International Journal of Thermal Technologies E-ISSN 2277 – 4114

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Research Article

Analysis and Comparison of Different Materials for a Single Cylinder

Four Stroke 225cc Piston using FEA
Mandeep Singh†* and Manish Bhargava†
†Department of Mechanical Engineering, Maharishi Arvind Institute of Engineering & Technology, Jaipur, Rajasthan, India

Accepted 20 Nov 2016, Available online 01 Dec 2016, Vol.6, No.4 (Dec 2016)

Abstract

A piston is a component of reciprocating engines which transfer force from expanding gas in the cylinder to the crank
shaft via piston rod and a connecting rod. It is one of the most complex components of an automobile, so engine
performance is influenced by the weight & design of the piston. In this work explained the distribution of stress in two
different alloys of Aluminum and Titanium Alloy with the help of simulation tool. For this purpose, a single cylinder
four stroke 225cc engine is used. Analytical design strategy of above mentioned materials is demonstrated. Piston is
modeled with the help of Pro/ENGINEER software. The model is analyzed with the help of ANSYS workbench. Then
the Von misses stress, Von misses strain, thermal stresses, factor of safety and deformations are calculated which
influenced a lot in piston material selection. Thus, the best piston material is ensured by the piston analysis process.

Keywords: Piston, Fatigue, Design Analysis, Al Alloy, Cast Iron, Ti Alloy, ANSYS.

1. Introduction cost and time. Thus, finite element analysis is carried

out for stresses, temperature gradient, and
1 Allinternal combustion engines have a moving part deformation and fatigue characteristics. In this paper, a
called Piston. It is surrounded by the cylinder and detailed stress analysis of piston is done under various
piston rings are used to gas tightened the piston. thermal and structural boundary conditions which are
Power is transferred by piston from cylinder to applied to the finite element model of the piston.
crankshaft through connecting rod. Piston experiences Structural, thermal and coupled thermo-mechanical
high mechanical and thermal stresses. Due to this stresses and temperature gradient are obtained from
reason, the main cause of the failure are thermo- the analysis. Life and Factor of safety for the piston are
mechanical stresses. Thus, to improve the quality and obtained from fatigue analysis. Practical guidelines can
performance of the piston, it has become very be provided for engine piston design in order to
important to discuss the thermal and mechanical improve performance and efficiency based on the
stresses. The following points are important in results from the analysis.
customer demand point view;
a) Piston must have higher strength to resist the high 2. Material
pressure.
b) Piston must have less weight to resist the inertia The material chosen for the analysis are Al Alloy 2024
forces. T3 tempered, Al Alloy 8090 T3 tempered, Ti Alloy.
c) Piston must provide enough bearing area to control
undue wear. Table 1 Properties of the material
d) Piston should not produce any unwanted noise.
e) Piston must be stiff making to resist mechanical Al Alloy Al Alloy Ti
Parameters
distortions. 2024 8090 Alloy
In spite of all the improvements and advancements in Young’s Modulus (GPa) 71 77 96
the technologies there exists large number of defective Ultimate Tensile Strength
310 340 1070
(MPa)
or damaged pistons. In the designing of pistons,
Yield Strength (MPa) 280 210 930
thermal and mechanical fatigue plays a prominent role.
Large numbers of complex fatigue tests are carried out Poisson’s Ratio 0.33 0.33 0.36
by piston manufacturers but this involves very high Thermal Conductivity (w/mk) 121 95.3 640
Coefficient of Thermal 21.4x10- 9.4x10-
23x10-6
Expansion (1/k) 6 6
*Corresponding author: Mandeep Singh; Dr. (Prof) Manish
Bhargava is working as Professor & Principal Density (kg/m3) 2770 2540 4620

355| International Journal of Thermal Technologies, Vol.6, No.4 (Dec 2016)

Mandeep Singh et al Analysis and Comparison of Different Materials for a Single Cylinder Four Stroke 225cc Piston using FEA

3. Model of piston

In this study, a full three-dimensional solid model of

piston is introduced to the ANSYS software. The three
kinds of the stress fields, named as thermal stress field,
mechanical stress field, thermal and mechanical
coupling stress field, can be obtained by the imposition
of the boundary conditions and loads on the FEA
model. Model of the piston is shown in figure 1.

Fig.4 Thermal Boundary condition of Al Alloy 8090 T3

Tempered

Fig.1 Model of Piston

4. Mesh generation

Finite element mesh is generated using triangular

elements (133424 elements). The von- mises stress is Fig.5 Thermal Boundary condition of Ti Alloy
checked for convergence. An automatic method is used
to generate the mesh in the present work. The meshing 6. Mechanical boundary condition
of piston is shown in figure 2.
The maximum explosive pressure is 10 MPa, and it acts
uniformly on the piston head. A fixed support has been
given to the piston. The boundary conditions are as
shown in figure 6,7,8.

Fig.2 Meshing of Piston

5. Thermal boundary condition

In the thermal analysis for model in ANSYS, the upper

part of the piston is having very high temperature
because of direct contact with the gas. So, a Fig.6 Mechanical Boundary condition of Al Alloy 2024
temperature of 560 degrees is provided to the upper T3 Tempered
surface of the piston. The thermal boundary conditions
of the piston are shown in figure 3,4,5.

Fig.3 Thermal Boundary condition of Al Alloy 2024 T3 Fig.7 Mechanical Boundary condition of Al Alloy 8090
Tempered T3 Tempered
356| International Journal of Thermal Technologies, Vol.6, No.4 (Dec 2016)
Mandeep Singh et al Analysis and Comparison of Different Materials for a Single Cylinder Four Stroke 225cc Piston using FEA

Fig.8 Mechanical Boundary condition of Ti Alloy Fig.11 Total Deformation on Al Alloy 2024 T3
Tempered
7. Result of the thermo-mechanical analysis

The various boundary conditions and load is imposed

on the FEA model of piston. Different kinds of the
stress field can be obtained. The total von-mises
stresses distribution on the whole surface of piston has
shown in figure 8,9,10. Figures 11,12,13 shows the
total deformation.

Fig.12 Total Deformation on Al Alloy 8090 T3

Tempered

Fig.8 Total Von-Mises Stresses on Al Alloy 2024 T3

Tempered

Fig.13 Total Deformation on Ti Alloy

Conclusion
It was observed that when considering all the aspects
on the same conditions on different materials, Ti alloy
Fig.9 Total Von-Mises Stresses on Al Alloy 8090 T3 has the minimum deformation (0.167167mm). And
Tempered considering about life cycles Al Alloy 8090 has the
maximum life cycles among all the materials.
Considering these result layouts the best material for
the design of the piston is Al Alloy 8090.
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357| International Journal of Thermal Technologies, Vol.6, No.4 (Dec 2016)
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