heat flu x of cast iron can be determined The ma ximu m and min imu m values of heat flu x are found to be MAX: 7.67 W/ mm2
By taking properties of Alu minu m and ZAMAK materia ls to piston rings the analysis performed and results are plotted
STRUCTARAL AND THERMAL ANALYS IS OF
PIS TON
Table 4.1.1structaral and thermal analysis of piston DEFORM A
TION (mm)
STRAIN (mm/mm)
STRESS (Mpa)
HEAT FLUX (W/mm2) cast
iron 0.00349 0.00191 97 8.3 Alumin
iu m A360
0.1282 0.00284 140 13.3 ZAMA
STRUTURAL AND THERMAL ANALYS IS OF
RINGS DEFORMATION:
Table no 4.2 deformat ion of rings
Deformatio
Aluminu
m (A360) Zamak rectangular 0.000768 0.00122 8.90E-05 semi circular 0.00063 0.001 7.29E-05 Taper face 0.00068 0.00102 7.26E-05
ELAS TIC STRAIN:
Table no 4.3 elastic strain of rings
Strain(mm/ m
Aluminu m (A360) Zama k rectangular 0.000826 0.00132 9.53E-05 semi circular 0.00071 0.001 8.07E-05 Taper face 0.000687 0.00101 7.79E-05
STRESS:
Table no 4.4 stress of rings
Stress(Mpa) Cast Iron Aluminu m (A360) Zama k
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TOTAL HEAT FLUX
Table no 4.5 total heat flu x of rings
He at flux
(w/ mm 2 )
Cast Iron
Aluminu m (A360)
Zama
k
semi circular 10.2 13 13.9
Taper face 8.47 10.05 10.9
TOTAL DEFORMATION
Graph no 4.1deformat ion vs different rings
Graph no 4.1 illustrates the semic ircu lar face ring with
za ma k accounted minimu m deformat ion
ELAS TIC STRAIN
Graph no 4.2 strain vs different rings
Graph no 4.2 illustrates that minimu m strain of 0.8e-5
accounted for semic ircular face ring with za ma k
STRESS
Graph no 4.3 stress vs different rings
Graph no 4.3 illustrates that minimu m stress of 72Mpa
accounted for taper face ring with Alu min iu m
TOTAL HEAT FLUX
TOTAL HEAT FLUX
Graph no 4.4 total heat flu x vs diffe rent rings Graph no 4.4 illustrates that semic ircula r face ring with
za ma k accounted ma ximu m heat flu x of 14 W/ mm2
STRUCTARAL AND THERMAL ANALYS IS OF
PIS TON AND PIS TON RINGS
DEFORMATION
Table no 4.6 deformat ion of piston and rings
Defor mation (mm) Cast Ir on Aluminum Zamak rectangul ar 0.005272 0.005275 5.65E-03
semi circular 0.005294 0.00529 5.31E-03
Taper face 0.005313 0.005322 5.31E-03
STRAIN
Table no 4.7 elastic strain of piston and piston rings
Strain (mm/mm)
Cast
Ir on Aluminum Zamak rectangul ar 0.000385 0.000542 1.28E-04
semi circular 0.000434 0.000485 1.98E-04
Taper face 0.000799 0.00124 1.22E-04
STRESS
Table no 4.8 stress of piston and pistonrings
Stress (Mpa) Cast Iron Aluminu m Zama k
TOTAL HEAT FLUX
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Table no 4.9 total heat flu x of piston and pistonrings
He at flux
(W/ mm 2 ) Cast Iron Aluminu m Zama k
rectangular 7.7 9.76 10.34
semi circular 10.05 13.15 14
Taper face 10.5 11.2 11.85
TOTAL DEFORMATION
Graph no 4.5 defo rmation vs diffe rent rings
Graph no 4.5 illustrates the rectangular face ring with
A360 accounted min imu m deformation
STRAIN
Graph no 4.6 strain vs different rings
Graph no 4.6 illustrates that minimu m strain of 0.00013
accounted for rectangular face ring with za ma k
STRESS
Graph no 4.7 stress vs different rings
Graph no 4.7 illustrates that minimu m stress of 122Mpa accounted for semic ircular face ring with Alu miniu m TOTAL HEAT FLUX
Gr aph no 4.8 total he at flux vs differe nt rings
Graph no 4.8 illustrates that semic ircula r face ring with
za ma k accounted ma ximu m heat flu x of 14 W/ mm2
4 CONCLUSIONS
piston and Ring’s calculations are done for 1300cc diesel engine Modeling of piston and Ring’s are prepared using parametric software creo(pro-engineer) and assembled Assembly was e xported to Ansys work bench to conduct structural and therma l analysis In the analysis piston and Ring’s were analy zed using 3 various materials Cast iron, Aluminu m(A 360) and Za mak.According to the results obtained from AnsysZamak materia l for piston is selected In the analysis 3 different rings were analyzed using 3 various materia ls Cast iron, Alu minu m and Zama k.In 3 different ring profiles semicircular face ring
is best as per the ansys results in deformations, strains and heat flu x Za ma k is having lo w deformat ion and high heat flu x properties compare to other 2 materia ls As per above results piston with Zama k is having high heat flux value than traditional materia ls As per analyses values Zama k is having good value so we can use Zama k
REFERENCES
[1] Thermo -Mechanical and Vibrat ion Analysis of the I.C Engine Piston made of Sic reinforced ZrB2 composite using Finite Ele ment Method (ANSYS) [2] M afzaa lma liket a l “Modeling of Piston Top Ring Lubrication by considering Cylinder Out-of-Roundness in Initial Engine Start up ”Proceedings of the World Congress on Engineering 2010 Vol II [3] “Design, Analysis and Optimization of Three Aluminu m Piston Alloys Using FEA”
[4] Mr v.n kongari“design and analysis of piston ring”International Conference on Mechanical & Industrial Eng ineering, 02nd June-2013, Bengaluru, [5] R Mr.K.Kada mbanathan “Fatigue analysis of a diesel piston ring by using FEA”Proceedings of the
“National Conference on Emerging Trends In Mechanical Engineering 2k13”
Trang 858 M.Srinadh, K Rajasekhara Babu
[6] v s n ch.dattu et al “Thermal Analysis on New
Piston Rings Face Profile” ISSN 2250-2459, ISO
9001:2008 Cert ified Journal, Volu me 4, Issue 3,
March 2014)
[7] K Ven kateswaraRao et a l “Modeling, Analysis and
Optimization of Diesel Engine Piston”IJREAT
International Journal of Research in Engineering &
Advanced Technology, Volu me 2, Issue 1, Feb-Mar,
[8] Dr Ahe mad“Thermal Effects on Diesel EnginePiston andPiston Compression Rings” Eng&tech journa l vol 27 NOV 2009
[9] Automobile engineering by Dr.kirpalsingh vol.2 [10] I C engines by v ganeshan