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Thermal Analysis and Optimization of I.C. Engine Piston Using Finite Element Method

S. Srikanth Reddy, Dr. B. Sudheer Prem Kumar

In this study, firstly, thermal analyses are investigated on a conventional (uncoated) diesel piston, made of aluminium silicon alloy for design 1 and design 2 parameters. Secondly, thermal analyses are performed on piston, coated with Zirconium material by means of using a commercial code, namely ANSYS. The effects of coating on the thermal behaviours of the pistons are investigated. The finite element analysis is performed by using computer aided design software. The main objective is to investigate and analyze the thermal stress distribution of piston at the real engine condition during combustion process. This thesis describes the mesh optimization by using finite element analysis technique to predict the higher stress and critical region on the component. In this work, the main emphasis is placed on the study of thermal behaviour of functionally graded coatings obtained by means of using a commercial code, ANSYS on aluminium and zirconium coated aluminium piston surfaces. The analysis is carried out to reduce the stress concentration on the upper end of the piston i.e. (piston head/crown and piston skirt and sleeve). With using computer aided design NX/Catia software the structural model of a piston will be developed. Furthermore, the finite element analysis is done using Computer Aided Simulation software ANSYS.